smart networks for the industrial internet of things
TRANSCRIPT
Building a SMART Network for the Industrial IoT
Richard WoodProduct Marketing Manager Industrial Ethernet Infrastructure
April 29, 2015
IIoT Webinar Series
Confidential
Agenda
Smart Factory Introduction – Market Trends
Smart Factory Challenges
SMART Factory Best practices
Case Studies
Confidential
Smart Factory IntroductionMarket Trend
Confidential
Megatrend – Internet of Things (IoT)“The IoT refers to devices, systems, and services communicating with each other via the Internet to enable smarter operations and new applications.”
Confidential
Industry Trend – Industry 4.0 (IIoT)IoT in Manufacturing - The Next Industrial Revolution
ObjectiveUtilize a combination of cyber
and physical systems to build up highly efficient Smart Factory
Industry 4.0
Confidential
Interconnected ERP, MES, and industrial automation systems together
The goal is to reach High Efficiency by reducing defects, unplanned downtime, waste, and waiting
Smart Factory is “The Factory of The Future”
MES
Machine (PLC)Manufacturing Prodution
Production Planning
ERP (PLM)Product Development
Device (Sensor)Manufacturing Prodution
Smart Factory
Network Integration
Confidential
SMART Factory ExampleReal-Time Interactive Communication
Network Integration
Confidential
Integration with Enterprise Networks
Industrial Ethernet is the Common Platform• Interconnect devices, systems, and services• Transmit data for analysis, decision making and control
Source: IEEE, 2014
SMARTFACTORY
Network Integration
Enterprise Network
Data Center
Industrial Network Top 3 ChallengesHow do we…
Simplify Installation & Deployment
Minimize Error Probability
Accelerate Error Discovery & Repair
• Optimized Network Topology
• Quick Mass Configuration
• Device Durability• Network
Redundancy• Cyber security
Protection
• Instant Active Alarm
• Easy SCADA Integration
• Remote Visualized Network Management
Top Strategies
SMART Factory Overview
Secure Infrastructure
Easy Centralized Management
High Availability
Robust Design
Enterprise InTegration
Confidential
Factory is Vulnerable to Cyber Attacks
Source: ICS-CERT 2013 Report, Region: the U.S.
Cyber attacks may come from both outside AND inside factory
Security
Confidential
Industrial Security Concerns
PLC/IO Network
Control Network
Field Site / FactoryControl Room
Attack frompublic network
Unauthorizedconnection
Malfunctioning PLC
Broadcast Storm
• VPN function for data encryption• VPN server for dynamic remote access• Standard protocol: IPSec, L2TP, PPTP
SECURED REMOTE ACCESS
• Protect unauthorized connections to critical devices (PLC, RTU, DCS)
• Isolated broadcast packets from malfunctioning device to entire network
CRITICAL DEVICE PROTECTION
VPN tunnel Firewall
Security
Confidential
Quick Mass Configuration How do we reduce industrial network installation
& configuration time?• Industrial Network Configuration Tools
Client ITS System Integrator
Current Solution
Configure 20+ switches individually thru Web UI
Pain Point
Cost a lot of time and manpower to complete the configuration
Auto IP configuration by distanceSequential IP settingRedundancyVLAN…
Smallest IP
Current With Tools 10 times faster
Management
Confidential
Visualized Network Management
How can maintenance engineers monitor & manage large scale industrial networks?• Visualized NMS
Industrial NMS Enterprise NMS
Design for… Industrial Engineers, Maintenance Engineers IT expert
Connection Physical link (Down to “port”) Logical link
Information Dispaly Visualization & List List
Response Real time Periodic
Visualization
Management
Network Availability/Reliability
Network Topology
Typical Enterprise Star Topology
• Single point of failure• Long, costly wire/fiber runs
Availability
Network TopologyTypical Industrial Ring Topology
• No single point of failure• Reduced wiring costs
Availability
Confidential
Build Up a Highly Reliable Communication Network
How do you choose the best redundancy for your application?Network switch/recovery time < Max. acceptable system downtime (Grace Time)
Non time critical< 1 s
Real Time< 100 ms
Isochronous Real Time< 1ms
Applications Non time critical applications
Process Automation / Factory
AutomationMotion Control
Grace Time
Reliability Availability
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Optimized Network Topology
Redundant Technology
Type Mesh Ring
Pros•Good reliability•High resilience•Standard protocol
•Better performance and recovery time: ~millisecond level•Lower cost
Cons •Slow recovery time ~second level •Limited Scale
Available Technology RSTP
General Fast Recovery (millisecond level)
RSTP (20 ms @ 250 devices)
Applied Environment Commercial Harsh environment, Industrial automation
Backup Link
Backup Link
Root
Source: Moxa
Industrial Preferred
Availability
Confidential
Fast Boot-up is Critical to Increase Network Availability
• PLC Boot-up Time*: ~20 sec• Most Switches: 40 sec ~ 1.5 min.
• Industrial Ethernet Switches: 10 secThe time for switches to boot-up should be shorter than the PLC in order to improve the stability of the network
* Siemens S7300, Allen Bradley CompactLogix 1769
Higher system availability, lower maintenance cost
Prevention of unnecessary alarm messages
Benefits
Ready !
Ready !
Ready !
Not yet!
Availability
Confidential
Seamless Communications Allows mobile devices (like AGVs) to be
constantly connected to a wireless network Reduces downtime and ensures all data gets
through
Availability
Confidential
Zero Packet Loss - Overview Traditional Approach Vulnerable to Packet Loss
• Single-RF devices • When interference disrupts data transmission, communication
is disabled
• Dual-RF devices • The secondary frequency is activated and data transmission
resumes• However, packet loss will occur during the switching period. • Threshold setting will generate a “ping-pong” effect between
two bands making the switching mechanism very inefficient
Availability
Confidential
Zero Packet Loss: Concurrent Dual-Radio Technology Eliminates the possibility of wireless interference
• Duplicate packets and transmit via two independent modules simultaneously
• When interference interrupts data transmission on the primary channel, concurrent transmission via the secondary frequency eliminates packet loss
Increase the throughput by reducing the number of resend request
Availability
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Harsh Industrial EnvironmentsRobust Industrial Design
Field Sites
Extended Operating Temperature
Severe Vibration / Shock
Electromagnetic Interference
High Humidity / Pollution
CONTROLLED TEMPERATURE
CONTROLLED HUMIDITY
CONTROLLED AIR QUALITY
Control Center
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Pipeline Monitoring System, Russia
-40°C
75°C Moxa Inside
Example: Switches Operating 24/7 in Harsh Environments
Drilling System, Saudi-Arabia,
Robust Industrial Design
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Integration with Control Level Network
SCADA Integration?• Plant field SCADA to control and manage devices through
industrial protocols• Some switches support industrial protocols in order to
integrate with SCADA• PROFINET• Ethernet/IP• Modbus TCP
There are industrial automation specific switches that enable industrial protocols
by default - Plug-n-Play!
Systems Integration
Integrating from Device to Enterprise
Confidential
Systems Integration
Device Servers
Gateways
Core Switches
Edge Switches
Case StudiesBest Practices
Confidential
Facility Management >> Country: Taiwan
NMS enables SCADA to monitor network status The switches have 3 GbE ports for creating a
GbE redundant ring and GbE uplink Ring and Chain technologies allow Gigabit
redundancy < 50 ms
Solution & Benefits
A semiconductor plant invested in thousands of dry pumps for an exhaust system to protect workers from toxic gases
Solutions needed to simplify pump system control and monitoring
Background & Requirements
Environmental Monitoring forAir Purification Systems
Confidential
Warehouse Automated Guided Vehicle System
Facility Management >> Country: Germany
A wireless solution saves wiring cost, and supports wireless AP, bridge, and client modes for easy deployment and mobility
Enables wireless VLAN and secure polling Supports fast roaming for millisecond-level
handover
Solution & Benefits A factory in Europe chose an industrial
access point to control and monitor numerous AGVs to support their fast growing warehouse management system
Background & Requirements
Thank You
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