Ethernet to the field of process automation Dr. Raimund Sommer, Managing Director Endress+Hauser Process Solutions AG Reinach, Switzerland

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1 Ethernet to the field of process automation, Managing Director Endress+Hauser Process Solutions AG Reinach, Switzerland February 10-13, 2014 Orlando, FL

2 Overview Endress+Hauser: brief introduction 40 years Ethernet Why talking about old stuff? Internet of Things Ice cream and Industrial Ethernet Target industries Classical and future communication architectures Something is missing for the process industries Conclusions Slide 2

3 Who we are Vision Customers perceive Endress+Hauser as an international automation solution supplier, with a wide range of process measurement instrumentation and a strong presence worldwide. We develop our employees, we foster a responsible attitude towards the community and our environment, while ensuring business success. Slide 3

4 2013 the year of the 40 th anniversary Slide 4

5 The popular inventor of Ethernet Robert Metcalfe, Xerox, 1973 and co-inventor David Boggs Slide 5

6 Ethernet is more than 40 years old Why am I invited to talk about old stuff? Slide 6

7 Short history of Ethernet IEEE : Ethernet invented 1980: Ethernet Blue Book 1982: Intel chip for 10 Mb/s Pioneers: DIX group 1990: Switched Ethernet 1995: 100 Mb/s 1998/99: 1000 Mb/s 2002: 10 Gb/s 2003: Power over Ethernet Slide 7

8 Short history of Ethernet IEEE : Ethernet invented 1980: Ethernet Blue Book 1982: Intel chip for 10 Mb/s 1985: First PLC with Ethernet connectivity 1990: Switched Ethernet 1995: 100 Mb/s 1998/99: 1000 Mb/s 2002: 10 Gb/s 2003: Power over Ethernet Slide 8

9 Many Ethernet competitors disappeared Token Ring IEEE Token Bus IEEE ARCNET FDDI Slide 9

10 Latest trends The latest trends bringing new perspectives! Slide 10

11 All things will be on the Internet Also field instruments and actuators will become things Slide 11

12 Complexity Ethernet to the field of process automation The idea of Industry 4.0 First mechanical weaving loom, st industrial revolution: Mechanical production powered by water/steam First band-conveyer, slaughterhouse in Cincinnati, nd industrial revolution: Mass production powered by electrical energy First PLC, Modicon, rd industrial revolution: Automation of production by means of electronics and IT today 4 th industrial revolution: Automation based on Internet of Things/Services and Cyber Physical Systems time Slide 12

13 Complexity Ethernet to the field of process automation The idea of Industry 4.0 First mechanical weaving loom, st industrial revolution: Mechanical production powered by water/steam First band-conveyer, slaughterhouse in Cincinnati, nd industrial revolution: Mass production powered by electrical energy 4 th industrial revolution: Automation based on Internet of Things/Services and Cyber Physical Systems First PLC, Modicon, rd industrial revolution: Automation of production by means of electronics and IT today 4 th industrial revolution: Automation based on Internet of Things/Services and Cyber Physical Systems time Slide 13

14 My vision: Internet technologies will reach the field Internet, or more general, Information Technologies will be directly integrated in devices on the shop floor respectively on the field level of process plants. Classical industrial communication technologies - particularly fieldbuses - will be substituted in the long run by Internet based technologies. Industrial Ethernet will play an important role in this scenario. All kinds of wireless technologies - WLAN, WWAN, PAN, WSAN - will also perfectly fit into these architectures. This will bring open, transparent network architectures for seamless horizontal and vertical integration. Remark: Due to the long life cycles of process plants there will be a long period of time of coexistence of classical and advanced technologies. Slide 14

15 Which benefits can customers/users get out of it? Increased efficiency/productivity More flexibility since markets change fast Improved energy and raw material efficiency Improvement of plant availability and reliability Improved competitiveness Slide 15

16 From Ethernet to Industrial Ethernet Let s not be starry-eyed! There are significant differences between Ethernet for office/home networks and industrial networks. Industrial Ethernet versus Ethernet for office/home networks follows extended specifications regarding robustness mechanical, environmental, electrical network topologies line, ring, redundant ring network dimensions geographically extended networks very short reaction time mainly for fast processes in factory automation, in specific applications also in process automation to enable it for industrial use. Slide 16

17 Back to Ethernet Ice cream and Industrial Ethernet Slide 17

18 What have ice cream and Industrial Ethernet in common? Slide 18

19 lots of different flavors! Slide 19

20 Which Industrial Ethernet flavors will become important? There are two main Industrial Ethernet protocols in the market that have significant market shares and growth rates and seem to become important for process automation: EtherNet/IP and PROFINET. Forecast 2015 according to IMS Research, % 20% PROFINET EtherNet/IP Modbus TCP 14% 19% POWERLINK EtherCAT sercos III 5% HSE 7% 8% 8% 9% other Gigabit Slide 21

21 Target Industries Demand for Industrial Ethernet in the field for process automation will initially emerge out of the hybrid industries. Manufacturing Industries Automotive Robotics Material Handling Machine Tools PLC Hybrid Industries Food & Beverage Life Sciences Environmental Process Industries Oil & Gas Chemical Power & Energy Primaries & Metal DCS Ethernet Slide 22

22 Classical fieldbus architectures in Process Automation Engineering station Operator Station Plant Asset Management? Field level only accessible via fieldbus through automation controllers or gateways Slide 23

23 Open Industrial Ethernet based architecture Engineering station Operator Station Plant Asset Management Industrial Ethernet Field level accessible through transparent switched Ethernet network or gateways Slide 24

24 Customers/user benefits One single network architecture from ERP to the field Higher bandwidth for more services running in parallel on highway of data. More flexible, modular field infrastructure installation. Fewer networks and hardware to engineer, configure, commission and maintain. (i.e. gateways, remote I/O ). Easier integration into existing Ethernet installations and corporate networks, no special requirements or conditions to meet. Slide 25

25 Target Industries After success within the hybrid industries Ethernet will go to the field of process industries. Manufacturing Industries Automotive Robotics Material Handling Machine Tools PLC Hybrid Industries Food & Beverage Life Sciences Environmental Process Industries Oil & Gas Chemical Power & Energy Primaries & Metal DCS Ethernet Ethernet Slide 26

26 Something is still missing to close the gap Engineering station Operator Station Plant Asset Management Industrial Ethernet? 4-wire devices TP Ethernet? Slide 27

27 Something is still missing to close the gap Engineering station Operator Station Plant Asset Management Industrial Ethernet 2-wire devices Power over Ethernet 4-wire devices TP Ethernet? Slide 28

28 Something is still missing to close the gap Engineering station Operator Station Plant Asset Management Industrial Ethernet? 2-wire devices Power over Ethernet 4-wire devices TP Ethernet 2-wire devices Intrinsic safe Ethernet Slide 29

29 Outstanding requirements of process automation Key requirements according to NAMUR NE 74 Slide 30

30 Summary/selection of important NE 74 requirements Open and effective. Environmental and topological conditions according to the needs of chemical process technology. Application in explosive atmospheres is an imperative Exchange of devices without written permission, e.g. intrinsically safe. To be handled by skilled workers, no engineers required. Operating functions of one device must under no circumstances interfere with the remaining field bus system. Connection technology must be robust and easy to use, if possible by using existing cable infrastructure. Cycle time: 10 ms 1s for digital signals, 100 ms 2s for analog data. Flexible topology, cable length up to 1000 m, spur up to 20 m. Up to 30 devices per segment redundancy not required. 2-wire cable for data and power. Slide 31

31 Conclusions Internet technologies move into the field. Automation is going to become an application of the Internet of Things. Industry 4.0 builds on the Internet of Things, customers gain in efficiency and productivity. Industrial Ethernet will be a core network in these new architectures and substitute the classical fieldbuses in the long run. There are preconditions to be fulfilled. Standards have to be developed and IT/Cyber security becomes an important subject to all products with Ethernet connectivity - also to field devices for process automation. Important steps towards the new paradigm of industrial production are already done. But there are still gaps to be closed. Slide 32

32 Industrial Ethernet on its way to process automation PI traditionally deals with process automation requirements based on PROFIBUS DP/PA since a long time. Therefore such requirements have already been specified in PROFINET. Latest news: ODVA started Process Initiative! Slide 33

33 Ethernet to the field of process automation Thank you for your kind attention

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