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PRODUCTIVITY & BEST PRACTICES: EDITOR’S COLUMN Kevin Parker Senior Contributing Editor
Straight talk on industrial integration Hybrid environment of proprietary and open-source standards will persist
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Modbus or Profibus, into a standardized interface allows the Industrial Internet of Things unfolds, will ing SCADA systems to interface with a “middleman” it avoid the pitfalls that have plagued previous who would convert generic OPC read/write requests into generations of integration tools? device-specific requests, and vice versa. If there can be such a thing as irony in industrial autoMore recently, “the new sensor gateways are a way mation, then it’s ironic that the myriad of device drivers originally promulgated for SCADA integration continue to to network many different types of sensors, acting as a connectivity bridge for use of these transport protoplay such a big role in industrial environments, even for cols,” said Paine. Gateways are moving down to the emerging areas like industrial cybersecurity. sensor level, just as control functions are. “It is an integration sticking point,” said Tony Paine, “Even if middleware modalities are still often needed, CTO, industrial automation, at PTC. “While the realthat also will be an appliance,” ity of having individual device said Paine. drivers for integration of many The same kinds of concerns different data sources will persist for some time to come, the Integration and interoperability apply to modeling and the propagation of digital twins. layer of abstraction above the “Everyone will have a modeling device driver, the application makes computing powerful, scheme, but we don’t want to programming interface, can be map to every vendor. The OPCdistilled into a half-dozen to a but present a kind of UA standard plays a role here, dozen or so standards.” providing companion specificaGiven the mix of devices in chicken-or-egg conundrum. tions on how to model a given the installed base and in the protocol,” said Paine. new generations of technology coming on line, Paine sees a hybrid approach continuing for some time. “When it An ecosystem of your own comes to new technologies, product designers realize The automation companies have gotten pretty good that devices no longer stand alone. Rather than every at adapting to the industrial marketplace what works in supplier writing one-off device drivers, they will likely consumer and commercial markets. Fieldbus standards choose from a menu.” like HART, Profinet, and EtherNet/IP originated from major automation suppliers having the resources to create an ecosystem of their own. However, the standards have Middlemen remain relevant subsequently been released to open source. Examples of standards relevant to these efforts include “A lot of great, formerly proprietary information has transport protocols MQTT, CoAP for small sensors, AMQP been made available,” said Paine, “but the decision still from Microsoft, and web services in a generic sense, Paine said, adding, “Through the OPC Foundation, suppli- has to be made to support a particular standard.” That’s one reason why Paine is convinced further ers are coming together to ensure interoperability.” progress in interoperability and integration depends on The OPC interoperability standard defines an interpartnerships that reduce development risk, provide guidface between clients and servers, as well as servers and ance for users, and solve what is at the end of the day a servers. When the standard was first released in 1996, kind of chicken-or-egg conundrum. IIoT its purpose was to abstract PLC-specific protocols, e.g.,
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www.controleng.com/IIoT
Industrial Internet of Things
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CONNECTIVITY & COORDINATION
Is EtherCAT the answer? Standards-based IP used over low-power link technologies
By Andrew Caples
Emerging developments
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For resource-constrained devices, protocols historically deployed for data transport and cloud integration were proprietary and not internet protocol (IP)-based. This was due to the large overhead and resource requirements associated with IP packets. Proprietary
ith the introduction of networked systems on factory floors, industrial automation environments are experiencing rapid technology transformation. However, even with networked machines, connectivity’s full potential isn’t realized, as machines still typically operate as islands, or individual modules, not interacting with or even being aware of preceding or subsequent machines. To realize the potential of Industrrie 4.0, individual machines must be able to control or influence other machines in the factory. The industrial-automation future is a production environment in which devices, machines, and materials are equipped with sensors. Major industrial automation suppliers promise interoperability among factory-floor devices, and extending to cloud -based enterprise applications and corporate data centers. This bridges the divide between networks for information technology and those for operations technology. Every sensor, actuator, and factory machine becomes a network participant. Access to the data throughout the enterprise supports operational efficiency. However, a standardsbased approach that leverages existing infrastructure is required, while remaining platform and operatingsystem agnostic to support many different devices.
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Internet Engineering Task Force (IETF). It originated from the idea that the IP could and should be applied even to the smallest devices, and that lowpower devices with limited processing capabilities should be able to participate in the Internet of Things. Thus, the use of standards-based IP over low-power link technologies is now possible. 6LoWPAN is an adaption layer between the IP link and the network layer to enable transmission of IPv6 packets over low-power wireless connections like IEEE 802.15.4. 6LoWPAN provides header compression and packet fragmentation to reduce payload size, which allows the low-power transmission of standards-based IPv6 packets. With layer-2 packet forwarding, 6LoWPAN supports large quantities of nodes in low-power networks requiring multiple hops over large areas.
IPv6 over 6LoWPAN allows low-power devices with limited processing capabilities
Address legacy infrastructures
to participate in the Industrial Internet of
Large industrial-automation players drove market fragmentation by promoting different fieldbus technologies. Yet connectivity is essential to further advances in factory automation. The future is adoption of standards-based fieldbus technologies that leverage traditional network infrastructure. Ethernet for control automation technology (EtherCAT) is one example of a fieldbus solution that uses existing standard Ethernet infrastructure. EtherCAT is a globally emerging technology that could potentially lead toward a standard for Ethernet fieldbus.
Things. Graphic courtesy: Mentor
protocols were embraced because IP was not considered practical for lowpower network nodes, like sensors and actuators, as IP was bandwidthhungry and memory-intensive. However, with the introduction of IPv6 over Low Power Wireless Personal Area Networks (6LoWPAN) the industrial internet of things (IIoT) landscape has changed. According to Wikipedia, 6LoWPAN is the name of a concluded working group in the internet area of the
www.controleng.com/IIoT
Ethernet for Control Automation Technology (EtherCAT) is a fieldbus solution that allows connectivity to both operations and enterprise systems.
EtherCAT is Ethernet-based with real-time support and built-in security. It is one of the most efficient Ethernet-based industrial communication protocols available. Further, EtherCAT is based on standard Ethernet hardware for real-time communication for industrial applications. Processing “on-the-fly” is a key feature of EtherCAT. As network traffic is generated from the master EtherCAT controller, EtherCAT slave devices process each frame “on-the-fly” without stopping them. Data reads and writes can be extracted and inserted by each slave device as the frame navigates throughout the network without losing any overhead. As the required control-loop period can change depending on the control function required, EtherCAT offers flexibility. Longer cycles for I/O updates, or ultra-short cycle times for synchronizing robotic arms, for example, can coexist on the same wire. Because EtherCAT is Ethernet-based at the physical layer, it uses standard Category 5 cabling and networkinterface. To facilitate TCP/IP-based data transfers within an EtherCAT segment, an Ethernet over EtherCAT protocol can be used. Switchports are www.controleng.com/IIoT
A multi-platform approach provides the broadest portfolio of embedded-systems solutions for industrial automation, from end nodes and the industrial enterprise to the cloud.
needed to connect Ethernet devices to an EtherCAT segment. The Ethernet frames are tunneled through the EtherCAT protocol, which makes the EtherCAT network completely transparent to Ethernet devices. To prevent any degradation to performance, the switchport takes
care of inserting TCP/IP packets into the EtherCAT traffic in a manner that prevents the network’s realtime properties from becoming infected. Additionally, EtherCAT devices may also support internet protocols (such as HTTP) and can therefore behave like a standard IIoT For Engineers
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CONNECTIVITY & COORDINATION
Ethernet node outside of the EtherCAT segment.
Importance of OPC UA While EtherCAT is inherently secure, tunneling to other networks within the enterprise using TCP/IP can lead to
problems. Integration with EtherCAT demands protocols that address the security required to prevent device compromise connected to the fieldbus. Recently, EtherCAT and the OPC Foundation announced collaboration plans to jointly support the Industrie 4.0
standard. The OPC unified architecture (OPC UA) was designed with systemwide security in mind. OPC UA includes countermeasures against cyber threats such as denial-ofservice attacks, compromising extranet or cloud components, and introduction of malicious software via intranet or internet. It is implicitly secure, using access control, encryption, digital signatures, and X.509 certificates to address security requirements. Because OPC UA is platform-independent and scalable, it integrates devices throughout the enterprise. OPC UA can be deployed on embedded devices executing real-time operating systems or for services running Linux and Microsoft Windows platforms. With the combination of OPC UA and EtherCAT, standards-based protocols can integrate the factory floor with enterprise and supply-chain systems. Mentor embedded runtime solutions support multicore development for IIoT. Mentor Nucleus real-time operating system (RTOS) and the open-source Mentor embedded Linux are among popular runtime systems in use today. In addition, Mentor’s runtime solutions are integrated with industrial fieldbus support, including both EtherCAT and EtherNet/IP, supporting industrial protocols such as OPC UA, CANbus, Modbus, and others. EtherCAT is a highly useful fieldbus that’s enabling a vast number of connected devices to communicate within an already established IIoT/machineto-machine infrastructure. IIoT Andrew Caples is a product manager for Mentor’s embedded systems division.
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INFORMATION Search the Control Engineering magazine website for recent editorial features on EtherCAT specification, documentation, and solutions.
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SENSING & CONTROLS
Unleash data held captive Ways and means for achieving the free flow of machine data
By Garrett Schmidt
C
onsumer smart devices are periodically furnished with additional functionality via firmware upgrades. In much the same way, industrial facilities get more out of machinery already in production by equipping it with additional supporting capabilities. For example, making a commitment to technologies for monitoring equipment health improves a plant’s overall-equipment effectiveness (OEE). Remote-calibration and configuration capabilities save time and resources needed to pursue improvement. The lynchpin in these efforts is having equipment connected and communicating via Ethernet. However, the road to ubiquitous Ethernet connectivity is not without its obstacles. No one wants to disturb a functioning system or replace functioning devices. Managements won’t shut down productive capacity to affect a total change-over. Finally, some devices still may be unavailable with an Ethernet connection.
Get the most out of it Take HART as an example. HART is the global-communication protocol for sending and receiving digital information across 4-20 ma current loops. In the past, these loops were the most common way to connect field instruments to distributed control systems (DCS). It is said that www.controleng.com/IIoT
Converting Modbus RTU data to Modbus TCP supports facility modernization. All images courtesy: Phoenix Contact
more than 40 million HART devices are installed globally. Yet market surveys reveal that less than 10% of these devices are used to their potential. HART enables remote-transmitter configuration and calibration, and is a way to access diagnostic information on a device-by-device basis. The benefit is, in this type environment, that valves tell you if they’re stuck open, and flowmeters report pressure and temperature conditions. Unfortunately, most installed programmable logic controllers (PLCs) and DCS don’t have HART capability. Thus, what’s needed is a way to move HART data onto an Ethernet
network, without disturbing the existing control system. An Ethernet HART multiplexer solution is a simple way to parameterize and monitor HART devices via HART-IP, Profinet, Modbus TCP, and FDT/DTM for easy integration into nearly any host system. It is a modern alternative to traditional RS-485 HART multiplexers (For definitions of acronyms used in this article, see glossary on page 9). An Ethernet HART multiplexer’s modular design enables scalability and a phased DCS rollout. A multiplexer, including head station and HART expansion modules, can suit many application needs. Also of value is a 1x1 HART master, which means one HART master for each channel. It allows users to speed up maintenance routines, i.e., for multiple instruments at one maintenance interval. The head station includes an embedded web server that makes it easy to configure the device. Additionally, a CommDTM can be used with an FDT frame application, such as PACTware or any of the wide range of plant asset-management applications offered by automation-system suppliers.
Serial data with security Now, let’s look at those old serial devices. There are still a lot of them out there with simple RS-232 or RS485 ports that just spit out an ASCII string of characters—think bar-code IIoT For Engineers
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SENSING & CONTROLS
An ASCII converter module can make old data from a bar code usable in a modern Ethernet network.
An Ethernet HART multiplexer is a modern alternative for traditional RS-485 HART multiplexers.
scanners, weigh scales, RFID readers, and the like. Connecting these “dumb” devices to Ethernet gives them a new lease on life. This conversion is not really any stretch of the imagination; serial-device servers (or terminal servers) have been available for years. Keep in mind, though, it’s widely reported that malefactors are hacking into these devices when given the opportunity. Also, those old serial devices could, if set free to broadcast data, transmit something never meant for a “public” network. Thus, consider some type of data encryption and user authentication plan. Serial-device servers provide a simple way to migrate legacy serial devices to modern Ethernet networks. Devices, ranging from universal RS-232/485, to one-, two-, and four-port serial versions, with one or two Ethernet ports, are available.
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Device servers may be used as a “virtual COM Port” and as a native TCP or UDP Ethernet device. COM Port redirector software, as well as
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Industrial Internet of Things
Serial-device servers provide a simple way to migrate legacy serial devices to modern Ethernet networks.
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a Microsoft Windows driver, are available for integration with a PC application.
ASCII to Ethernet conversion Embedded web servers make start-up and configuration simple. To keep communications secure, look for a device with 256-bit AES
encryption and the ability to install your own authentication certificates. Devices with a wide operato o ing-temperature range (-40 to 70 C) and hazardous area approvals are suitable for use in any industry. To take it a step further, integrate those old serial devices into an industrial-control network. New possibilities come to life when an old serial bar-code scanner is converted into a Modbus TCP or EtherNet/IP bar-code scanner. A bar code can be scanned and used to direct a guided vehicle inside an automotive plant, or to push an item onto the correct conveyor belt in a warehouse. Plan to do more with what you already have. ASCII converter modules are used to convert raw or ASCII serial strings from devices such as bar-code scanners, weigh scales, or RFID tags into industrial protocols such as Modbus TCP or Ethernet/IP. One-, two-, and four-port serial versions, with one or two Ethernet ports are available to fit any need. Last, let’s not forget about those old controllers, PLCs, and remote www.controleng.com/IIoT
terminal units still clicking away in the far reaches of your domain. They still work fine, but require periodic visitations, not to mention they’re uncommunicative. They probably support an old communication protocol like Modbus RTU, but that’s not compatible with the shiny new Ethernet network that’s running since the recent facility expansion. Adapting those legacy devices for use with the new system can keep everything humming along for years to come.
Modbus RTU to Modbus TCP TCP/RTU gateways convert serialbased Modbus RTU (or ASCII) to Modbus TCP. These modules are extremely powerful and can be configured to almost any combination of Modbus client and server, including a shared memory configuration, allowing two Modbus masters (servers) to communicate with each other. Device ID aliasing also is supported to create a “virtual” Modbus ID for Modbus devices that do not have configurable Modbus addresses. One-, two-, and four-port serial versions, with one or two Ethernet ports, are available. With minimal investment and effort, you can take the first step into the realm of the IIoT. Equipment and machinery have lots to say, if you have a way to listen, and aging equipment can remain relevant with only a little assistance. IIoT Garrett Schmidt is communications interface manager with Phoenix Contact.
MORE
INFORMATION Search at the Plant Engineering website for recent editorial features on Ethernet networks, including emerging standards and best practices. www.controleng.com/IIoT
An explication of terms Below please find a brief glossary of some acronyms and terms mentioned in this article. AES (advanced encryption standard): a specification for the encryption of electronic data established by the U.S. National Institute of Standards and Technology (NIST). AES has been adopted by the U.S. government and is used worldwide. The algorithm described by AES is a “symmetric-key algorithm, meaning the same key is used for both encrypting and decrypting the data.” ASCII (American standard code for information exchange): ASCII codes represent text in computers and other devices. FDT/DTM (field device tool/device type manager): The FDT joint interest group was formed in 2003 by ABB, Endress + Hauser, Invensys, Metso Automation, and Siemens to establish an international standard based on field-device tool technology. HART (highway addressable remote transducer) communications protocol: a hybrid analog and digital industrial automation protocol. Its most notable advantage is that it can communicate over legacy 4-20 ma analog instrument current loops, sharing the wire pair used by the analog-only host system. Modbus: a serial communications protocol that today is a common means of connecting industrial electronic devices. It is often used to connect a supervisory computer with an RTU or PLC. Modbus TCP: a Modbus variant used for communications over TCP/IP networks. OEE (overall equipment effectiveness): a measure often used to identify process-improvement possibilities. Profinet (process field net): an industry technical standard for data communication over the industrial internet, with a particular strength in delivering data under tight time constraints. RFID (radio-frequency identification): use of electromagnetic fields to automatically identify and track tags attached to objects containing electronically stored information. TCP/IP (transmission control protocol/internet protocol): the internet protocol suite is the conceptual model and set of communication protocols used on the internet and similar computer networks. The suite provides end-to-end specification of how data should be packetized, addressed, transmitted, routed, and received. UDP (user datagram protocol): a network communications method and alternative to TCP, used primarily for establishing low latency and loss-tolerating connections between applications on the internet. IIoT For Engineers
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ENTERPRISE ANALYTICS
IIoT optimizes evaporative cooling Sensor network and calculation model confirm savings
By Chris Curry
E
vaporative cooling systems reduce the cost of operating the high-capacity compressors used for heating, ventilation and air conditioning (HVAC) in commercial and industrial buildings. By applying evaporative cooling to air drawn through condenser coils, HVAC-unit capacity increases while energy use decreases. Evaporative cooling reduces cost since a compressor needn’t run fully loaded as much as would otherwise be the case. Evaporcool’s systems collect data to monitor a host compressor. The data is transmitted via internet to workstations running analytics software from Seeq. Evaporcool worked with Seeq to build an operational model that evaluates how cooling systems perform, applying heattransfer and air conditioning efficiency constants to the data. The resulting “IIoT application” means managers monitor and measure the cooling system’s performance via internet. If the model is furnished with historical data from a given installation, its results can be specific. Unfortunately, these histories are seldom sufficiently detailed to furnish a comprehensive baseline. However, using data compiled from similar installations, performance can
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IIoT For Engineers
be predicted. Either way, a picture emerges of what it costs to operate HVAC with and without the evaporative cooling system.
Understanding the operation Think for a moment of the basic operation of an air conditioning system: it circulates interior air
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Once critical measurements are identified, upper and lower operating limits can be established.
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over the system’s evaporator coil, absorbing building heat. The compressed, heat-laden refrigerant gas rises to a temperature higher than the outdoor ambient and moves to the outdoor condenser coil. Fans circulate outdoor air over the condenser coil, causing the refrigerant to condense and releasing heat to the outdoors. Cooled liquid refrigerant is returned to the evaporator to repeat the cycle. As outdoor ambient temperature increases, the compressor works harder to establish the condenser temperature differential. On the
other hand, the cooler it is outside, the more readily heat transfer and dissipation happens. An evaporative cooling system has the same positive effect as running the HVAC system on a cooler day. The compressor doesn’t run as much to get the same cooling effect inside. Calculating the savings requires sensors to monitor condenser-air inlet temperatures, outside ambient conditions, compressor running time, current draw, and other parameters. Turning this data into meaningful information requires the datamoving capabilities of the Industrial Internet of Things (IIoT) to enable a system designer, armed with analytical tools, to create calculation algorithms and combine the results with historical data. Seeq tools allow system designers and subject-matter experts to interact with the data. It might be necessary to adjust data, for example, when outside ambient temperature readings are distorted by sun shining directly on a temperature sensor at certain times of day.
What-if model evaluations The model takes all relevant parameters and builds a picture based on actual experience. Sensor data fed into the operating calculations shows what is happening at that moment. The with-and-without www.controleng.com/IIoT
Evaporative cooling systems mount on the outside of an air conditioning unit, cooling air drawn over the condenser coils to improve heat transfer and efficiency. All images courtesy: Evaporcool
cost-comparison capability is a major benefit, and a critical tool for users. The energy consumption models developed by Evaporcool using Seeq tools have proven to be accurate, with an R-Value of 0.98. The closer the R-Value to 1, the better the model correlates to measured data. Once the system is running, remote users can see the savings in real time via internet. A summary graph shows what is happening, compared to what would have happened without evaporative cooling. Reviewing the graph over time can identify pockets of savings, and the analytics application totals the value for any period. The collected data provides additional value. Some is used for diagnostic purposes. For example, if the compressor motor current draw www.controleng.com/IIoT
begins increasing with no corresponding operational change to account for it, the bearings may be deteriorating. Once critical measurements are identified, upper and lower operating limits can be established, and appropriately alarmed. Managers can monitor operation remotely using IIoT connectivity. Those responsible for multiple sites can monitor performance from a central location.
The IIoT mechanics For multi-site installations, each building has a master controller hosting a connection to the Evaporcool cloud infrastructure using a cellularbased virtual private network (VPN). This connection is shared among all the other units onsite, with “client� controllers attached to each HVAC
unit via a local mesh network. Each client transmits recorded data to the master controller, which consolidates the data and sends it to servers in the cloud. There it is stored, analyzed, and made available via the Evaporcool performance portal. This same infrastructure enables real-time data access for onsite testing and diagnostics, and to update configuration parameters. Building managers use the portal to monitor equipment operational performance and energy costs. An optional BACnet connection integrates HVAC operational-performance information into any building management system. Dashboards deliver summary information for big-picture users, with drill-down available. Simple customizations deliver what information is IIoT For Engineers
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ENTERPRISE ANALYTICS
Using Seeq’s analysis, it is possible to watch operation and calculate performance with and without evaporative cooling system at any point of the operating cycle.
needed. For example, energy managers want different variables than do maintenance teams. Central monitoring points collect data generated by sensors, to verify outputs or identify trends in the granularity needed. Analytics tools make identifying trends and gradual changes affecting multiple systems or properties far easier. For example, extracting data during times of specific weather conditions or assessing the effects of changing thermostat-setting policies allows for accurate and objective evaluation.
Extending the model With an accurate model, it becomes a simple matter to apply it in situations where historical data is not available. For example, if a
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Connection to a cloud infrastructuren is via
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cellular-based VPN.
property manager is using an evaporative cooling system at one location, by changing a few parameters, it is easy to see how the system will work in a different environment. Historical weather and temperature data for a given location can be added to the model and combined with measured performance data. It becomes possible to predict savings with a very high degree of accuracy. Without the ability to capture data for analytics, users would have to
resort to complex and time-consuming spreadsheet programming to perform data analyses. Combining internet connectivity with Seeq analytic software’s ability to create the mathematical functions and Evaporcool’s domain expertise creates an IIoT application delivering real benefits at reasonable cost. IIoT Chris Curry is the president of Evaporcool. He has a bachelor of science degree from the U.S. Military Academy at West Point as well as an MBA from the University of Michigan’s Ross School of Business.
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INFORMATION Search at the Control Engineering website for recent editorial features on industrial and enterprise analytics, including challenges, benefits, and solutions.
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