ETSI #67 - The Wireless Factory
13 June 2008
Wireless Applications
at Machine Level
in Industrial Automation
Bruno FORGUE – EMEA Marketing Manager
The Wireless Factory
Wireless at Machine Level
Introduction
• Typical factory data communication model
• Devices and protocols
• Wireless for industrial automation
Who is ProSoft Technology?
• Communication solutions for industrial automation
• Application and support oriented company
Why do customers ask for wireless?
Application examples
Conclusion
June 13 2008 - ETSI - 2
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Introduction: Typical Factory
Data Communication Model
Information Technology Dept.
Control room
Plant floor
Machines
Indust. Automation
IT Systems
ERP software
PCs
HMI software
PLC Controllers
Sensors
Actuators
Operator interfaces
June 13 2008 - ETSI - 3
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Introduction:
Devices and Protocols
Equipments to be connected are:
•
•
•
•
•
•
Programmable controller: the CPU which controls the machine
Operator interface: for interaction between human and machine
PC: configuration, programming , maintenance…
Sensors: convert a physical variable to current or voltage (detect /
measure process information to bring to the CPU)
Actuators: convert a command to power (motors, valves, heater…
controlled by the CPU)
…
Equipment 1
Communication
Equipment 2
Industrial
Communication
Protocols
Profibus… EtherNet/IP… Modbus… DF1… ControlNet…
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Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Introduction: Wireless
for Industrial Automation
… to wirelessly access
remote plants or stations
…to wirelessly connect business
system to the control system
… to wirelessly connect HMI to
controllers and devices
… to wirelessly program,
configure, &
monitor the system
…to wirelessly link PLCs for messaging
…to wirelesly connect remote racks of I/O
… to wirelessly connect I/O devices,
sensors and actuators.
Diagram courtesy of Rockwell Automation
© 2005 Rockwell Automation
June 13 2008 - ETSI - 5
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Who is ProSoft Technology?
Communication Solutions
Integrate to non-native protocols into the architecture
…
Modbus TCP/IP
Modbus Plus
ASCII/Ethernet
Profibus DP
IEC 60870-5-104
HART
DNPSNET
DE
…
…
…
…
IEC 60870-5-103
Wireless
IEC 60870-5-101
Modbus
DNP 3.0
ASCII/Serial
June 13 2008 - ETSI - 6
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Communication Solutions for
industrial automation
“Where Automation Connects”
More than 20 years of experience
• Industrial Automation
• Industrial Protocols
• Industrial Wireless
In partnership with
• Rockwell Automation,
• Schneider Electric
• and other automation and process control leaders
June 13 2008 - ETSI - 7
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Who is ProSoft Technology?
Application Oriented Company
Bringing innovation
• Industrial wireless

Unique family of high performance solutions
• Interface gateways

High-speed gateways
• In-rack modules

PLC processor has direct access to memory via backplane
Benefits for Customer
• High performances!
• Ease of implementation!
• Unequaled Technical Support
June 13 2008 - ETSI - 8
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Who is ProSoft Technology?
Support Oriented Company
June 13 2008 - ETSI - 9
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Why do customers
ask for wireless?
Installation
Maintenance
Operation cost reduction
Flexibility
Moving & Rotating equipments
Distance
Reliability
…
June 13 2008 - ETSI - 10
Warehouse
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
June 13 2008 - ETSI - 11
Logistic – Material handling
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Moving parts
Remove data cables from
flexible cable runways
A lot of metal frames
Metal moving parts (cabinets
between rows of the warehouse)
Reliability, availability (moving
cabinet must not loose connection
when at stop points).
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Manufacturing
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
June 13 2008 - ETSI - 13
Manufacturing
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
OVEN 1
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OVEN 8
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June 13 2008 - ETSI - 14
Steel foundry
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
June 13 2008 - ETSI - 15
Coking
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
June 13 2008 - ETSI - 16
Coking
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
June 13 2008 - ETSI - 17
Heavy loads handling
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
A1
a1
b1
660 m
Wood Ladder
B1
June 13 2008 - ETSI - 18
Heavy load handling
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Anti-collisions system for heavy load handling
With two cranes – application fail-safe in event one crane
Loses power
Allow two portal cranes to work independently and
simultaneously while sharing a common rail track
Monitoring and control of Ethernet drives
Large number of multicast producer consumer packets per drive
June 13 2008 - ETSI - 19
Material handling
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
No more collisions
• Protects mechanical installation
against potential damages
• Avoid collisions
and repair costs
Increase availability
• Reduce amount of disturbances
and faulty situations
Replace slip-ring
• Improve network availability
June 13 2008 - ETSI - 20
Remote SCADA
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Tight time frame
Private line needed
2 roads crossings
No existing path for cables
June 13 2008 - ETSI - 21
Wireless in Industrial Automation
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Obstacles
• Rail way
• River
• Highway
Leverage maintenance
(Slip ring)
Extended network over
Widespread area
Moving parts
Distance
Ethernet
Telecontrol
Serial
FHSS
And more…
Harsh environment
IEEE802.11abg
Field Devices Protocols…
June 13 2008 - ETSI - 22
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Conclusion
Wireless at Machine Level
Industrial environment constraints for the
electronics
• Temperature, vibration, humidity, EMC…
Protocols and application specificities
• Automation specific protocols
• Functionalities
RF reflections / multi-paths (indoor)
and obstacles (outdoor)
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Control
Class 0: Emergency action
(always critical)
Class 1: Closed loop regulatory control
(often critical)
Class 2: Closed loop supervisory control (usually non-critical)
Class 3: Open loop control
NOTE:
(human in the loop)
Batch levels* 3 & 4 could be class 2, class 1 or even class 0, depending on function
*Batch levels as defined by ISA S88; where L3 = "unit" and L4 = "process cell"
Class 4: Flagging
Short-term operational consequence
(e.g., event-based maintenance)
Monitoring
Class 5: Logging & downloading/uploading
Importance of
Safety
message timeliness increases
One word about
standardization processes
No immediate operational consequence
(e.g., history collection, SOE, preventive maintenance)
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Before leaving…
Introduction
ProSoft Technology
Why Wireless?
Applications
Conclusion
Questions?
Thanks
Bruno FORGUE
[email protected]
June 13 2008 - ETSI - 25