INDUSTRIAL AUTOMATION II

Introduction
Industrial Network
Industrial communication network is a
special type of network made to handle real-time
control and data integrity in harsh environments
over large installations.
The examples of industrial communication
networks include Ethernet, DeviceNet, Modbus,
ControlNet, and so on.
Historical Overview
1960 digital computer as digital controller
PLC was developed to replace relay based control.
Many technologies in machine tools & discrete
production processes.
NC are controlled by computers and robots was
developed
More widespread use of digital computers Industrial
Communication networks developed.
In mid 70s first Distributed computer control system
was announced by Honeywell.
DCCS used in power plants and manufacturing systems
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LAN to automation system within industrial
automation system popular in 1980.
As industrial automation system become large,
automation devices increases become important
for industrial automation to provide standards.
International standardization efforts are made in
LAN
Open Systems Interconnection (OSI)
standard Permits any pair of Automation
devices to communicate reliably regardless of
manufacturer.
Seven layers of the
OSI
OSI Layers
Layer 7 - Application
The application layer where the user inputs data
and data is output to the user.
Usually software run off the local machine, but
depends on the network architecture.
The software could be cloud based, meaning it
runs off a server in a remote location and data is
transferred over the internet, or the software could
be run on a local server.
The application layer provides services for email,
Telnet and file Transfer for example.
An example of the application layer is an internet
browser, an FTP client or even Microsoft Word.
Layer 6 - Presentation
The presentation layer is Operating system
lies.
Responsible for data representation on your
screen
Encryption and decryption of the data
Data semantics and syntax
Layer 6 Presentation examples include
encryption, ASCII, EBCDIC, TIFF, GIF, PICT,
JPEG, MPEG, MIDI.
Layer 5 - Session
The session layer is responsible for creating and
maintaining sessions between the operating system
on the presentation layer and other, third party
machines.
Setup, Control, Maintain, Close Communicative
sessions.
The session layer sets up, coordinates, and
terminates conversations, exchanges, and dialogues
between the applications at each end.
It deals with session and connection coordination.
Protocols like NFS, NetBios names, RPC, SQL work
at this layer.
Online Bank account time out
Layer 4 - Transport
Responsible for the transparent transfer of data
between end systems
Responsible for end-to-end error recovery and
flow control
Responsible for complete data transfer.
Responsible for determining what and how
much information is transferred between the
operating system and the web server.
Protocols like SPX, TCP, UDP work here
Layer 3 - Network
Switching and routing technologies work here
Creates logical paths between two hosts across
the world wide web called as virtual circuits
Routes the data packet to destination
Routing and forwarding of the data packets.
Internetworking, error handling, congestion
control and packet sequencing work at this layer
Router works at layer three
Different network protocols like TCP/ IP, IPX,
AppleTalk work at this layer
Layer 2 - Data Link
Responsible for encoding and decoding of the electrical
signals into bits.
Manages data errors from the physical layer
Converts electrical signals into frames
The data link layer is divided into two sub-layers
The Media Access Control (MAC) layer
Logical Link Control (LLC) layer.
The MAC sublayer controls how a computer on the
network gains access to the data and permission to
transmit it.
The LLC layer controls frame synchronization, flow
control and error checking.
MAC address is a part of the layer 2.
Devices like Switch work at this layer
Layer 1 - Physical
Responsible for electrical signals, light signal,
radio signals etc.
Hardware layer of the OSI layer
Devices like repeater, hub, cables, ethernet work
on this layer
Protocols like RS232, ATM, FDDI, Ethernet
work on this layer
Hierarchical
Levels in
Industrial
Communication
Networks
Field Level
Lowest level consists of field devices such as
sensors and actuators of processes and machines.
The task of this level is to transfer the information
between these devices and technical process
elements such as PLCs.
The information transfer can be digital, analog or
hybrid.
The measured values may stay for longer periods or
over a short period.
The common serial communication protocol
standards used in this level include RS232, RS422
and RS485. There are many other field level
communication networks available which are
characterized different factors such as response
time, message size, etc.
Field Level
Nowadays Field bus technology is the most
sophisticated communication network
This is a bidirectional communication system in
which many variables are taken care by single
transmission.
Different types of field buses include HART,
ControlNet, DeviceNet, CAN Bus, Profibus, and
Foundation Field Bus
Control Level
This level consists of industrial controllers such
as PLCs, distributed control units, and computer
systems.
The tasks of this level include configuring
automation devices, loading of program data
and process variables data, adjusting set
variables, supervising control, displaying
variables data on HMIs, historical archiving, etc.
So this level requires characteristics like short
response time, high speed transmission, short
data lengths, machine synchronization, constant
use of critical data, etc.
Control Level
Local Area Networks (LANs) are widely used as
communication networks in this level to achieve
desired characteristics.
The Ethernet with TCP/IP protocol is mostly
used as control level network to connect control
units with computers.
In addition, this network acts as a control bus to
coordinate and synchronize between various
controller units.
Some fieldbuses are also used in this level as
control buses such as Profibus and ControlNet.
Information Level
This is the top level of the industrial automation
system which gathers the information from its
lower level i.e., control level.
It deals with large volumes of data that are
neither in constant use or time critical. Large
scale networks are exists in this level.
So Ethernet WANs are commonly used as
information level networks for factory planning
and management information exchange.
Sometimes these networks may connect to other
industrial networks via gateways.
MODBUS Protocol
ASCII, RTU, TCP/IP
Introduction
Modbus serial Communication
protocol developed by Modicon in
1979.
Modbus is open Protocol
Can be used Via. Ethernet as well
serial cable.
Three types of Modbus ASCII, RTU
and TCP/IP
RTU binary coding & CRC error
checking
RTU uses one of three electrical
interfaces : RS232, RS485, RS422
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RS-485 with 32 Nodes

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Data speed is in bits per
second(Baud Rate)
9600 19200 Typical Speeds
RS-485 with 32 Nodes
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MODBUS RTU
MODBUS configuration in Vijeo
SoMachine
MODBUS configuration in SoMachine
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