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1
The Strange Physical World of Industrial Ethernet
Mike Nager
METZ CONNECT
IEEE Information Technology Professional
Conference at The College of New Jersey, Ewing
Township, NJ, March 15, 2014
2
What is Industrial Ethernet?
It’s a specific type of “Internet of Things” used to
describe Ethernet used on manufacturing plant floors
or in process facilities.
It is rapidly growing already. 23% of the 31.3 million
industrial networked nodes in 2011 were based on
Ethernet. – IMS Research
Total economic value of IoT will be $1.9T by 2020 with
manufacturing and health care verticals leading at
15% each. – Gartner Inc.
What is Industrial Ethernet
3 9/5/2016
What is Industrial Ethernet
4
140 Devices per
Person on Earth
2013
Total 1 TrillionThe Industrialization of the Internet … Internet of Things
5 Devices per
Person on Earth
2010
Total 35 Billion
Total 500 Million
1/10th
of a Device per
Person on Earth
2007
business
consumer
industrial
the net
social media web 2.0
internet of things web 3.0
1997–2001
productivity >>>
2003–2009
2010–2013
Source: Forester Research, CISCO
The Internet of Things
Industrial Ethernet Accounts for the Biggest Growth
The Internet of Things
5
“Industrial” Looks Different
Ethernet is the biggest thing to hit manufacturing
facilities but it’s a lot different then the typical
Enterprise network.
According to IMS Research only about 40% of
installed industrial Ethernet nodes are standard
TCP/IP and seems to be decreasing slightly over
time.
6
A Look at the Past
Islands of Automation
Machines were self contained entities with little
communication between each other or the plant
facility. Relay logic prevailed.
7
A Look at the Past
Islands of Automation
Relays were replaced by PLCs and remained ‘stand-
alone’. Some specialized networks started to replace
the direct wiring but control and information
remained locked to that machine.
8
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Ethernet to the Rescue
Islands of Automation
Ethernet was seen as method of extracting
information from the PLC and maybe even its I/O so
at least reports could be made.
9
GW
ETHERNETGW
GW
GW
Discrete
Control
DeviceNet Profibus SERCOS
Progression
But Why Not All the Way?
If machines were connected via Ethernet, why couldn't
they be CONTROLLED by Ethernet? Little by little, the
objections were overcome.
• Ethernet isn’t Fast Enough – We need ‘Real Time Controls’
• Ethernet isn’t Deterministic – We can’t have jitter
• Ethernet Topography isn’t suitable – Star won’t work
• Ethernet isn’t redundant – Can’t have single Source of failure
• Ethernet Components aren’t designed for industry – this presentation!
10
Progression
But Why Not All the Way?
If machines were connected via Ethernet, why couldn't
they be CONTROLLED by a variant Ethernet
11
ETHERNET
Ethernet/IP Profinet Ethercat SERCOS/IP
Seemless Infrastructure
12
ERP
MES
Machine
Device
Supervisor
DCS/ PLCs / IPCs
Sensors/Actors
Data Center
Building Network
IndustrialEthernet
Transparent Communication
over all business levels without
Interfaces and communication losses
use of common IT processes for
operation and observation
via web technology
Web server on PLCs
and machines, remote
maintenance and teleservice
directly from the network
Easy installation
and operation with
convergent using
The Buzz Now
Trade Publication
Industrial Ethernet is discussed ALL THE TIME
13
Outlook
Outlook of Industrial Ethernet
Recent poll from Automation World
14
You Aren’t in Kansas Anymore
Users familiar with NEMA / IP ratings and rather
than MICE. (Mostly Mice 2 and 3 areas)
DIN rail mounted devices not 19” Racks
Supply voltage is 24VDC not -48V
Classified hazardous areas exist (Division 1 and 2)
No Plenum/Riser Cables – Oil Resistant or High Flex
15
IP Environmental Ratings
16
IP Environmental Ratings
IP20 for components
inside control
cabinets
IP65/67 for
components outside
control cabinets
17
General “Industrial” Requirements
Industrial locations include the manufacturing floor,
process plant, traffic control, water treatment, and
transit systems needing:
“Real Time” Control Needs
Multiple levels of redundancy
More extreme vibration and shock
Water, Dust, Coolant Exposure
18
Industrial Device Connections
19
Internet
of
Things
Gigabit-
terminal block
IP20
M12
X-coded IP67
M12 plug
D-coded IP67
M12 plug
X-coded IP67
Industry V4 plug
Industry V1 plug
Industry field plug
Cu IP20
Industry V1 plug
Industry V14 plug
M12 LP-socket
X-coded IP67
RJ 45 LP-jack IP20
Industrial Bus Networks
20
Network Founder Organization
Ethernet/IP Rockwell Automation ODVA
Profinet Siemens PTO
MODBUS-TCP Schneider Electric Modbus IDA
Foundation Fieldbus Fieldbus Foundation Fieldbus Foundation
SERCOS Bosch Rextroth Interest Group Sercos
EtherCAT Beckhoff Automation EtherCAT Technology
Group
Cable Recommendations
Profinet recommends Shielded Cables
Ethernet/IP prefers unshielded systems
- But Recommends shielding for
• Induction welding processes
• RF Sources
• Electrostatic processes
• High current devices (more than 100 amps)
- Uses shields with RC network to prevent DC
ground loops
21
Physical Layer Issues
According to an ISA.org online article, Physical
Layer failures accounted for 35% of total failures
in plant automation
Two ways to provide reliability is to
– Harden the physical layer
– Change the network topography
22
Connector Recommendation
Industrial Control Manufacturers
Guidelines are given by the manufacturers, in this
case for EtherNet/IP systems.
23
First Step – Harden RJ45
24
Nylon Locking
Tab and Strain
Relief
Need to accomodate
large individual
conductors
Metal Die
Cast Housing
Second Step – Harden Some More
Rugged Construction
Here is a metal version of the “V1” connector system.
25
Threads and Gaskets
for Sealing
Cable Glands and
Stress Relief
Second Step – Harden Some More
Rugged Construction
Here is a metal version of the “V14” connector system.
26
Snap on
connector
Second Step – Harden Some More
Rugged Construction
A custom built connector that is explosion proof for
the Oil and Gas industry.
27
Third Step – Engineer New System
High Band Width Connectors – M12 Footprint
“D” Code for 2 Twisted Pairs
“X” Code for 4 Twisted Pairs
28
Cutting Edge Standard
X Code M12 for Industrial Gigabit Speeds
29
4 Shielded Pairs
in an X shape
Typically PUR or
PVC Cable
IP67 Ethernet Switch
Electronics
Not only connectors need to be rugged.
30
Metal Housing
M12 Connectors
Conversion from RJ45 to M12
31
Inside the Cabinet – DIN Rail
32
Inside the Cabinet – DIN Rail
RJ45 Jack Meets DIN Rail
DIN Rail is the defacto mounting method on the plant
floor so devices and connectors are needed in this
form factor.
33
Inside the Cabinet – DIN Rail
Fiber Optic Meets DIN Rail
34
Reliable Extensions and Repairs
Practicality
Repairs and Extensions to Ethernet cable need to be
done on the plant floor – they will not re-run wires
through plants or machines with moving parts unless
absolutely necessary. Think of it as a type of
consolidation point.
35
Key Take-Aways
Internet of Things is growing rapidly
Much of it is in the industrial sector – Industrial
Ethernet
Environmental considerations are much different
than office environments
Physical component failure is the single biggest
failure point so the physical layer components
have to be well considered
36
37
The Strange Physical World of Industrial Ethernet
Mike Nager
METZ CONNECT
IEEE Information Technology Professional
Conference at The College of New Jersey, Ewing
Township, NJ, March 15, 2014

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IEEE Conference - Industrial Ethernet

  • 1. 1 The Strange Physical World of Industrial Ethernet Mike Nager METZ CONNECT IEEE Information Technology Professional Conference at The College of New Jersey, Ewing Township, NJ, March 15, 2014
  • 2. 2 What is Industrial Ethernet? It’s a specific type of “Internet of Things” used to describe Ethernet used on manufacturing plant floors or in process facilities. It is rapidly growing already. 23% of the 31.3 million industrial networked nodes in 2011 were based on Ethernet. – IMS Research Total economic value of IoT will be $1.9T by 2020 with manufacturing and health care verticals leading at 15% each. – Gartner Inc.
  • 3. What is Industrial Ethernet 3 9/5/2016
  • 4. What is Industrial Ethernet 4
  • 5. 140 Devices per Person on Earth 2013 Total 1 TrillionThe Industrialization of the Internet … Internet of Things 5 Devices per Person on Earth 2010 Total 35 Billion Total 500 Million 1/10th of a Device per Person on Earth 2007 business consumer industrial the net social media web 2.0 internet of things web 3.0 1997–2001 productivity >>> 2003–2009 2010–2013 Source: Forester Research, CISCO The Internet of Things Industrial Ethernet Accounts for the Biggest Growth The Internet of Things 5
  • 6. “Industrial” Looks Different Ethernet is the biggest thing to hit manufacturing facilities but it’s a lot different then the typical Enterprise network. According to IMS Research only about 40% of installed industrial Ethernet nodes are standard TCP/IP and seems to be decreasing slightly over time. 6
  • 7. A Look at the Past Islands of Automation Machines were self contained entities with little communication between each other or the plant facility. Relay logic prevailed. 7
  • 8. A Look at the Past Islands of Automation Relays were replaced by PLCs and remained ‘stand- alone’. Some specialized networks started to replace the direct wiring but control and information remained locked to that machine. 8 http://www.flickr.com/photos/92287895@N00/267323861/in/p hotolist-pC756-3RpqjT-4b86wT-4bc7HW-4bc7NQ-73JDy1- eoYJAp-fySBbZ-aTkNbV-aTkLQ2-aTkP8P-a3Qx5T-bjcrXK- aTkxyg-aTkeA6-faqaCM-faqaVz-cLL5F3-awSD6D-dzbGD5- b1XcEn-8dkSKQ-bie2Q4-bidUjp-a17jSR-a17iPX-a1abCo- a17jki-a1aaRf-a17jbZ-a1ab2J-a17j8x-a1aaLd-a17jxn-a1abej- a17jAp-9ZNoSk-9ZRf8W-a1ab3J-a1aaFW-ffTdSt-a1ab4Y- a17j2X-a17jRi-a17jrF-a17jEK-a17jqB-a17jHD-a17jmn-a17jS4- a1abib
  • 9. Ethernet to the Rescue Islands of Automation Ethernet was seen as method of extracting information from the PLC and maybe even its I/O so at least reports could be made. 9 GW ETHERNETGW GW GW Discrete Control DeviceNet Profibus SERCOS
  • 10. Progression But Why Not All the Way? If machines were connected via Ethernet, why couldn't they be CONTROLLED by Ethernet? Little by little, the objections were overcome. • Ethernet isn’t Fast Enough – We need ‘Real Time Controls’ • Ethernet isn’t Deterministic – We can’t have jitter • Ethernet Topography isn’t suitable – Star won’t work • Ethernet isn’t redundant – Can’t have single Source of failure • Ethernet Components aren’t designed for industry – this presentation! 10
  • 11. Progression But Why Not All the Way? If machines were connected via Ethernet, why couldn't they be CONTROLLED by a variant Ethernet 11 ETHERNET Ethernet/IP Profinet Ethercat SERCOS/IP
  • 12. Seemless Infrastructure 12 ERP MES Machine Device Supervisor DCS/ PLCs / IPCs Sensors/Actors Data Center Building Network IndustrialEthernet Transparent Communication over all business levels without Interfaces and communication losses use of common IT processes for operation and observation via web technology Web server on PLCs and machines, remote maintenance and teleservice directly from the network Easy installation and operation with convergent using
  • 13. The Buzz Now Trade Publication Industrial Ethernet is discussed ALL THE TIME 13
  • 14. Outlook Outlook of Industrial Ethernet Recent poll from Automation World 14
  • 15. You Aren’t in Kansas Anymore Users familiar with NEMA / IP ratings and rather than MICE. (Mostly Mice 2 and 3 areas) DIN rail mounted devices not 19” Racks Supply voltage is 24VDC not -48V Classified hazardous areas exist (Division 1 and 2) No Plenum/Riser Cables – Oil Resistant or High Flex 15
  • 17. IP Environmental Ratings IP20 for components inside control cabinets IP65/67 for components outside control cabinets 17
  • 18. General “Industrial” Requirements Industrial locations include the manufacturing floor, process plant, traffic control, water treatment, and transit systems needing: “Real Time” Control Needs Multiple levels of redundancy More extreme vibration and shock Water, Dust, Coolant Exposure 18
  • 19. Industrial Device Connections 19 Internet of Things Gigabit- terminal block IP20 M12 X-coded IP67 M12 plug D-coded IP67 M12 plug X-coded IP67 Industry V4 plug Industry V1 plug Industry field plug Cu IP20 Industry V1 plug Industry V14 plug M12 LP-socket X-coded IP67 RJ 45 LP-jack IP20
  • 20. Industrial Bus Networks 20 Network Founder Organization Ethernet/IP Rockwell Automation ODVA Profinet Siemens PTO MODBUS-TCP Schneider Electric Modbus IDA Foundation Fieldbus Fieldbus Foundation Fieldbus Foundation SERCOS Bosch Rextroth Interest Group Sercos EtherCAT Beckhoff Automation EtherCAT Technology Group
  • 21. Cable Recommendations Profinet recommends Shielded Cables Ethernet/IP prefers unshielded systems - But Recommends shielding for • Induction welding processes • RF Sources • Electrostatic processes • High current devices (more than 100 amps) - Uses shields with RC network to prevent DC ground loops 21
  • 22. Physical Layer Issues According to an ISA.org online article, Physical Layer failures accounted for 35% of total failures in plant automation Two ways to provide reliability is to – Harden the physical layer – Change the network topography 22
  • 23. Connector Recommendation Industrial Control Manufacturers Guidelines are given by the manufacturers, in this case for EtherNet/IP systems. 23
  • 24. First Step – Harden RJ45 24 Nylon Locking Tab and Strain Relief Need to accomodate large individual conductors Metal Die Cast Housing
  • 25. Second Step – Harden Some More Rugged Construction Here is a metal version of the “V1” connector system. 25 Threads and Gaskets for Sealing Cable Glands and Stress Relief
  • 26. Second Step – Harden Some More Rugged Construction Here is a metal version of the “V14” connector system. 26 Snap on connector
  • 27. Second Step – Harden Some More Rugged Construction A custom built connector that is explosion proof for the Oil and Gas industry. 27
  • 28. Third Step – Engineer New System High Band Width Connectors – M12 Footprint “D” Code for 2 Twisted Pairs “X” Code for 4 Twisted Pairs 28
  • 29. Cutting Edge Standard X Code M12 for Industrial Gigabit Speeds 29 4 Shielded Pairs in an X shape Typically PUR or PVC Cable
  • 30. IP67 Ethernet Switch Electronics Not only connectors need to be rugged. 30 Metal Housing M12 Connectors
  • 31. Conversion from RJ45 to M12 31
  • 32. Inside the Cabinet – DIN Rail 32
  • 33. Inside the Cabinet – DIN Rail RJ45 Jack Meets DIN Rail DIN Rail is the defacto mounting method on the plant floor so devices and connectors are needed in this form factor. 33
  • 34. Inside the Cabinet – DIN Rail Fiber Optic Meets DIN Rail 34
  • 35. Reliable Extensions and Repairs Practicality Repairs and Extensions to Ethernet cable need to be done on the plant floor – they will not re-run wires through plants or machines with moving parts unless absolutely necessary. Think of it as a type of consolidation point. 35
  • 36. Key Take-Aways Internet of Things is growing rapidly Much of it is in the industrial sector – Industrial Ethernet Environmental considerations are much different than office environments Physical component failure is the single biggest failure point so the physical layer components have to be well considered 36
  • 37. 37 The Strange Physical World of Industrial Ethernet Mike Nager METZ CONNECT IEEE Information Technology Professional Conference at The College of New Jersey, Ewing Township, NJ, March 15, 2014