Industrial Automation
Automation Industrielle
Industrielle Automation
Office
network
TCP - IP
Ethernet
Plant Network
Ethernet, ControlNet
Fieldbus
intelligent field devices
FF, PROFIBUS, MVB, LON
Sensor Busses
simple switches etc.
CAN, DeviceNet, SDS, ASI-bus, Interbus-S
3 Industrial Communication Systems
3.1 Field Bus: principles
Buses de terreno: principios
Bus de terrain: principes
Feldbusse: Grundlagen
Prof. Dr. Hubert Kirrmann - 2013
Field bus: principles
3.1 Field bus principles
Classes
Physical layer
3.2 Field bus operation
Centralized - Decentralized
Cyclic and Event Driven Operation
3.3 Standard field busses
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 2
Location of the field bus in the plant hierarchy
File
Edit
SCADA level Operator 23 12
Engineering
4 2 2
33
Plant bus
Programmable
Plant Level Logic Controller
Field bus
Field level
Sensor/
Actor
Bus
Sensor / direct I/O
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 3
What is a field bus ?
A data network, interconnecting an automation system, characterized by:
- transmission of numerous small data items (process variables) with bound delay (1ms..1s)
- transmission of non-real-time traffic for commissioning (e.g. download) and diagnostics
- harsh environment (temperature, vibrations, EM-disturbances, water, salt,…)
- robust and easy installation by skilled people
- high integrity (no undetected errors)
- high availability (redundant layout)
- intrinsic safety (in some applications: oil & gas, mining, chemicals,..)
- clock synchronization (milliseconds down to a few microseconds)
- continuous supervision and diagnostics
- low attachment costs ( € 5.- .. €50 / node)
- moderate data rates (50 kbit/s … 5 Mbit/s) but large distance range (10m .. 4 km)
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 4
Expectations
- reduce cabling
- increased modularity of plant (each object comes with its computer)
- easy fault location and maintenance
- simplify commissioning (mise en service, IBS = Inbetriebssetzung)
- simplify extension and retrofit
- large number of off-the-shelf standard products to build “Lego”-control systems
- possibility to sell one’s own developments (if based on a standard)
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 5
The original idea: save wiring
marshalling tray
I/O dumb devices
bar capacity
PLC
(Rangierung,
tableau de brassage (armoire de triage)
COM
PLC
field bus
but: the number of end-points remains the same !
energy must be supplied to smart devices
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 6
Marshalling (Rangierschiene, Barre de rangement)
The marshalling is the interface between
the PLC people and the instrumentation
people.
The fieldbus replaces the marshalling bar
or rather moves it piecewise to the process
(intelligent concentrator / wiring)
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 7
Distributed peripherals
Many field busses are just
extensions of the PLC’s Inputs
and Outputs,
field devices are data
concentrators.
Devices are only visible to the
PLC that controls them
relays and fuses
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 8
Field busses classes
Office
network
TCP IP
Ethernet
Plant Network
Ethernet, ControlNet
Fieldbus
intelligent field devices
FF, PROFIBUS PA, LON
Sensor Busses
simple switches etc.
CAN, DeviceNet, SDS, ASI-bus, Interbus-S
The field bus depends on:
its function in the hierarchy
the distance it should cover
the data density it should gather
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 9
Geographical extension of industrial plants
The field bus suits the physical extension of the plant
1 km .. 1000 km Transmission & Distribution
Control and supervision of large distribution networks:
• water - gas - oil - electricity - ...
1 km .. 5 km Power Generation
Out of primary energy sources:
• waterfalls - coal - gas - oil - nuclear - solar - ...
50 m .. 3 km Industrial Plants
Manufacturing and transformation plants:
• cement works - steel works - food silos - printing - paper
pulp processing - glass plants - harbors - ...
500m .. 2 km Building Automation
• energy - air conditioning - fire - intrusion - repair - ...
1 m .. 1 km Manufacturing
flexible manufacturing cells - robots
1 m .. 800 m Vehicles
• locomotives - trains - streetcars - trolley buses - vans -
buses - cars - airplanes - spacecraft - ...
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 10
Fieldbus over a wide area: example wastewater treatment
Pumps, gates, valves, motors, water level sensors, flow meters, temperature sensors,
gas meters (CH4), generators, … are spread over an area of several km2
Some parts of the plant have explosive atmosphere.
Wiring is traditionally 4..20 mA, resulting in long threads of cable (several 100 km).
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 11
Fieldbus over a wide area: Water treatment plant
Japan Control Room source: Kaneka, Japan
LAS
R emote SCADA Ethernet
Maintenanc e
Malaysia
Sy s tem Bus Monitor
H1 Speed Fieldbus
JB Segment 1 Segment 3 JB
Sub Station
AO
AI
P ID
PLC
AO
P ID
AI AI AI AI AI AI AI AI P ID AO
AO AO
DI M.C.C.
FB Protoc ol
C onv erter
JB Segment 2 JB Segment 4 D igital Input/Output
AI AI
S S S S S
AI AI AI P ID AI P ID AI AI AI AI
AO AO
Numerous analog inputs (AI),
low speed (37 kbit/s) segments merged to 1 Mbit/s links.
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 12
Fieldbus application: Building Automation
Source: Echelon
low cost, low data rate (78 kbit/s), may use power lines (10 kbit/s)
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 13
Fieldbus Application: locomotives and drives
radio power line
cockpit
diagnosis Train Bus
Vehicle Bus
brakes power electronics motors track signals
data rate 1.5 Mbit/second
delay 1 ms (16 ms for skip/slip control)
medium twisted wire pair, optical fibers (EM disturbances)
number of stations up to 255 programmable stations, 4096 simple I/O
integrity very high (signaling tasks)
cost engineering costs dominate
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 14
Fieldbus Application: automobile
- 8 nodes
- 4 electromechanical wheel brakes
- 2 redundant Vehicle Control Unit
- Pedal simulator
- Fault-tolerant 2-voltage on-board power supply
- Diagnostic System
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 15
Application: Avionics (Airbus 380)
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 16
Networking busses: Electricity Network Control: myriads of protocols
Inter-Control Center Protocol
SCADA
control IEC 870-6 control ICCP control High
HV Voltage
center center center
Modicom IEC 870-5 DNP 3.0 Conitel RP 570 serial links (telephone)
RTU RTU RTU RTU Remote Terminal Units
COM RTU
substation substation
Medium
MV Voltage
FSK, radio, DLC, cable, fiber,... RTU
RTU
houses RTU RTU
Low
LV Voltage
low speed, long distance communication, may use power lines or telephone modems.
Problem: diversity of protocols, data format, semantics...
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 17
The ultimate sensor bus
power switch and
bus interface
requires integration of power electronics and communication at very low cost.
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 18
Engineering a fieldbus: consider data density (Example: Power Plants)
Acceleration limiter and prime mover: 1 kbit in 5 ms
Burner Control: 2 kbit in 10 ms
per each 30 m of plant: 200 kbit/s
Fast controllers require at least 16 Mbit/s over distances of 2 m
Data are transmitted from the periphery or from fast controllers to higher level, but slower links to
the control level through field busses over distances of 1-2 km.
The control stations gather data at rates of about 200 kbit/s over distances of 30 m.
The control room computers are interconnected by a bus of at least 10 Mbit/s,
over distances of several 100 m.
Planning of a field bus requires to estimate the data density per unit of length (or surface)
and the requirements in response time and throughput over each link.
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 19
Assessment
• What is a field bus ?
• Which of these qualities are required:
1 Gbit/s operation
Frequent reconfiguration
Plug and play
Bound transmission delay
Video streaming
• How does a field bus supports modularity ?
• What is the difference between a sensor bus and a process bus ?
• Which advantages are expected from a field bus ?
Industrial Automation
Prof. Dr. Hubert Kirrmann - 2013 Field buses: principles 3.1 - 20
