Industrial Automation

Automation Industrielle
Industrielle Automation
3 Industrial Communication Systems
3.1 Field Bus: principles
Buses de terreno: principios
Bus de terrain: principes
Feldbusse: Grundlagen

CAN, DeviceNet, SDS, ASI-bus, Interbus-S
Ethernet, ControlNet
TCP - IP
Ethernet
Sensor Busses
simple switches etc.
Plant Network
Office
network
Fieldbus
intelligent field devices
FF, PROFIBUS, MVB, LON
Field buses: principles 3.1 - 2
Industrial Automation
2013
Field bus: principles
3.1 Field bus principles

3.2 Field bus operation
Centralized - Decentralized
Cyclic and Event Driven Operation

3.3 Standard field busses
Field buses: principles 3.1 - 3
Industrial Automation
2013
Sensor/

Actor

Bus
Field bus
Programmable
Logic Controller
Plant bus
SCADA level
Plant Level
Field level
File
Edit
Engineering
Operator
2
12
2
33
23
4
Location of the field bus in the plant hierarchy
direct I/O Sensor /
Actor
Field buses: principles 3.1 - 4
Industrial Automation
2013
What is a field bus ?
A data network, interconnecting an automation system, characterized by:

- many small data items (process variables) with bounded delay (1ms..1s)
- transmission of non-real-time traffic for commissioning and diagnostics
- harsh environment (temperature, vibrations, EM-disturbances, water, salt,)
- robust and easy installation by skilled people
- high integrity (no undetected errors) and high availability (redundant layout)
- intrinsic safety (for oil & gas, mining, chemicals,..)
- clock synchronization (milliseconds to microseconds)
- continuous supervision and diagnostics
- low attachment costs ( 5.- .. 50 / node)
- moderate data rates (50 kbit/s - 5 Mbit/s), large distance range (10m - 4 km)
Field buses: principles 3.1 - 5
Industrial Automation
2013
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
- off-the-shelf standard products to build Lego-control systems
Field buses: principles 3.1 - 6
Industrial Automation
2013
The original idea: save wiring
marshalling
bar
I/O
PLC
PLC
But: the number of end-points remains the same !
energy must be supplied to smart devices
dumb devices
field bus
(Rangierung,
tableau de brassage (armoire de triage)
C
O
M

tray
capacity
Field buses: principles 3.1 - 7
Industrial Automation
2013
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)
Field buses: principles 3.1 - 8
Industrial Automation
2013
Distributed peripherals
Many field busses are just extensions
of the PLCs inputs and outputs,
field devices are data concentrators.
Devices are only visible to the PLC that
controls them.
relays and fuses
Field buses: principles 3.1 - 9
Industrial Automation
2013
Field busses classes
CAN, DeviceNet, SDS, ASI-bus, Interbus-S
Ethernet, ControlNet
TCP IP
Ethernet
Sensor Bus
simple switches etc.
Plant Network
Office
network
Fieldbus
intelligent field devices
FF, PROFIBUS PA, LON
The field bus depends on:
its function in the hierarchy
the distance it should cover
the data it should gather
Field buses: principles 3.1 - 10
Industrial Automation
2013
Geographical extension of industrial plants
The field bus requirements follow the physical extension of the plant
Control and supervision of large distribution networks:

water - gas - oil - electricity - ...
Out of primary energy sources:

waterfalls - coal - gas - oil - nuclear - solar - ...
Manufacturing and transformation plants:

cement works - steel works - food silos - printing - paper
pulp processing - glass plants - harbors - ...
locomotives - trains - streetcars - trolley buses - vans -
buses - cars - airplanes - spacecraft - ...
energy - air conditioning - fire - intrusion - repair - ...
Transmission & Distribution
Power Generation
Industrial Plants
Vehicles
Building Automation
Manufacturing
flexible manufacturing cells - robots
50 m .. 3 km
1 km .. 5 km
1 km .. 1000 km
1 m .. 800 m
500m .. 2 km
1 m .. 1 km
Field buses: principles 3.1 - 11
Industrial Automation
2013
Fieldbus over a wide area: example wastewater treatment
Pumps, gates, valves, motors, water level sensors, flow meters, temperature
sensors, gas meters (CH
4
), generators, etc are spread over an area of
several km
2
. Some parts of the plant have to cope with explosives.

Field buses: principles 3.1 - 12
Industrial Automation
2013
Fieldbus over a wide area: Water treatment plant
S
M.C.C.
Control Room
Sub Station
SCADA
Bus Monitor
JB JB
Remote
Maintenance
System
Ethernet
Segment 1
Segment 2
Segment 3
Segment 4
FB Protocol
Converter
PLC
Digital Input/Output
PID
PID PID
PID
PID
H1 Speed Fieldbus
LAS
JB JB
AI AI AI AI AI
AI AI AI AI AI
AI
AI AI
AI AI AI
AI
AO AO
AO
AO
AO
AO
DI
S S S S
AI
AO
AI
Japan
Malaysia
Numerous analog inputs/outputs (AI/AO),
low speed (37 kbit/s) segments (Hart) merged to 1 Mbit/s links (H1 Speed Fieldbus).
source: Kaneka, Japan
Junction
Box
Motor
Control
Center
Field buses: principles 3.1 - 13
Industrial Automation
2013
Fieldbus Application: locomotives and drives
cockpit
motors power electronics brakes
power line
track signals
Train Bus
diagnosis
radio
data rate

delay

medium

number of stations
1.5 Mbit/second

1 ms (16 ms for skip/slip control)
twisted wire pair, optical fibers (EM disturbances)
up to 255 programmable stations, 4096 simple I/O
Vehicle Bus
cost engineering costs dominate
integrity very high (signaling tasks)
Field buses: principles 3.1 - 14
Industrial Automation
2013
Fieldbus Application: automobile
- Electromechanical wheel brakes
- Redundant Engine Control Units
- Pedal simulator
- Fault-tolerant 2-voltage on-board power supply
- Diagnostic System
Field buses: principles 3.1 - 15
Industrial Automation
2013
Application: Avionics (Airbus 380)
Field buses: principles 3.1 - 16
Industrial Automation
2013
Networking busses: Electricity Network Control: myriads of protocols
houses
substation
Modicom
ICCP
control
center
Inter-Control Center Protocol
IEC 870-6
HV
MV
LV
High

Voltage
Medium

Voltage
Low

Voltage
SCADA
FSK, radio, DLC, cable, fiber,...
substation
RTU
RTU RTU
RTU
COM
RTU RTU RTU Remote Terminal Units RTU
RTU
IEC 870-5 DNP 3.0 Conitel RP 570
control
center
control
center
low speed, long distance communication, may use power lines or telephone modems.
Problem: diversity of protocols, data format, semantics...
serial links (telephone)
Field buses: principles 3.1 - 17
Industrial Automation
2013
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
For each 30 m of plant: 200 kbit/s
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.

Fast controllers require at least 16 Mbit/s over distances of 2 m
The control room computers are interconnected by a bus of at least 10 Mbit/s,
over distances of several 100 m.
Field bus planning: estimate data density per unit of length or
surface, response time and throughput over each link.
Field buses: principles 3.1 - 18
Industrial Automation
2013
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 support modularity ?
Which advantages are expected from a field bus ?