Industrial networking: One network for full enterprise connectivity

05/24/2013


Industrial networks

ctl1306-f4-networks-Turck-x2-Factory-Automation-w.jpgWith the migration away from traditional point-to-point fieldbus, advanced networking architecture ensures connectivity, collaboration, and integration from the device level to enterprise business systeWhile industrial networking is a powerful tool for improving operations, it is not a “one-size-fits-all” solution. There are several considerations, such as environment, traffic, security, and cabling, that must be taken into account before implementing the appropriate solution for individual networking needs.

With Ethernet originally being created for the office environment, it is crucial that users consider their environmental conditions when determining what type of cabling is needed. Industrial Ethernet cabling is designed to meet and exceed the requirements of industrial applications, and the environmental conditions will generally determine the type of cordset used. Cordsets are expected to perform in applications that involve everything including welding, high-flex robotics, washdown, or hygienic conditions. Cordsets must be designed to withstand shock and vibration, crushing and pulling, bending or twisting, dust and dirt, water, oils, chemicals, corrosive gases, or temperature extremes.

Along with the environmental considerations, industrial networks must be able to manage plant traffic and interface with existing systems. Traffic ranges from data transfers to mission critical transmissions, and being able to distinguish between the two, identifying high-priority traffic to ensure it continues to operate efficiently. Additionally, since many processes deal with sensitive information, manufacturers should use security mechanisms to avoid outside intrusion and protect internal communications.

Networks are layered and require filtering to allow information to pass through a system based on its source, application, and destination. Filtering can be done based on various parameters, such as IP address, port type, and physical parameters. Additionally, establishing network redundancy is also important because if a problem occurs, an alternate link will ensure production is back online automatically, preventing lost information.

Before implementation, plant managers need to consider network communications signal requirements, including CAT 5, 5e, 6, 6A and 7; two-pair or four-pair cabling; D-code or X-code cordsets; solid or stranded cabling; and shielded or unshielded cabling. This will enable users to select an appropriate solution.

Plant-floor networking

As demand grows and industries become more competitive, operation data must travel across greater distances, at faster speeds, and in larger quantities. Due to this, maintaining reliable enterprise connectivity is necessary for continued overall production. Therefore, protocols connecting the office with the plant floor must offer seamless interoperability among manufacturing enterprise networks. Implementing a complete, end-to-end networking solution provides a wide range of benefits, including a lower overall total cost of ownership (TCO), a higher return on investment (ROI) due to real-time visibility and flexibility, reduced network maintenance, and decreased labor costs.

When moving the network from the back office to the factory floor, manufacturers require high-level reliability and security, with sophisticated features that allow constant access to critical production information. The advances offered with industrial networking protocols now enable one, high-quality network that can control an entire plant operation.

By providing comprehensive integration with administrative-, control-, and device-level management, information moves freely throughout the entire enterprise, providing unparalleled visibility. This degree of simplistic, complete information sharing ensures a more seamless production by automatically updating inventory information, distribution data, and real-time status updates.

Additionally, deploying one factory-wide network eliminates excess costs, maintenance requirements, and time-consuming installations. By monitoring every aspect of product, industrial networking can work to identify any issues faster to minimize downtime and prevent costly lost production.

- Karie Daudt is director of marketing for Turck. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering and Plant Engineering, mhoske@cfemedia.com.

ONLINE extras

www.turck.us

Learn about industrial network products.


<< First < Previous 1 2 Next > Last >>

Anonymous , 11/07/13 02:56 AM:

I personally agree that having access to data (process data as well as equipment health and instrument health etc.) is key to improved efficiency, productivity, and profitability since it can increase product quality, throughput, and process availability as well as reduce cost of operation & maintenance.

I also agree with digital communication networks are required to achieve this. I would personally also like to add that this digital networking has to start from the very “first meter”; at the sensors and actuators. That is, we cannot limit ourselves using point-to-point hardwired 4-20 mA and on/off signals for sensors and actuators. Instead we should go “digital everywhere” using digital communication networks also to connect transmitters, analyzers, control valve positioners, on/off valves, electric actuators and the like at the lowest level to get intelligence in every device. This enables not only real-time digital closed loop control, but also access to diagnostics etc. from the field instruments:
http://www.eddl.org/DeviceManagement/Pages/DeviceDiagnostics.aspx

Therefore we have to be careful with the term “fieldbus” because there are two very distinct types of “fieldbus”: H1 fieldbus and H2 fieldbus.

“H2 fieldbus” is used at level 1-1/2 of the Purdue reference model to connect variable speed drives, motor starters, MCC, small package unit PLCs, and wireless gateways etc. to the main DCS control system. The fieldbus protocols traditionally used are DeviceNet, Modbus/RTU, and PROFIBUS which correspond to the new industrial Ethernet variants of these protocols: EtherNet/IP, Modbus/TCP, and PROFINET. Indeed there appears to be a migration away from the “H2” fieldbus towards their industrial Ethernet variants at this level.

However, “H1 fieldbus” is a different story. H1 is used at level 1 of the Purdue reference model. Industrial Ethernet is not taking the place of H1 fieldbus. This is why we have to explicitly make the difference between H2 and H1. H1 fieldbus is used for devices which are not available in an industrial Ethernet version. These are devices which traditionally use 4-20 mA and on/off signals, but the use of H1 digital commutation is on the rise. These include for example pressure transmitter, temperature transmitter, level transmitter, interface level transmitter, vortex flow meter, pH analyzer, conductivity analyzer, amperometric analyzer, control valve positioner, and on/off valve etc. As you can see, the devices connected by H1 fieldbus are quite different from those that connect using Industrial Ethernet. That is, H1 fieldbus and industrial Ethernet complement each other; together they cover all the devices around the plant. Indeed the H1 fieldbus at level 1 of the Purdue reference model enables access to more data from a massive amount of field instruments which in turn drives faster growth of industrial Ethernet at level 1-1/2 and above to get this data to the user.

Also, traditional fieldbus is not point-to-point. Traditional fieldbus is a bus topology. Point-to-point hardwiring is only used for 4-20 mA and on/off signals.
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Hannover Messe 2016: Taking hold of the future - Partner Country status spotlights U.S. manufacturing; Honoring manufacturing excellence: The 2015 Product of the Year Winners
Inside IIoT: How technology, strategy can improve your operation; Dry media or web scrubber?; Six steps to design a PM program
World-class manufacturing: A recipe for success: Finding the right mix for a salad dressing line; 2015 Salary Survey: Manufacturing slump dims enthusiasm
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Digital oilfields: Integrated HMI/SCADA systems enable smarter data acquisition; Real-world impact of simulation; Electric actuator technology prospers in production fields
Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
Warehouse winter comfort: The HTHV solution; Cooling with natural gas; Plastics industry booming
Managing automation upgrades, retrofits; Making technical, business sense; Ensuring network cyber security
Designing generator systems; Using online commissioning tools; Selective coordination best practices

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
click me