smart networks for the industrial internet of things

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Building a SMART Network for the Industrial IoT Richard Wood Product Marketing Manager Industrial Ethernet Infrastructure April 29, 2015 IIoT Webinar Series

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Page 1: Smart Networks for the Industrial Internet of Things

Building a SMART Network for the Industrial IoT

Richard WoodProduct Marketing Manager Industrial Ethernet Infrastructure

April 29, 2015

IIoT Webinar Series

Page 2: Smart Networks for the Industrial Internet of Things

Confidential

Agenda

Smart Factory Introduction – Market Trends

Smart Factory Challenges

SMART Factory Best practices

Case Studies

Page 3: Smart Networks for the Industrial Internet of Things

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Smart Factory IntroductionMarket Trend

Page 4: Smart Networks for the Industrial Internet of Things

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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.”

Page 5: Smart Networks for the Industrial Internet of Things

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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

Page 6: Smart Networks for the Industrial Internet of Things

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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

Page 7: Smart Networks for the Industrial Internet of Things

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SMART Factory ExampleReal-Time Interactive Communication

Network Integration

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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

Page 9: Smart Networks for the Industrial Internet of Things

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

Page 10: Smart Networks for the Industrial Internet of Things

SMART Factory Overview

Secure Infrastructure

Easy Centralized Management

High Availability

Robust Design

Enterprise InTegration

Page 11: Smart Networks for the Industrial Internet of Things

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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

Page 12: Smart Networks for the Industrial Internet of Things

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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

Page 13: Smart Networks for the Industrial Internet of Things

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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

Page 14: Smart Networks for the Industrial Internet of Things

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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

Page 15: Smart Networks for the Industrial Internet of Things

Network Availability/Reliability

Page 16: Smart Networks for the Industrial Internet of Things

Network Topology

Typical Enterprise Star Topology

• Single point of failure• Long, costly wire/fiber runs

Availability

Page 17: Smart Networks for the Industrial Internet of Things

Network TopologyTypical Industrial Ring Topology

• No single point of failure• Reduced wiring costs

Availability

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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

Page 19: Smart Networks for the Industrial Internet of Things

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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

Page 20: Smart Networks for the Industrial Internet of Things

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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

Page 21: Smart Networks for the Industrial Internet of Things

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Seamless Communications Allows mobile devices (like AGVs) to be

constantly connected to a wireless network Reduces downtime and ensures all data gets

through

Availability

Page 22: Smart Networks for the Industrial Internet of Things

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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

Page 23: Smart Networks for the Industrial Internet of Things

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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

Page 24: Smart Networks for the Industrial Internet of Things

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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

Page 25: Smart Networks for the Industrial Internet of Things

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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

Page 26: Smart Networks for the Industrial Internet of Things

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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

Page 27: Smart Networks for the Industrial Internet of Things

Integrating from Device to Enterprise

Confidential

Systems Integration

Device Servers

Gateways

Core Switches

Edge Switches

Page 28: Smart Networks for the Industrial Internet of Things

Case StudiesBest Practices

Page 29: Smart Networks for the Industrial Internet of Things

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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

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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

Page 31: Smart Networks for the Industrial Internet of Things

Thank You

© 2013 Moxa Inc. All rights reserved.