PROFINET and the

Industrial Internet

of Things

The Machine Building Show – Sept 2015

Peter Thomas

(Control Specialists Ltd)

Chairman of the

PROFINET & PROFIBUS International Training Centres

(PITC‘s)

The four stages of the Industrial Revolution

1st Industrial Revolution

• Follows introduction of water and steam powered mechanical manufacturing facilities

2nd Industrial Revolution

• Based on mass production achieved by the division of labor concept and the use of electrical energy

3rd Industrial Revolution

• Uses electronics and IT to achieve further automation of manufacturing

4th Industrial Revolution

• Based on Cyber Physical Systems

• IoT

• IIoT

End of 18th century

End of19th century

1970’s

today

Increased networking needed!

2

Industry 4.0 – Why it matters.3

40% of the worldwide manufacturing value is held by emerging countries. This

equates to 6,577 Billion Euros.

Industry makes up 15% of the European economy. This drives research, innovation, productivity, job creation

and exports.

The emerging countries have doubled their share in the

past 20 years.

Western Europe has lost over 10% of worldwide

manufacturing valueTo assume a leading role in

Industry 4.0, Europe will have to invest 90 Billion Euros per annum over the next 15 years.

Source – Roland Berger Strategy Consultants – March 2014

IoT – The Internet of Things4

The Internet of Things (IoT) is an environment in which objects, animals or people are provided withunique identifiers and the ability to transfer data over a network without requiring human-to-humanor human-to-computer interaction (whatis.techtarget.com)

IIoT – The Industrial Internet of Things5

The Industrial Internet of Things (IoT) is the use of Internet of Things (IoT) technologies inmanufacturing.

IoT verses IIoT

Internet of Things (IoT)

Industrial Internet of Things(IIoT)

Impact Revolution Evolution

Current status New devices and standards Existing devices and standards

Connectivity Ad-Hoc Structured

Criticality Important but not critical Mission critical• Analytics• Security

• Data integrity• Response times

Data Volume Medium to High Very High(Big Data – see next slide)

Servicing User User, OEM, Vendor

6

Big Data and the 3 V’s7

• Big data is an evolving term that describes any voluminous amount of structured, semi-structured and unstructured data that has the potential to be mined for information. It is often characterised by the 3 V’s:

• The extreme VOLUME of data.

• The wide VARIETY of types of data.

• The VELOCITY at which the data must be must processed.

• Although big data doesn't refer to any specific quantity, the term is often used when speaking about Petabytes (PB) and Exabyte's (EB) of data where:

• 1 PB = 1015 bytes of data, 1,000 terabytes (TB) or 1,000,000 gigabytes (GB).

• 1 EB = 1018bytes of data, 1000 petabytes (PB) or 1 billion gigabytes (GB).

Source: TechTarget.Com

Volume of Data – IoT verses IIoT8

IIoT and the need for Interoperability9

“At the core of Industry 4.0 and IIoT is the need for interoperability—of devices, software, and

entire systems.”

IIoT – The challenges10

Ethernet is the Key11

What about Fieldbuses?12

http://global.ofweek.com/news/Fieldbus-market-is-still-twice-as-big-as-industrial-Ethernet-24515

The road to IIoT13

PROFIBUS PA

PROFIBUS DP

• Evolution

• Existing devices

• Existing networks

• Legacy data

Electrical - Hard-wiredPneumatic Manual

PROFINETFieldbuses

IIoT - Multiple Protocols14

What is PROFINET?15

PROFINET is the standard for industrial networking in automation. It connects devices, systems,and cells, facilitating faster, safer, less costly and higher quality manufacturing. It easilyintegrates existing systems and equipment while bringing the richness of Ethernet down to thefactory floor.

Completely standard Ethernet (IEEE802.3).

High speed, operating at 100Mbit/s or faster over copper or fibre-optic cables,

Makes use of existing IT standards. But, is “real-time” and deterministic,

PROFINET is very well thought out to incorporate all the requirements of automation and control systems.

PROFINET is totally compatible with PROFIBUS and provides seamless integration with other fieldbus technologies.

PROFINET and the 7-layer OSI model.16

PROFINET – the backbone of Industry 4.0 and IIoT17

Energy Management

Security

DiagnosticsCondition Monitoring

�Safety

� Real time communication

17

� Performance

Industrial Wireless LAN

Flexible topologies

Expandability

Web tools

Open standard

One cable for all purposes

Fast device replacement

Ruggedness/stability

Easy cabling

Media redundancyLarge quantity structures

High transmission rate

Speed High precisionFast start-up

PROFINET addresses each of these imperatives

efficiency

performance

flexibility

PROFINET – The same standard for different industries18

FACTORY AUTOMATION

An exclusive TCP/IP layer enables simple exchange of any data with response times in the range of 100 ms.

PROCESS AUTOMATION

The real-time feature RT handles cyclic signal exchange of I/O data with response times in the range of 10 ms.

DRIVES

IRT enables safe real-time communications in the range of less than 1 ms jitter of less than 1µs.

PROFINET – Enhancements for Process Automation19

Fieldbus Integration

DCS

HART

PROFIBUS PA

FF H1

PROFIBUS DP

PROFINET

Configuration in Run (CiR)

DCS

Remote I/O Proxy

Time sync / stamping

System Master Clock

(GPS, DCF77, …)

Controller 1 Controller 2 Controller 3

Proxy

Device Device

Backup

Clock Master

Scalable RedundancyRedundant Controller

PrimaryBackup

Redundant Network

Device with redundant connectivity

Device with singularconnectivity

PROFINET IRT – High Speed Applications20

PROFINET enables the simultaneous realisation

of Real-Time and IT-communications on one cable

• Isochronous Real Time (IRT) communication for Motion Control Applications with PROFIdrive-profile

• With PROFINET Specification V2.3 we can achieve short and deterministic reaction time: up to 31.25µs, Jitter < 1µs

• Integration of distributed field devices

• TCP/IP for engineering, diagnosis and HMI-connection

IIoT and Security Requirements21

• Security for systems without their own security functions

• Lack of technical resources necessary for security functions

• Security functions have to be integrated in existing systems

• Real-time operation

• Security functions must not slow down critical reaction time

• Ensure deterministic behavior

• Transparent and cost-efficient integration

• Integrate security functions with minimal configuration effort

• Automation experts are generally not security experts

• Robustness

• Withstand temporary exceptionally-high communication loads

Security Strategies22

Great Wall

“Unconquerable” wall single layer of protection

no more checkpoints behind the wall

Defence in Depth

Multiple layers of protection each layer supports the

other layers for every transition between two layers an

attacker must spend time and effort!

���� No single security measure is good enough to prevent intrusions !

Defence in Depth – Multiple layer security23

23

Physical Security

- Physical access to facilities and equipment

Policies & procedures

-Security management processes

-Operational Guidelines

-Business Continuity Management & Disaster Recovery

Security cells & DMZ

-Secure architecture based on network segmentation

Firewalls and VPN

- Implementation of Firewalls as the onlyaccess point to a security cell

System hardening

- adapting system from default to secure

User Account Management

- Administration of operator und userrights (role based access control)

Patch ManagementMalware detection and prevention

- Anti Virus and Whitelisting

Potential Threat

DCS

PROFINET and Security24

General security requirements for automation networks and differences to office-IT

Specific condition and requirements of PROFINET networks regarding security, e.g. real time capabilities

Elements and organization of a Security Management Process

Security concepts for the solution of the requirements � Defence in depth approach

Example configuration

Communication Networks - Scalability

Corporate

IT

Central data backbones

Production Network Production Network

Production Network

25

Communication Networks - Scalability

Corporate IT

Central Data Backbones

Production Network Production Network

Production Network

Field

Corporate

Production

26

Communication Networks - Interactivity

Field

Production

Corporate

Produktionsnetz

10101001111

ERP

• Connection to Corporate IT (ERP -Enterprise Resource Planning), Data exchange across production facilities

• Quality data, Track & Trace, Optimisation of production processes

• Remote Services for central Maintenance

27

Communication Networks - Requirements

Field

Production

Corporate

Produktionsnetz

ConditionMonitoring

Energy-management

Cloud

New RequirementsBandwidth Realtime Usability

28

The base of today and tomorrow: conformance with IEEE, IETF, IEC etc.

Requirements of the future

Self Configuration

Openness

Bandwidth

• PROFINET uses100 Mbit/s today

• PROFINET will be usable with higher bandwidth

• Scalability is possible

• IP-based communication is supported by PROFINET

• Importance of IP-based communication will increase, e.g. with OPC UA

• Already name based configuration today

• In the future automatic assignment of IP-addresses

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Self-configuring / Dynamic Networks

Machine Builder Plant Operator

Delivers machine with automation solution and network configuration

Integrates machine in plant � requires changes in network configuration

Automation and network configuration intrinsically tied together today

Production Network

30

Separation of Automation and Network

Test independent of network configuration

No IT-Services

Commissioning with temporary configuration

Doesn’t want to deal with IP-Addresses

Simply wants to connect the machines

Automation and Network Configuration must be separate in the future

Automation

Machine Builder

Operation

Plant Operator

Integration in existing network

Individual requirements of local IT

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PROFINET and IIoT - Conclusions32

• Seamless enterprise-wide integration, global accessibility.

• Unlimited node count, powerful capabilities, greater scalability.

• Full TCP/IP, internet and web compatibility, with real-time determinism

• Ethernet cabling eases installation, and familiar IT and Internet tools help during operation, maintenance and

diagnostics.

• Wireless and functional safety easily added.

• Protects investments in plant and people by easily integrating all popular automation networks.

• Strategic links with PROFIBUS include common infrastructure, common engineering platforms, common quality

assurance and common application profiles.

• Modular, flexible, comprehensive - use only what you need now.

• Easily extended and expanded as enterprise needs change.

References and UK Support

References

• PROFIBUS & PROFINET International (PI) – www.profibus.com• PROFIBUS Association of Australia (PAA) – www.profibusaustralia.com.au• PROFINEWS – www.profinews.com

UK Support - The PROFIBUS Group

• Regional PROFIBUS & PROFINET Association – www.profibusgroup.com• Certified PROFINET Installer / Certified PROFINET Engineer Training

33

Thank You!

peter.thomas@controlspecialists.co.uk

September 2015