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  3. Time analysis of transmission of control signals through multi-stage links on industrial networks in order to implement wide control loops with high flexibility.

Time analysis of transmission of control signals through multi-stage links on industrial networks in order to implement wide control loops with high flexibility.

Number of pages: 118 File Format: word File Code: 32193
Year: 2014 University Degree: Master's degree Category: Electrical Engineering
Tags/Keywords: Control loops - Control signals - Ethernet - Industrial automation - Industrial networks - Multi-step links - Sensor - Signal transmission
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  • Summary of Time analysis of transmission of control signals through multi-stage links on industrial networks in order to implement wide control loops with high flexibility.

    Master thesis in electrical engineering (control)

    Abstract

    Temporal analysis of control signal transmission through multi-stage links on industrial networks in order to implement wide control loops with high flexibility

     

    The advancement of technologies related to communication networks in recent decades and their expansion in the upper layers of the industry, such as the monitoring and management layers, require methods to use these networks at lower levels, i.e. networking devices and sensors, to be invented and used, each of which has advantages and disadvantages compared to traditional methods.

    In this dissertation, we will have a brief look at industrial automation and the role of communication networks in the development of industry, and by describing the history of industrial networks, including Ethernet and Profibus, we will mention the basic information and hierarchical levels of industrial automation and its protocols. In the following, the basic requirements of the design and communication of different parts of Ethernet and Profibus network will be described, and by mentioning the advantages and disadvantages of each, we will show how we can use high-speed but non-real-time networks such as Ethernet in processes that require real-time data, and finally, by combining high-level networks (Ethernet) with lower-level networks (such as Profibus), we will examine the time analysis of the transmission of control signals through multi-stage links.

    Due to the widespread use of the Profibus network and the industrial Ethernet network, in this thesis we will specifically focus on the simultaneous use of these two types of networks for the exchange of control signals and we will study the behavior of time-varying delay, sending errors and other issues in the transmission of signals through both networks and the effect they can have on the performance of the control system with the aim of using the results of the analysis to be able to specifically Determine the fulfillment of real-time constraints for each control system. We will also seek to provide solutions to help meet these limitations. Digital automation became available, they were used to improve and develop industrial automation systems. Concepts such as automatic industries [1] and automatic distributed control systems [2] were introduced in the field of industrial automation and the use of communication networks grew almost significantly. With the expansion of communication networks in industrial automation systems, information gathering and low-level control operations were entrusted to these networks. This development progressed to the point that today in a modern automation system, devices at different levels of the system transmit data through these communication networks. Therefore, efforts were made for international standardization in the field of networks, the important achievement of which was the industrial automation protocol MAP in line with the compatibility of communication systems. The MAP protocol was developed to overcome communication problems between different automation devices and was accepted as an industrial standard for data communication in factories. The performance and reliability of an industrial automation system actually depends on its communication network. In an industrial automation communication network, the improvement of network performance and its reliability and the standard of communication are determined according to the size of the system and the increase in the volume of information [1]. In such rooms, there are no more old big panels [3] on which the shape of the process was drawn and equipped with many signal lights. Everything should be searched in computer screens or so-called HMI[4]. But the explorers behind these pages are looking for physical connections between the computer and the process, and with a cursory search they come across the nearby panels where the communication equipment is located.But the explorers behind these pages are looking for physical connections between the computer and the process, and with a brief search, they come across the nearby panels where the communication equipment is installed. And by looking at the hardware communication equipment of the network at a glance, they realize that the network used is the famous industrial Ethernet network [5] [2].

    Today, the Ethernet network has become so popular and common in office applications that many non-expert users are also familiar with its equipment such as hubs, switches, cables, etc. are familiar In any case, in the application of HMI, although it is possible to observe the above communication in other ways and through other industrial networks, but in modern systems today, it rarely happens that a network other than industrial Ethernet is used at the HMI level.

    To clarify the topic, we will discuss the position of two Ethernet and Profibus networks in this automation pyramid:

    Ethernet's position in the automation pyramid

     

    The structure of a comprehensive automation system, which includes various control and monitoring equipment, is compared to a pyramid-shaped structure. In this structure, each category of equipment has a special place depending on the type and application. Based on this, different levels are defined for this pyramid and at each level they introduce relevant equipment along with usable industrial networks. The lowest level are sensors and actuators. As its name suggests, it is the surface where sensors and actuators are placed. One of the famous industrial networks used at this level is ASI [6]. The higher level is the field. At this level, equipment such as remote inputs, outputs, registers [7] and other field devices are placed, and the network used by them can be Profibus. When we go higher than the field level, we reach the control level. In this level, PLCs [8], DCS systems [9] and HMIs are placed, in some divisions the control level is divided into two levels, HMI and control; And finally, it is the highest level of management where management information systems such as production, maintenance, repair, sales and purchase systems are placed. In some cases, the information available in the control level cannot be used in raw form for the management level and must be processed. Therefore, the intermediate level between Indo is defined as MES[10]. But what needs to be noticed is that in the above pyramid, the more we approach from the lower level to the higher level, the more information is concentrated. Therefore, to move them, we need higher speed networks [3].

     

    Figure 1?1: Automation pyramid[2]

    For example, field equipment information that is highly scattered in one or more Remote I/O are centralized and the information of several Remote I/O is concentrated in one PLC and the information of several PLCs is concentrated in one HMI system. Perhaps it is because of this concentration that the structure is displayed in a pyramidal form.

    Another point comes to mind from the concentration of information at higher levels. At these levels, the volume of information has increased and we need higher speed networks to move them.

    At lower levels, a network like ASI with a maximum of 170Kbps and a network like Profibus [11] with a maximum speed of 12Mbps. It can move information. This speed may be slow for data exchange at high levels.

    Today, industrial Ethernet transfers information at a speed of 100Mbps or 1Gbps at high levels such as the Cell Level, and at the Management level, faster Ethernets such as 1Gbps are usually used. They are rarely used in them. But the question that comes to mind is why fast networks such as Ethernet are not used at low levels such as the field level.

    Dear reader, after reading the next parts of this thesis, he will understand that in Ethernet, there is no certainty for sending data on time and the time of sending data may be different from the previous times. This difference is due to the feature of the access technique in Ethernet, which is called CSMA/CD, where there is a phenomenon of information collision.

  • Contents & References of Time analysis of transmission of control signals through multi-stage links on industrial networks in order to implement wide control loops with high flexibility.

    List:

     

    1- Introduction. 2

    1-1-               General. 2

    1-2-              Ethernet position in the automation pyramid. 3

    1-3-              Fieldbus position in the automation pyramid. 7

    2- Introduction of industrial networks. 11

    2-1-              Introduction. 11

    2-2-              Introduction of Ethernet network. 12

    2-2-1-           A look at the history of the emergence of Ethernet. 13

    2-2-2-          A look at the evolutionary process of Ethernet. 15

    2-2-3-          A look at the evolutionary process of real-time Ethernet. 17

    2-2-3-1- On Top of TCP/IP. 20

    2-2-3-1-1- Modbus/TCP. 20

    2-2-3-3-2-    Ethernet/IP. 20

    2-2-3-1-3-    P-NET. 20

    2-2-3-1-4-    Vnet/IP. 20

    2-2-3-2- On Top of Ethernet. 21

    2-2-3-2-1-    Ethernet Power Link (EPL) 21

    2-2-3-2-2-    Time-Critical Control Network (TCNET) 21

    2-2-3-2-3-    Ethernet for Plant Automation. 21

    2-2-3-2-4- Profinet CBA. 21

    2-2-3-3- Modified Ethernet. 21

    2-2-3-3-1- Serial Realtime Communication System. 22

    2-2-3-3-2-    Ethercat. 22

    2-2-3-3-3-    Profinet IO. 22

    2-3-              Profibus network. 22

    2-3-1-          A look at the history of the Profibus network. 23

    2-4-              Logical communication in industrial networks (Ethernet and Profibus) 24

    2-5-              Communication technology in Ethernet. 25

    2-5-1-           Physical layer. 26

    2-5-1-1- 10BASE 5. 27

    2-5-1-2- 10 BASE 2. 27

    2-5-1-3- 10 BASE-T. 28

    2-5-1-4-        10 BASE-FL. 29

    2-5-1-5-       100 BASE or Fast Ethernet. 30

    2-5-1-6-        1000 BASE or Gigabit Ethernet. 31

    2-5-2-          General comparison of Ethernet networks based on IEEE 802.3. 32

    2-5-3-          Data link layer in Ethernet. 32

    2-5-3-1- Data framing in Ethernet. 33

    2-5-3-2-      Bus access method in Ethernet. 36

    2-5-4-          Network layer in Ethernet. 39

    2-5-4-1-       IP Address in the Network layer. 40

    2-5-4-1-1-    IP-v4 address  40

    2-5-4-1-2-    IP-v6 address  40

    2-5-5-           Transport layer in Ethernet. 41

    2-6-              Communication technology in Profibus. 43

    2-6-1-           Physical layer. 44

    2-6-6-1- Transmission with copper cable. 44

    2-6-1-2- Optical fiber transmission. 48

    2-6-2-          Profibus network topologies. 50

    2-6-2-1- Bus topology using repeater 50

    2-6-2-2- Tree topology using repeater 51

    2-6-3- Data link layer: 52

    2-6-3-1- Data transmission format and its security. 53

    2-6-3-2- How to access the bass. 54

    2-6-3-3- Token frame. 56

    2-6-4-          Profibus FMS. 56

    2-6-5-          Profibus PA. 57

    2-7-               Conclusion. 60

    3-                  Data exchange between PLCs using industrial networks. 62

    3-1-              Introduction. 62

    3-2-              Network design. 63

    3-2-1-           Feasibility. 64

    3-2-2-          Analysis. 65

    3-2-3-          Design. 65

    3-2-4-          Implementation 66

    3-2-5-          Maintenance and updating. 66

    3-3-              Network access techniques. 67

    3-4-              Networking PLCs using Ethernet. 67

    3-4-1-          Send / Receive communications in the Ethernet network. 68

    3-4-2-          Communication functions. 69

    3-4-3-          Configuration and programming of S7 Connection. 70

    3-4-3-1-      Hardware configuration 70

    3-4-3-2-        Communication configuration in Netpro. 71

    3-4-3-3-     Data exchange programming in Ethernet. 72

    3-5-              Networking PLCs using Profibus. 73

    3-5-1-          Profibus network settings. 75

    3-5-1-1-       75

    3-5-1-1- Highest Profibus Address parameter. 76

    3-5-1-2- Transmission parameter. 76

    3-5-1-3- Profibus profiles. 77

    3-5-2-          IntelLigent Slave. 77

    3-5-3-           Data exchange programming in Profibus. 77

    6-3-              Conclusion. 78

    4-                  Theoretical and practical analysis of industrial networks. 80

    4-1-              Introduction. 80

    4-2-              Profibus communication time calculation. 81

    4-2-1-           Calculation of communication time between a master and a slave theoretically. 82

    4-2-2-           Calculation of communication time between a Master and a Slave in practical terms. 85

    4-2-3-           Calculation of communication time between a master and two slaves theoretically. 88

    4-2-4-           Calculation of communication time between a Master and two Slaves in practical terms. 89

    4-3-              Ethernet communication time calculation. 91

    4-4-              Time to make Ethernet real. 96

    4-5-              Multi-stage systems. 98

    4-5-1-          DP-LAN-DP first mode. 99

    4-5-2-           LAN-DP-DP second mode. 102

    4-5-3-          Comparison of two systems. 104

    4-6-               Conclusion. 105

    5- The effect of industrial networks on the control loop. 107

    5-1-              Introduction. 107

    5-2-              The examined model without time delay. 108

    5-3- Introducing delay to the system (delay caused by the network) 110

    5-4-               Modeling with a combined network. 113 5-5 Conclusion: 114 6 Summary and recommendations. 116

    6-1-               Conclusion. 116

    6-2-               Offers. 119

     

    Source:

    M. Hanna, "Real-Time Analysis of FIP-based Systems", Cairo University, Egypt, Oct. 2004.

    http://www.profibus.com/technology/

    Sh. Kumra, L. sharma, Y. Khanna, A. Chattri, "Analyzing An Industrial Automation Pyramid And Providing Service Oriented Architecture", International Journal of Engineering Trends and Technology- Volume3Issue5, 2012.

    Simatic PCS 7 Catalugue, http://www.siemens.com, June 2013.

    S. Tanenbaum, J. Wetherall, "Computer Networks (5th Edition)", Prentice Hall, October 2010.

    Building on the Structural Relationships, http://www.iebmedia.com.

    Oxford Dictionery.

    "IEEE Standards for Local Area Networks: Part 3: Carrier Sense Multiple Access with Collision Detect on (CSMA/CD) Access Method and Physical Layer Specifications", IEEE Std. 802.3, 2002.

    J. Decotignie, "Ethernet-Based Real-Time and Industrial Communications", June 2005.

    R. Perlman," Interconnections, Bridges and Routers", 2nd Edition, Addison Wesley, 2000.

    M. Felser, “Real-Time Ethernet—Industry Prospective”, IEEE, June 2005.

    http://www.modbus.org.

    http://ab.rockwellautomation.com.

    http://www.p-net.dk.

    http://www.yokogawa.com.

    http://www.ethernet-powerlink.org.

    http://www.toshiba.co.jp.

    http://www.epa.org.cn.

    http://www.automation.siemens.com.

    http://www.sercos.com.

    http://www.ethercat.org.

    “PROFIBUS Installation Guidelines”, Verwer Training & Consultancy Ltd, Oct. 2013.

    http://www.profibus.com/nc/pi-organization/members.

    http://www.ieee802.org.

    IEEE 802.3 10 BASE 5 Std.

    IEEE 802.3 10 BASE 2 Std.

    IEEE 802.3 10 BASE T Std.

    IEEE 802.3 10 BASE FL Std.

    IEEE 802.3 - IEEE Standard for Ethernet, 2012.

    http://www.mathcs.emory.edu.

    http://www.cs.duke.edu.

    S. Manny, Z. Jing, C. Chris, Z. Kevin, K. Clark; K. Thomas, "RS-422 and RS-485 Standards Overview and System Configurations, Application Report", May 2010

    http://hairilhazlan.com.

    “Simatic DP Bus Connector for Profibus Datasheet”, Siemens, July 2014.

    “Simatic PB FC Standard Cable GP”, Siemens, July 2014

Time analysis of transmission of control signals through multi-stage links on industrial networks in order to implement wide control loops with high flexibility.
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