10.

2017 Issue 102

ISSN 1470-5745

The Journal of Industrial Networking and IoT

OPC UA TSN: new standards

for factory automation 8

Communication enables Future of Bluetooth IIoT edge gateways bridge Optimizing OEE critical
new business models 15 mesh networking 22 between domains 25 for Industry 4.0 36

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GET CONNECTED… www.iebmedia.com/ethernet n www.iebmedia.com/wireless

Contents
OPC UA TSN Juggernaut Contents
Even though we are a magazine founded
on the potential of Industrial Ethernet to Industry news 4
transform real-time manufacturing worldwide,
it’s still difficult to find the right words to OPC UA TSN solutions: from the field to the cloud 8
predict the overall impact of OPC UA TSN.
IoT platform emphasis on cybersecurity risks & efficiency 12
Obviously, we are living in a different time
now than when IEB began publishing in Industrial communications for new digital business models 15
the late 1990s. Both computer power and
communications bandwidth have expanded Update from IIC TSN testbed: perspectives & progress report 18
exponentially, but now with the impetus
provided by the Industrial Internet of Things, Use of SafetyBridge technology in plastics production 20
Industry 4.0 and the rapid expansion of cloud
services, the sky seems to be the limit on Bluetooth history and the future of Bluetooth mesh networking 22
the potential of this new technology even
though we are still at the very beginning of IIoT edge gateways create bridges between domains 25
its technological ascent.
Ethernet line extenders for control of electrical substations 28
This issue is filled with perspectives on this
technology and the benefits it will offer. OPC UA TSN: universal language for real-time data exchange 30
Here’s a sampling:
• The goal of Time-Sensitive Networking Data integration for cloud-based Industry 4.0 & IoT applications 32
and OPC UA is to provide easy access
to data from machines, controllers and Changing face of connectivity basis for enhanced automation 34
I/O systems, regardless of who built the
individual devices. Device connectivity key to optimal OEE in Industry 4.0 36
• With its information models, OPC UA IIoT-ready switch technology using MQTT connectivity 40
transmits not just data, but information
that can be correctly interpreted by any Cyber-physical systems drive industrial network innovations 42
node on the network.
• The combination of OPC UA and TSN will Miniaturised connections and higher data transfer rates 44
set the stage for entirely new industrial
automation architectures. One of the New Products 45
most notable features of these new
designs will be increasingly blurred lines Private Ethernet 50
between IT and OT networks.
• OPC UA TSN is providing a way to Industrial Ethernet Book
seamlessly share information from all The next issue of Industrial Ethernet Book will be published in November 2017
kinds of machines, devices and sensors Deadline for editorial: September 29, 2017 Deadline for artwork: October 20, 2017
in real-time.
Product & Sources Listing
• It looks to be a foundational element All Industrial Ethernet product manufacturers (not resellers) are entitled to free of charge
of machine interoperability and entries in the Product locator and Supplier directory sections of the Industrial Ethernet Book.
information transparency for the fourth If you are not currently listed in the directory, please complete the registration form at
wave of industrial revolution. www.iebmedia.com/buyersguide/ to submit your company details.
On page 8, you’ll find how OPC UA TSN provides
solutions from the field to the cloud. Update your own products
If you wish to amend your existing information, login to the Editor section
On page 30, take a look at OPC UA TSN as a www.iebmedia.com/buyersguide/register.htm and modify your entry.
universal language for real-time information
exchange. Do you want to receive issues of Industrial Ethernet Book? Call, mail or e-mail your details, or
subscribe at www.iebmedia.com/service/
An update and progress report from the
IIC TSN testbed starts on page 18, and the
technology report on page 32 presents how
Editor: Al Presher, [email protected]
OPC UA is enhancing data integration for
Industry 4.0 and IoT applications. Contributing Editor: Leopold Ploner, [email protected]
Advertising: map Mediaagentur Ploner, [email protected]
The amount and breadth of industry support
for this technology is significant, so you Tel.: +49-(0)8192-933-7820 · Fax: +49-(0)8192-933-7829
can expect to read more about OPC UA TSN Online Editor: Adela Ploner. [email protected]
developments in future issues of the Industrial Circulation: [email protected]
Ethernet Book as well. We’re glad to be on
this journey together, as real-time control, Published by
business data gathering and decision-making IEB Media, Bahnhofstrasse 12, 86938 Schondorf am Ammersee, Germany
come together to transform the state-of-
ISSN 1470-5745
the-art in factory automation.
Al Presher

1 0. 2017 i n d u str i a l e th e r n e t b o o k 3
 Team to develop next-
Industry news

generation cybersecurity
U.S. Department of Energy sponsors a team to develop next-generation network security for critical
infrastructure. New Ethernet communications technology aims to keep systems operational under cyberattack.

THE U.S. DEPARTMENT OF ENERGY (DOE) is

SOURCE: DOE
funding a research team to develop a secure
networking solution that reduces cyberattack
exposure for U.S. industrial and utility
mission-critical networks.
The team, which includes representatives
from Schweitzer Engineering Laboratories,
Inc. (SEL), Veracity and Sempra Renewables,
will focus on developing technology to reduce
the cyberattack surface of energy delivery
systems. The project includes automating
the identification of unwanted behavior, the
containment of affected network areas and the
rerouting of critical information. The ultimate
goal is for critical energy delivery and control
systems to remain safe and operational, even
in the event of a cyberattack.
The project team will create technology and
methods to define security state policies and
an automated system to manage the transition
between security states. This will enable faster
response to unauthorized traffic, streamline The vision of OE’s cybersecurity program is that, by 2020, resilient energy delivery systems are designed, installed,
the identification and containment of affected operated, and maintained to survive a cyber incident while sustaining critical functions.
networks and reroute critical information and
control flows. the OpenFlow specification. introduced an SDN flow controller and a
The project will deliver the following: • The ability to apply an action to encrypt/ substation-hardened SDN switch to the
• A security state policy enforcer decrypt packets on a per-flow basis and market.
application that runs on the northbound automate key management. For more information, visit the DOE CEDS
interface of a flow controller. This project builds on the already successful program webpage at https://energy.gov/oe/
• A DIN rail mount software-defined completion of the DOE’s Watchdog and SDN services/cybersecurity.
networking (SDN) Ethernet switch. projects, which were sponsored by the DOE’s
• An industrial control system extension to Cybersecurity for Energy Delivery Systems News from Schweitzer Engineering
the open source SDN specification using (CEDS) program. These projects successfully Laboratories.

Siemens and ISA partnership focuses on industrial cybersecurity

AS THREATS TO AUTOMATION EQUIPMENT are ransomware attacks have demonstrated Siemens Plant Security Services adhere to
always changing and evolving, so too is the the possible impacts in the last weeks. the IEC62443 guidelines and are available
protection concepts for industrial plants. To Our customers need to adequately manage for existing Siemens customers and third-
address this challenging landscape, Siemens the associated cyber risk, arising from the party equipment, providing a multi-layer
and the International Society of Automation vulnerabilities of IT technology combined with protection-level approach, asset inventory and
(ISA) have entered a global partnership to the increased connectedness in our digital tracking, patch and vulnerability management,
foster the awareness for industrial security age,” said Henning Rudolf, Global Head of network segmentation, industrial security
needs and global standards. Siemens Plant Security Services. management, incident handling and security
Both parties will share expertise in consulting services.
protecting the automation environment based ISA Security Compliance Institute Siemens also provides a comprehensive
on the IEC 62443 standard and appropriate The ISA Security Compliance Institute (ISCI, Product Computer Emergency Response
security measures in the form of events, www.isasecure.org) operates one of the first Team (ProductCERT) for Siemens solutions.
webinars and educational material. Together, standardized assessment schemes for the IEC Siemens operates several “Cyber Security
ISA and Siemens intend to raise awareness and 62443 IACS cybersecurity standards, and this Operation Centers” (CSOC) for the production
share best practices for industrial security with program has been heavily adopted by Siemens of industrial facilities, with joint locations in
owner-operators of industrial equipment. as a leading provider of automation equipment Lisbon, Munich and Milford (Ohio) in the USA.
“Cyber security needs to be addressed and industrial security services, as well as
by industrial companies as recent global being a global manufacturing company. Industry news from Siemens and ISA.

4 in d u s t r ial et h er ne t b o o k 10.2017
IEB102_p5.indd 5 09.09.1736 16:04
 Official release of PLCopen
Industry news

Safe Motion version 1.0

The introduction of safety approved networks makes the control of drives and motors more and more
controlled in software, with hard-wired systems replaced by software commands over networked systems.

The PLCopen Safe Motion specification version

SOURCE: PLCOPEN
1.0 is now officially release, and available on
the PLCopen website for downloading.

Safety-approved networks
The introduction of safety approved networks
makes the control of drives and motion more
and more a software item; hard-wired systems
are replaced by software commands over
networked systems.
This is also pushed by initiatives like
Industry 4.0 to create more flexibility
preferably at the same quality and price
levels. However, the different networks
Work by the PLCopen Motion and PLCopen Safety activities have both resulted in a new suite of specifications.
come with different solutions, which create
problems at the users especially in production
environments with heterogeneous networks. This new solution is based on an existing the safety functionality is in the drive, incl.
To harmonize this, PLCopen started a functionality as already specified in PLCopen all relevant parameters.
working group on Safe Motion, which created Safety: SF_SafetyRequest. With this most of This work is a continuation of the PLCopen
a generic proposal to solve the motion control the safety drive functionalities can be mapped Motion and PLCopen Safety activities, which
safety aspects over the different networks easily, especially by providing a “guideline” both resulted in a suite of specifications.
like ProfiSafe, Safety over Ethercat, CIP with defined naming conventions, containing Inside these published specifications the
Safety over Sercos, OpenSafety, CC-Link IE a generic scheme how to name signals related safety aspects around motion have been
and Mechatrolink, as well as user area’s as to the functions supported by a safety drive. described only partially. This new document
described in OMAC. Combined with an I/O or Drive configurator fills this gap.
Also there are many Safe Motion related these names can be generated automatically
commands, and it makes no sense that a for the bits in the drive‘s status / control word, http://www.plcopen.org
function block is created for all of them while matching the drive‘s profile (symbolic names).
the functionality is mostly the same. This proposal is based on the architecture that Industry news by PLCopen.

OPC UA Companion Standard for Sercos released

THE OPC FOUNDATION AND SERCOS sense to plug into an OPC UA namespace.
International announce that the Sercos OPC The Sercos OPC UA Companion Specification
UA Companion Specification Release is now enables machine to machine interoperability,
available. This specification describes the and machine integration with the cloud-based
mapping of the Sercos device model and the applications at a minimum. Sercos suppliers
Sercos device profiles to OPC UA, so that will now be able to take advantage of the
functions and parameters of Sercos devices rich service oriented architecture of OPC UA,
are made accessible via OPC UA in a vendor- truly facilitating the vision of the embedded
independent manner. world having information integration into the
This initiative aims at simplifying the cloud,” said Thomas J. Burke, OPC Foundation
communication between machine periphery President and Executive Director. OPC-UA in the Sercos system architecture.
and supervisory IT systems and to support “The OPC community will now be able to
the requirements of Industrie4.0 regarding easily extend their products to support the and maintained, resulting in significant total
semantic interoperability. The OPC Foundation great networking technology of Sercos. cost of ownership (TCO) during the entire
and Sercos International started their Both organizations are working together to product life cycle. “New business models can
collaboration with the common aim to improve facilitate and help the suppliers bring certified be easily implemented because users and
the machine integration and to simplify the products to the marketplace supporting this suppliers can rely on a consistent and vendor-
communication between machine periphery new companion specification,” he added. independent semantic,” said Peter Lutz,
and higher-level IT systems. In today’s manufacturing systems Managing Director of Sercos International.
“Sercos provides a very rich robust device automation devices & systems from many
model and device profiles that made logical different manufacturers have to be integrated News by OPC Foundation & Sercos Intl.

6 in d u s t r ial et h er ne t b o o k 10.2017
 Engineer a Better Network
Introducing the industry’s first field-hardened
SDN-enabled Ethernet switch.
Today’s power system engineers need the convenience of Ethernet combined with
low latency and fast healing to support mission-critical substation applications.
The SEL-2740S Software-Defined Network Switch and SEL-5056 Software-Defined
Network Flow Controller provide an innovative solution that employs software-defined
networking (SDN) to enhance the dependability, performance, configuration, and
management of proactive OT and dynamic IT networks.

Engineer a better network—it starts with the SDN-enabled SEL-2740S.

• With failover times of less than 100 microseconds, ensure the performance of
mission-critical applications under all conditions.
• Simplify the design, testing, and implementation of critical power utility and
industrial OT networks by using the SEL-5056 Flow Controller.
• Strengthen cybersecurity through deny-by-default network access control.
• Seamlessly integrate with existing network infrastructure through OpenFlow 1.3
standard support.

Order your evaluation system to see the advantages of SDN for yourself.
For details, visit www.selinc.com/betternetwork.

IEB102_p7.indd 7 09.09.1736 16:07

 OPC UA TSN solutions:
Applications
Technology

from the field to the cloud

The combination of Time-Sensitive Networking and OPC UA provides easy access to data from machines,
controllers and I/O, regardless of who built the individual devices. With its information models, OPC UA also
transmits not just data, but information that can be correctly interpreted by any node on the network.

THERE’S NO DENYING THE VALUE that the

SOURCE: OPC FOUNDATION

Industrial IoT holds in store for the future
of manufacturing. Efforts to tap into this
potential, however, have far only begun to
scratch the surface.
Now, spurred by demand from end
customers, automation suppliers are poised to
clear the first hurdle on the road to Industrial
IoT solutions: seamless communication based
on open standards. Time-Sensitive Networking
(TSN) in combination with OPC UA provides
unimpeded access to data from machines,
controllers and I/O systems, regardless of who
built the individual devices.
As an open communications architecture,
OPC UA has already found widespread use in
a diverse range of industrial applications.
Nearly all manufacturers offer OPC UA in their
controllers and other products. OPC UA is Operators of industrial machinery and equipment can use the combination of TSN and OPC UA, and no longer have to
developed and promoted by many different worry that the simple act of selecting a communication technology will lock them in with a specific vendor.
manufacturers under the oversight of the
OPC Foundation. Operators of machinery and Information, not data for example, we have a sensor that measures a
equipment no longer have to worry that the Among the greatest advantages of OPC UA temperature of 5°C. Coming from a traditional
simple act of selecting a communication are its information models. Traditional bus protocol, the controller would receive this as
technology will lock them in with a specific systems transmit dimensionless data – simple an integer data type with the value “5”. The
vendor. numbers unaccompanied by units or any other fact that the number represents a temperature
Establishing this type of uniform system information. The application running on the value measured in degrees Celsius, and the
connectivity opens up challenges and controller knows how to interpret these fact that there are certain limits to be applied,
opportunities for differentiation at a whole numbers using what is known as a semantic is defined in the application running on the
new level. Where we’ve been accustomed to data model. controller.
seeing 30 or 40 nodes in a network, we’ll There is absolutely nothing wrong with OPC UA takes a different approach. The value
eventually be seeing 1,000 or more. this approach, of course, as long as machines “5” is provided along with all of its semantic
are operating independently of one another. context. In this case, it is a temperature value
Growing number of nodes However, as soon as it becomes necessary measured in degrees Celsius, and it has limit
The challenge will be to find a way to manage to use the data elsewhere – be it on other values that should be applied.
and control this increased number of nodes machines, in SCADA systems or even in
effectively. Within this challenge, however, cloud-based ERP systems. The semantic Information on demand
lies an opportunity for automation suppliers meaning is lost, and all that remains are the Since other nodes on the OPC UA network are
to differentiate themselves by offering their dimensionless numbers. able to query this information, it can be used
customers added value. in a much wider variety of ways. If you want
Software tools that streamline the setup and Fewer errors to generate a new ERP report, for example,
configuration of complex networks with large In the past, the semantic context has been the ERP system can browse the network for
numbers of nodes will become substantially transmitted to other systems in lengthy tables appropriate information. Once found, this
more important. These tools will also need or even in handwritten form. This painstakingly information can be collected in a database and
to be designed for users without extensive IT tedious undertaking – a notorious source of viewed in the report. It used to be necessary
training. errors – is eliminated entirely with OPC UA, to program this data transfer manually, and
It’s not only the number of nodes that is making it considerably easier to implement the semantic information for each individual
increasing so rapidly, however; the volume of more agile and responsive manufacturing value would need to be stored in the ERP
data will also continue to grow exponentially. solutions. system. With this static structure, changes to
Managing the flood of big data with With its information models, OPC UA variables on the machine would also require
conventional industrial protocols is becoming transmits not just data, but information that reprogramming in the ERP system.
increasingly difficult, and this is where OPC UA can be correctly interpreted by any node on the This example highlights just how much OPC
promises substantial improvement. network without any further explanation. Say, UA simplifies communication from the control

8 in d u s t r ial et h er ne t b o o k 10.2017
 Open road to a common goal:
Your Industrial IoT future

POWERLINK
and OPC UA TSN
The seamless solution
for integrated connectivity.
Efficient, vendor-independent,
optimized for fast cycle times and
structured access to big data.
Let's shape the future.
www.ethernet-powerlink.org

IEB102_p9.indd 9 09.09.1736 16:11

 SOURCE: OPC FOUNDATION
Technology

Until now, there has been no way to implement both best-effort and deterministic cyclic traffic on the same network. With Time-Sensitive Networking (TSN), that’s about to
change. TSN provides a group of extensions to the Ethernet standard that will allow both general and time-critical data to be transferred over the same network.

layer up to higher-level systems. With that, which is something that cannot be permitted standardized interfaces and mechanisms for
however, we arrive at the next hurdle: When on a machine network. configuration.
higher-level IT systems are sending queries Until now, there has been no way to
down into the machine network – referred to implement both best-effort and deterministic Bye-bye bandwidth blues
in this context as operational technology, or cyclic traffic on the same infrastructure. With If you combine the mechanisms described
OT – the network load inevitably increases. Time-Sensitive Networking (TSN), that’s about above in a network, it becomes possible to
For an IT computer network, delays in the to change. TSN is a group of extensions to the transmit time-critical and cyclic data on
millisecond range are generally not a big deal Ethernet standard that will allow both general the same physical layer as non-time-critical
to worry about. For a precisely synchronized and time-critical data to be transferred over data. Since modern production networks rely
manufacturing process, on the other hand, the same network. on Gigabit Ethernet transfer rates or higher,
sub-millisecond accuracy is absolutely The first step toward equipping a network this simultaneously resolves the bandwidth
essential. Here, a delay in the millisecond with deterministic behavior is to ensure all of bottleneck issue that currently plagues not
range can shut down a machine, reduce its nodes are on the same page with regard only fieldbus systems, but industrial Ethernet
output quality or even cause significant harm to timing. The IEEE 802.1 AS-Rev standard protocols as well.
to equipment and personnel. was developed for this purpose. It describes The combination of OPC UA and Time
This is why nearly every manufacturing a mechanism for synchronizing the clocks of Sensitive Networking will set the stage
facility has traditionally maintained a clear all the nodes in the network to establish a for entirely new industrial automation
separation between its IT and OT networks. IT uniform network time. architectures. One of the most notable features
networks have historically lacked determinism The next step is to guarantee that of these new designs will be increasingly
and cyclic data traffic – two deal breakers at deterministic data traffic is given priority on blurred lines between IT and OT networks.
the OT level. the network. This is covered by the standards This applies not only to new plants built with
IEEE802.1 Qbv and Qba, which specify that full connectivity from the ground up, but
A single shared network network switches must operate in such a way brownfield plants as well.
IT networks follow a principle known as “best- that deterministic data traffic is transmitted OPC UA TSN covers all the requirements
effort delivery”, which means that data packets within a guaranteed time frame, even if this of today’s most demanding manufacturing
all share the same level of priority and are means that other traffic must wait. applications above the control layer.
transmitted as quickly as possible. If capacity To establish a uniform approach to
is exceeded at any point in the process, there configuring this type of network, the Stream Sebastian Sachse, Dipl. Ing. at B&R Industrial
will be a bottleneck and interruption of timing Reservation Protocol (IEEE802.1Qcc) provides Automation GmbH.

10 in d u s t r ial et h er ne t b o o k 10.2017
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IEB102_p11.indd 11 09.09.1736 16:12

 IoT platform emphasis on
Technology

cybersecurity risks & efficiency

By enabling access to trusted devices, applications and users, along with secure and timely delivery of
data across the industrial control system (ICS) IoT ecosystem, new IoT security platforms are combating
cybersecurity risks.

THE INTERNET OF THINGS (IoT) has rapidly platform have the potential to change the way to assembly, but also sets the stage for a
expanded in recent years, and shows no signs manufacturers do business. seamless replacement process later on.
of slowing down. Since 2016, the number of In addition to improved asset tracking,
connected things has jumped 31 percent and An added degree of security the new technology offers advanced human
is expected to reach up to 20 billion by 2020. No industry is immune to cybersecurity machine interface (HMI) authentication.
But as the presence of IoT devices continues threats, manufacturing included. According to According to a recent report, the HMI market
to increase, so will cybersecurity risks within the 2016 Manufacturing Report from Sikich, is expected to grow at a compound annual
control systems. From industrial espionage just about one in five manufacturers have growth rate of 9 percent over the next five
and physical damage to financial loss due suffered a loss of intellectual property from years, eventually reaching $5.86 billion by
to downtime, organizations struggle to fend cyberattacks. 2022.
off many of the dangers that accompany an By enabling manufacturers to tie their A steadily increasing number of
unsecure digital infrastructure. Worse yet, the products to a unique, secure identity that can manufacturers are implementing more
proliferation of connectivity options have led extend throughout the supply chain, ioTrust sophisticated HMIs, and for good reason. Not
to a lack of security and data silos. technology prevents the unauthorized use of only do HMIs offer control over equipment, but
New security platforms and technologies are assets or materials from going missing. When they also provide insights into performance.
combating these issues by providing a single, it comes to supply chains with multiple levels Given the expanding interest in more powerful
end-to-end security solution that enables of suppliers, such tracking capabilities can HMIs, it’s important that manufacturers
access to trusted devices, applications and prove to be a big help. do all they can to secure such interfaces.
users, and the secure and timely delivery If, for example, a car contains several By combining several identity capabilities,
of data across the industrial control system electronic control units, each of which has such as supply chain validation and securing
(ICS) IoT ecosystem. With key features such its own manufactured components, an original hardware and software keystores, ioTrust
as identity issuance and data security, as equipment manufacturer may demand that technology can help do just that.
well as scalable deployment options that the units and their components are uniquely In addition, ioTrust can protect the ICS IoT
provide on premise and cloud management identified. Doing so not only guarantees ecosystem through stronger VPN credentials,
models, models such as the ioTrust technology the units are genuine from supply chain cryptography, embedded systems, trusted

SOURCE: ENTRUST DATACARD

A large part of cybersecurity readiness is built on establishing trusted identities, secure issuance for proper authentication and electronic validation of network access.

12 in d u s t r ial et h er ne t b o o k 10.2017
 Ethernet communication between electronic equipment has increased with Industry 4.0 which brings
efficiency of manufacturing with ICT technology. In response to this increasing demand HIROSE
had standardized a new miniaturized Ethernet mating interface in compliance with IEC/PAS 61076-
3-124. The ix IndustrialTM socket size is reduced by 70% compared to the existing RJ45 modular
connectors, and offers ideal space saving cabling for applications with miniaturized requirements.

■ Compact: 70% smaller in size than a RJ45

■ Robust: 5000 mating cycles
■ High-speed: Ethernet 1Gbps/10Gbps
■ High EMC resistance
■ Complies with IEC/PAS61076-3-124

▶ Security System ▶ Data Center ▶ Communications

▶ Transportation ▶ Robotics ▶ Factory Automation

www.hirose.com/eu - [email protected]

IEB102_p13.indd 13 12.09.1737 16:36

 SOURCE: ENTRUST DATACARD
Technology

The combination of edge and service gateways can fit into an overall plant network using secured data paths and end point agents to effectively manage identities.

infrastructures and predictive maintenance. For however, must also accompany such changes. efficiency, the IoT continues to open up new
remote administrators, secure authentication The removal of obstacles greatly increases the opportunities for the manufacturing industry.
no longer stands to be an issue. Using new attack surface of manufacturing environments, With new security technology, Manufacturing
technology, users can quickly authenticate making secure connectivity vital. Proxies used in conjunction with a service
themselves before reading data or issuing With ioTrust technology, manufacturers gateway integrates production processes and
commands with a secure programmatic API. have an ability to potentially break apart provides on-demand issuance of manufacturer
Meanwhile, the secure flow of data from data silos while also maintaining high security identities. This type of real-time information
sensors to cloud data hubs allows devices, standards. Operators who have previously can set the stage for improved performance
applications and employees to receive struggled to derive insights from unconnected as well as availability. The ioTrust Endpoint
insights, such as system stability and device systems can now leverage millions of sensors Agent, a Java application that logs endpoint
lifespan that can be used to predict when to learn about system stability and device telemetry data and securely acquires ioTrust
repairs might be needed. lifespan, without creating a security risk in identities through SCEP and EST protocols,
the process. simplifies the identity management process
Cultivating communication When it comes to trust between partners for manufacturers.
Whether from a technology or communication and systems, ioTrust can usher manufacturers Finally, identity and data security measures
standpoint, connectivity remains an area into an ecosystem with enhanced visibility, including automated payload encryption
of growth for the manufacturing industry. security and access control. Demand for and infrastructure monitoring helps ensure
Point solutions that lack the ability to greater efficiencies has driven the employment sensitive information doesn’t fall into the
communicate with one another have made it of external experts capable of conducting wrong hands.
tough for operators to quickly diagnose issues. detailed analysis across a wide range of While the IoT promises to eliminate
Instead of getting to the root of a problem, plants. By securing the data being shared many of the barriers that often stonewall
manufacturers spend time sorting through along with the identities of multiple partners, communication, such connectivity puts
data from multiple unconnected systems. But ioTrust can help create a foundation of trust pressure on manufacturers to be prepared for
with the IoT, an uptick in efficiency may not that facilitates communication and ultimately an increased risk of cyberattacks.
be too far off. boosts the efficiency of manufacturing plants. By shoring up security, new security
The IoT is paving the way for connectivity technology and platforms are clearing the
by eliminating traditional barriers within The modern way to work path for greater connectivity and, in turn,
manufacturing environments. Roadblocks that It’s no surprise nearly 35 percent of all U.S. efficiency.
prevent manufacturers from simultaneously manufacturers believe it’s extremely critical
examining data across an entire plant could to adopt an IoT strategy in their operations. Josh Jabs, VP of PKI and IoT Solutions, Entrust
soon go by the wayside. An upgrade in security, From improving connectivity to jumpstarting Datacard.

14 in d u s t r ial et h er ne t b o o k 10.2017
 Industrial communications for

Technology
new digital business models
What came first, the chicken or the egg? When it comes to industry digitalization, a similar question arises
with new digital business models. Is business vision or technological innovations required first? A recipe for
success can be building a digital infrastructure and step-by-step, experimental strategy development.

SOURCE: SIEMENS
Integration of PLM and 3D print
Production Engineering End-to-End
Engineering Data Analytics
Technology

De-Coupling Smart Tools

of cells Cloud Computing
Semantical Flexible
Collaborative Data Integration Automation Usage information
robots

Digitale Infrastructure
Process

Production Sales and

Product Design Anlagenplanung Material Flow Services
Control Distribution

Services based on usage data

Enable mass individualization

Strategy

Schnellere Produktentwicklungen

Reduction of cost

New payment models

Requirements for communication networks due to digitalization (Weinländer: Industrielle Kommunikation: Basistechnologie für die Digitalisierung der Industrie).

WHEN TALKING ABOUT DIGITALIZATION, the of specific installations at the customer costs (CAPEX or capital expenditures) can
technological perspective is often focused on (remote maintenance). Tied to that can be be converted in favor of use-oriented costs
how connectivity between the field level and performance and availability guarantees by the (OPEX or operational expenditures). This
the cloud can be established, which aspects manufacturer. The benefit for the customer: makes it easier for the customer to try out
must be considered for the virtualization, The customer does not buy a machine with a new concepts, because the manufacturer can
what is needed for a comprehensive security performance promise, but instead pays for the be tied more strongly – also financially – to
concept and much more. actual performance and quality. the achievable results of the investment.
All of these topics are important, but a A second option is the digitalization of one’s Payments can also be based on actual
different question takes center stage when it own service provision, i.e., the introduction availabilities. Through a continuous remote
comes to digitalization. How can companies of digital technologies to improve one’s own monitoring of machinery and equipment, the
achieve a strategic competitive advantage processes and methods. Industrie 4.0 focuses manufacturer can ensure in a timely manner
through digital concepts? It is about nothing on this option. Besides lowering throughput that its performance promise is fulfilled; its
less than a digital business model to be able times and costs, as well as increasing the own risk becomes controllable through the use
to succeed against global competition. achievable quality, from a strategic perspective of appropriate technologies.
it is above all the ability to control complex
Digital business models product offerings in a customer-specific mass Technological innovations
Three possible starting points are available production. As a result, manufacturers are able All of these business innovations, though, are
for the development of a digital business to meet the ever more demanding customer based on technological innovations ranging
model. For instance, the actual product requirements in a more targeted way than with from end-to-end engineering to 3D printing
can be digitalized first. Although industrial a conventional organization of development, and collaborative robotics to new, data-driven
products are rarely as easy to substitute production and logistics. service offerings – which are also discussed
digitally as the vinyl record by CDs and MP3 The third option is covered by the at length in the context of Industrie 4.0. All
downloads, a digital customer benefit can also introduction of new payment models, which of these technologies can lead to spectacular
be created by means of appropriate services, go far beyond just machinery and equipment results for some companies, while other firms
which, for example, take over the monitoring sales. First of all, the necessary investment are unable to discover the right benefits for

1 0. 2017 i n d u str i a l e th e r n e t b o o k 15
 SOURCE: SIEMENS
Applications

Increasing number of network nodes, Increasing Data volumens per year De-coupling of hierarchical
e.g. connected machines (bln. pieces) (exabytes) communication architectures
40
(Cloud: 15)

+1.250 % +3.300 %
15

1,2
12 (Cloud: 0,05)

2010 2020 2000 2025

For high-quality transport containers, new service and payment models can be established thanks to industrial communication networks.

themselves and their customers. The processes also take place in the marketplace, e.g., by networks are required. In addition, there
and strategies that can be derived from them, initially testing a new offering with a number is a need for a scalable software platform,
too, are only possibilities that companies can of partners before a broad market roll-out. which enables the corresponding processing
implement in various combinations. Business model simulations are possible as capabilities through algorithms and apps. Such
However, since there can be no automatism well, e.g., in order to test the actual effects a platform can be MindSphere from Siemens,
and no recipe for success, an agile approach of a pay-per-use model in collaboration with which functions as an operating system in the
is recommended in practice. On the one hand, pilot customers. “Internet of Things (IoT)”. The establishment
the technological possibilities are reflected Applying to almost all digital approaches and expansion of the digital infrastructure is
and explored against the background of is the necessity for a powerful infrastructure therefore a third possibility for a company to
one’s own company and its strengths and to make the implementation in the company prepare for the digitalization.
weaknesses. The objective is to develop a clear possible. Digital processes essentially mean the
picture of how technological innovations can exchange of data between all possible partners; Networks as digital infrastructure
be put to good use. On the other hand, small, for all of these information flows, powerful, The basis for this digital infrastructure is
defined experiments with innovations should reliable, flexible and secure communication the industrial communication network. It

SOURCE: SIEMENS
Apps
Plattform

Enterprise IT MindSphere Public networks

Aggregation

SCALANCE XR500 Ruggedcom RX1400

Industrial IoT Gateway

SCALANCE SCALANCE
S615 S615

SCALANCE SCALANCE
XC200 XC200
Cell Segments

MindConnect
Nano

ET200SP RFID Reader S7-1500 Mobile RFID Smart Drive S7-400 PLC
CP1543SP-1 RF600 CP1543-1 RF650M CP443-1
MindConnect FB

Simplified representation of a network reference architecture in a digital company.

16 in d u s t r ial et h er ne t b o o k 10.2017
must satisfy the most diverse

SOURCE: SIEMENS
Digital Offerings
requirements. First of all, (products and services)
today’s applications must e.g. guaranteed performance
values, remote maintenance
continue to run undisturbed,
Value
especially in the production, Proposition
i.e., the automation
requirements regarding Digital Payment Digital Processes
Models e.g. end-to-end
bandwidth, availability and e.g. engineering,
special needs such as real-time Pay-per-Use Production-
in-networks
communication continue to
Revenue Value
apply without restrictions. Structure Creation
In addition, the network
must be open and flexible
so that it is also suitable for
Digital business models can be realized in three ways.
future digital applications
or at least can be expanded
accordingly. For these reasons, providers Use for new business strategies
such as Siemens supply a broad portfolio of How can such an architecture be utilized for
network components that meet a wide range business strategies? The sky is the limit when
of requirements, e.g., via modularized devices. it comes to the possibilities; especially for
Digitalization can affect three aspects of medium-sized providers, there are interesting
the network architecture: Firstly, significantly opportunities. For instance, the shower tray
more participants enter the network; secondly, manufacturer Bette has established a made-to-
the data volume increases considerably; and order business model based on RFID and digital
thirdly, new communication relationships will networking, and can now much better meet
evolve, which will less and less correspond the needs of customers and architects (cf.
to today’s hierarchical design. Studies Ermer/Weinländer: International Marketing.
are expecting about 15 billion networked Publicis: Erlangen, Germany, 2017). Würth
machines by 2020; the annual data volume Industrie Service, a provider of C-parts for the
is estimated to be 40 exabytes. Nevertheless, industry, has also expanded its business model
the overall networking cost is a critical factor with industrial communication technology. Its
to keep in mind. RFID-supported e-Kanban system turns the
For a network reference architecture, three company from purely a supplier into a system
guiding principles can be formulated from that partner for its customers.
include segmentation, increasing aggregation A third example pertains to the operators/
and security-in-depth. Segmentation means owners of high-quality transport containers
that not all communication end nodes must when pooled or in their own logistics. Here,
be grouped together in a flat network. Instead, the use of the containers can be tracked
individual communication cells are formed more precisely by means of a suitable
resulting in significantly fewer participants to communication architecture; on the one
manage per segment. hand, to more optimally coordinate the own
Further segments can be integrated as services (e.g., cleaning), and on the other
necessary. The increasing aggregation across hand, to establish a payment model that
vertical levels gradually adds additional also automatically incorporates the usage
bandwidth for higher performance as well as duration. To this end, it may be useful to set
further redundancy mechanisms for improving up small, self-sufficient installations at the
overall network reliability. Finally, Siemens’ logistics partners, suppliers and customers.
multi-level security-in-depth concept ensures On an experimental basis, this can initially
that attacks are reliably averted and network represent only a few selected key partners in
availability is maintained. the value chain.
An important alternative can be the use By linking new and proven technologies and
of public mobile communications networks, architectures, strategic competitive advantages
which realize cloud and IoT connections can be gained. Industrial communication plays
without connecting to the automation a key role, because it is the infrastructure for
network, e.g., when it comes to connecting numerous other innovations. This does not
special, additional sensors or the goods necessarily involve a radical strategic change
acquisition by RFID at the supplier or logistics of course; rather many ideas allow experience
partner. Here, for example, the industrial IoT to be gradually gained and market acceptance
gateway Ruggedcom RX1400 from Siemens can to be tested. Successful implementation
be employed, which on the one hand provides examples demonstrate how companies have
a variety of interfaces (including WLAN) at the succeeded in digitally supplementing their
field level, and on the other hand enables an business models.
aggregation of data prior to the transmission
into the cloud by means of its own processing Markus Weinländer, PD PA / Process Industries
logic. and Drives, Siemens.

1 0. 2017 i n d u str i a l e th e r n e t b o o k 17
 Update from IIC TSN testbed:
Technology

perspectives & progress report

The IEEE 802.11 task group and work spearheaded by the Internet Engineering Task Force has extended the
ability to operate time sensitive systems over standard Ethernet networks. Technical work continues that will
allow convergence of low latency control traffic and standard Ethernet traffic on the same network.

SOURCE: AVNU
The testbed is a showcase of how TSN standards can work within the manufacturing ecosystem, including high-performance and latency-sensitive applications.

THE INDUSTRIAL INTERNET OF THINGS (IIoT) network. TSN can also support other common can be remedied. The on-site Industrial
is growing at an exponential rate, with more traffic found in manufacturing applications Internet Consortium’s IIC Time Sensitive
manufacturing and automation companies at the same time as the control, driving Networking or Flexible Manufacturing Testbed,
moving to network-based operations convergence between IT and operational known as the TSN testbed, is one such
and adding new devices to the network. technologies. example. The testbed has also been travelling
The successful implementation of these As the Avnu Alliance (avnu.org) has shown to various industry events across the world.
connected automation and control networks success in audio/video applications, it is
require a solution that ensures complete helpful to be able to reuse this technology Major goals for TSN testbed
interoperability. in modern machines using video cameras The world’s first testbed for TSN was developed
Standard Ethernet has evolved to enable next in control loops. As TSN-based network with two major goals: to show TSN’s readiness
generation control systems. With this, recent infrastructure become more prevalent, many of to accelerate the marketplace; and to show the
work by IEEE 802, the Internet Engineering today’s modified Ethernet networks can move business value of accelerating the adoption of
Task Force (IETF), and other standards groups to TSN-based networks, using their OT-based time sensitive networking technology.
has extended the ability to operate time- application layers on standard 802.1 Ethernet. It stands as a showcase of the value
sensitive systems over standard Ethernet In January 2017, National Instruments that TSN standards within the ecosystem of
networks, supporting diverse applications and announced the opening of the NI Industrial manufacturing applications can bring to the
markets including professional audio/video, Internet of Things (IIoT) Lab, sponsored by market, including the ability for the IIoT to
automotive, and industrial. Avnu Alliance and others at the Austin, TX incorporate high-performance and latency-
These standards, driven primarily by the headquarters. The NI IIoT Lab’s goals are to sensitive applications.
IEEE 802.1 Time-Sensitive Networking (TSN) foster collaboration between various vendors IIC member participants include key
task group, define new mechanisms for to prove out interoperability. industry leaders like: Analog Devices, Belden/
creating distributed, synchronized, real-time In this space, communication protocols, Hirschmann, Bosch Rexroth, B&R, Cisco,
systems using standard Ethernet technologies controller hardware, I/O components, Hilscher, Intel, KUKA, National Instruments,
that will allow convergence of low latency processing elements, and software platforms OPC Foundation, Renesas Electronics,
control traffic and standard Ethernet traffic are combined to validate end-to-end solutions Schneider Electric, SICK, TTTech and Xilinx
on the same network. that will dramatically change the way – many of which are also Avnu Alliance
businesses operate. members. The work coming out of the TSN
TSN-based network infrastructure A working showcase for IIoT technologies, testbed is already having a direct impact
TSN supports real-time control and solutions and systems architectures, the NI on suppliers and manufacturers who see the
synchronization, for example, between motion IIoT lab features demonstrations of real-world technology as a value add for their system
applications and robots over a single Ethernet industrial industry challenges and how they structure.

18 in d u s t r ial et h er ne t b o o k 10.2017
 The benefit of the testbed is that it over a single Ethernet network. TSN drives
demonstrates real-world solutions. One such convergence and increased connectivity,
use case currently being conducted is a unlocking the critical data needed to achieve
setup of two separate large scale robot and the promise of IIoT,” Soley added.
automation control suppliers who are seeking Tom Weingartner, Marketing Director,
to implement TSN technology to increase Deterministic Ethernet and IIoT Communication
interoperable communication between their Technology at Analog Devices said that “ADI
devices and systems. They will coordinate has been involved with the IIC TSN Testbed
and control PLCs and the monitoring of from its inception. It has always been
the sensor data between robots and PLCs. successful as a tool to test interoperability
This coordination requires a combination of among industry vendors’ equipment, but ADI
receiving highly time-sensitive, synchronized finds real value in the continuing evolution
information from sensors and then passing of the TSN standards being tested and the
control commands back into the environment growing number of participants involved
to other types of devices on the network. bringing a diverse set of applications. For any
Without TSN, these companies would have company getting involved with TSN, the IIC
to perform this communication with separate TSN Testbed should not only be part of their
proprietary, non-standardized networking verification and validation plans, but also part
technologies that may not talk to each other of their up-front development efforts.”
on an IoT network. Axel Schneider, Director R&D at Hirschmann
Now in Q3 2017, Avnu Alliance members Automation and Control GmbH, added: “To
and testbed participants are working on test the interoperability of TSN in multi-
new activities and developments, with the vendor scenarios starting right from the
expectation that the testbed will continue to beginning of this next evolutionary step of
grow and expand upon its current capabilities standard Ethernet, pre-competitive joint
and offerings. efforts by the involved innovating companies
are needed to ensure the market success of
Testbed participants weigh in this new technology. Testbeds such as the
According to Dr. Richard Soley, Executive IIC TSN Testbed, which Hirschmann joined
Director of the Industrial Internet Consortium, in October 2016, provide the necessary
“Our testbed program is where the innovation framework for these activities. Moreover,
and opportunities of the Industrial Internet they offer an excellent technical framework
– new technologies, new applications, new for pre-competitive proof of interoperability
products, new services, new processes – can for key TSN mechanisms including time
be initiated, thought through, and rigorously synchronization, traffic scheduling and
tested to ascertain their usefulness and configuration in a multi-vendor infrastructure.
viability before coming to market.” Thus, testbeds are essential for the testing
Soley said that the Time Sensitive Networking of TSN as well as the integration of OPC UA
Testbed, which is housed in Germany and in with TSN. In addition, testbeds not only offer
North America, is used for plug-fest activities the possibility to test the interoperability of
where member companies collaborate to test pre-production products, but also enable early
implementations and interoperability. “TSN feedback to standardization bodies such as the
is important to the success and adoption of IEEE and certification organizations like the
the IIoT given its ability to support real-time Avnu Alliance.”
control and synchronization, for example
between motion applications and robots, Technical report by Avnu Alliance.

1 0. 2017 i n d u str i a l e th e r n e t b o o k
 Use of SafetyBridge technology
Applications

in plastics production
The Chemours company utilized SafetyBridge technology to create a TÜV-certified safety system that is
independent of the S7 standard PLC, while still being completely integrated into the existing factory network.
The new system offers both flexibility and simultaneous conformity with the latest safety guidelines.

the approach. “From the beginning of the

SOURCE: PHOENIX CONTACT

project, we were clear that a major priority
was the separation of the safety system from
the main control PLC.
After reviewing all possible solutions, we
selected Phoenix Contact Inline I/O with
the TÜV-certified SafetyBridge Technology
protocol. We found that the system could be
easily connected to the S7 standard PLC but,
at the same time, has its own integrated,
on–board safety CPU, so it could be operated
completely independently of the standard PLC,
while still being completely integrated into
the existing network.”

Extension by additional I/O modules

As the factory finishing and packaging
processes are spread over a wide area with
a number of related remote control cabinets,
for the first time, the distributed safety
I/O could be used to connect the various
safety sensors and interlocks positioned
throughout the processes. Johan Sterrenburg
reports: “Compared with hardwired systems,
Retrofitting safety functions can be a daunting task, and needs to be both carefully planned and coordinated. SafetyBridge offered us a number of
advantages. We know our processes very well
IF SAFETY CONTROL SYSTEMS have to be products are finished and automatically and try to think ahead as much as possible.
integrated in large-scale applications, packaged before dispatch, are controlled For this reason, for the two packaging
specialised know-how is typically required. locally by PLCs that use either Profinet or lines we chose the version 3 LPSDO (logic
Only like that all relevant requirements Profibus as the communication backbone programmable safe output device) option of
can be considered completely so that the across the automated machines. SafetyBridge which is future-proof”.
machine operators are reliably protected Operators have access to process In this configuration, Chemours Netherlands
against dangerous situations. Solutions information that is presented on HMIs at B.V. can use one LPSDO to control up to 16
like SafetyBridge technology prove to be various locations that also allow them to safety input or output terminal blocks remotely
advantageous because it combines the control and, if necessary, correct process across the network. If more safety signals will
simplicity of a configurable system with the non-conformities. The production philosophy be needed in the future, the employees can
benefits of I/O modules distributed within the is to react on alarms by adjusting process simply add I/O slices or introduce a new LPSDO
automation network. parameters centrally from the control room. module with related I/O. This possibility fits
exactly to the type of flexibility the chemical
Decentralized control systems Separation of safety and control company has set as the original project goal.
Chemours’ Dordrecht site in the Netherlands When it came to the safety-related parts
is their largest production facility in Europe of the machine control systems, while the Safety function blocks
and is focused on the production of plastics main process was controlled via a dedicated With the safety zones and system interaction
(fluoropolymers) for applications such as safety PLC, the finishing and packaging clearly defined and specified, the SafetyBridge
non-stick coatings and refrigerants with the parts were still based on rigid, hardwired system offers various safety I/O modules from
core brands produced being Teflon, Opteon systems. As a result, a project was initiated which a complete system can be assembled.
and Viton. in order to modernize the outdated safety The central control component and heart of
At the widespread Dordrecht plant, all control systems with the goal of providing each SafetyBridge system is the logic module.
operations in different factories are controlled more flexibility, whilst still ensuring that the It generates and monitors the SafetyBridge
and monitored from a central control room processes complied with strict plant safety protocol and processes the safe logic. Using
that has access to all mission critical data procedures and directives. the Safeconf configuration software, the
as it comes from each production process. Johan Sterrenburg, chief engineer for user can assign up to 16 different safe I/O
The final stages of the factories, where the electrical systems and instruments, explains modules, each with a unique address, to

20 in d u s t r ial et h er ne t b o o k 10.2017
SOURCE: PHOENIX CONTACT

Safety sensors and interlocks are now integrated into the automation network via SafetyBridge.
Precise and simple!
one, central logic module. For the individual any errors or compromise the functional Time synchronization
functions, the Safeconf software offers a
function-block toolbox that is based on the
safety. This ensures a worry-free handling
of the system in any control and network
using IEEE 1588/PTP
PLCopen specification and covers all common environment where it ensures a maximum of
types of safety sensors and sensor-related functional safety. ş 7LPHV\QFKURQL]DWLRQYLD
functions such as muting. (WKHU1HW,3RU3URĬQHW
The allocated sensor inputs in the hardware Simple, functional and flexible
can be adapted to the sensor type to create a SafetyBridge Technology enables the ş +LJKHVWWLPLQJDFFXUDF\LQ
perfect match, for example, to sensor specific integration of a functional safety control QDQRVHFRQGUDQJH
test-pulse filter widths or discrepancy times. system into a machine that is independent
Depending on the power control elements, the of both the PLC and the automation network. ş 5HGXQGDQF\WKURXJKDXWRPDWHG
user can also choose between output modules The system is designed to be as simple as a VZLWFKLQJRIUHIHUHQFHFORFNV
with semiconductor outputs or floating relay configurable safety module whilst offering the ş /RFDOJHQHUDWLRQRIWLPHFRGHVOLNH
contacts. The hardware modules have a service functionality and flexibility of a programmable
,5,*%'&)RU33;3XOVHV
life of 20 years and can be used up to EN ISO PLC with safe I/O terminals that can be
13849-1 PLe or EN IEC 62061 SIL 3, depending distributed across an automation network.
on the configuration and wiring. The SafetyBridge system consists of safe
input and output modules and so-called
Errors excluded by programmers logic modules. The input and output modules
Once the safety logic is set up, the distribution monitor safety sensor signals and switch off
and physical location of the I/O modules power control elements. The logic module
in the network plays no role and does not generates and monitors the safety-related
influence the logic. To implement or retrofit SafetyBridge transmission protocol and
the safety logic into an existing standard PLC, processes the user-configured safety logic. In
the programmer does not need any experience addition, the logic modules also have eight
or special training on the subject of functional safe outputs.
safety.
From the point of view of the PLC, the Summary
SafetyBridge system is seen as a standard Retrofitting safety functions to an existing
I/O and simply ensures the communication plant can be a daunting task for the project
OMICRON Lab IEEE 1588/PTP
backbone for the safety data packages the team. The approach needs to be structured,
contents of which cannot be accessed or well thought out and can take several months
Timing Solutions:
viewed. The safety modules themselves to implement. In accordance with European OTMC 100
continually monitor the safety data regulations, the technology also needs to ,(((373*UDQGPDVWHU&ORFN
package contents and if a non-conformity be state of the art. For Chemours, selecting
is recognized, the system is immediately Inline I/O with SafetyBridge technology TICRO 100
transferred to a safe state. offered the possibility to use a TÜV-certified ,(((3737LPH&RQYHUWHU
For the Chemours Netherlands B.V. safety system at the Dordrecht plant that is
operation, it was also imperative that independent of the S7 standard PLC while still
the status data is fed back to the central being completely integrated into the existing www.omicron-lab.com/timing
control room - another advantage of a factory network.
network integrated system. Due to the safety
mechanisms integrated in the SafetyBridge Simon Davis, Product Marketing Manager
system, the PLC programmer cannot make Safety, Phoenix Contact Electronics GmbH.

1 0. 2017 i n d u str i a l e th e r n e t b o o k
Smart Timing Solutions
 Bluetooth history and the future
Technology

of Bluetooth mesh networking

Bluetooth mesh networking is most likely to be initially adopted for use in building automation, commercial
lighting and sensor network. But as the latest chapter in Bluetooth development, it has potential uses in
many new applications and provides a wide range of networking benefits.

SOURCE: BLUETOOTH SIG

BLUETOOTH TECHNOLOGY IS WELL-KNOWN
and it is one of the most ubiquitous wireless
communications technologies on the planet.
It’s been in existence since 2000, and has
found its way into billions of devices. Since
then, Bluetooth has been carefully and
systematically improved, enabling it to keep
pace with market requirements, continuing to
support and inspire innovation.
Bluetooth mesh networking is the latest
chapter in the Bluetooth story, bringing
with it many new applications, use cases
and benefits for developers, businesses and
consumers alike.

Flavours and features

Those with a keen interest in Bluetooth
technology will be familiar with regular
new releases, typically equipping Bluetooth
with additional features, or improving upon
existing capabilities. Occasionally, however,
an entirely new “flavour” of Bluetooth is
released; a distinct variant, using radio in
a different way, optimised in its design and
implementation for broad sets of use cases.
Bluetooth Basic Rate/Enhanced Data Rate
(BR/EDR) was the first flavour of Bluetooth
to be released, and was intended to act as a
cable replacement technology. It soon came to
dominate wireless audio products, and turned
into the enabler for new computer peripherals,
such as wireless mice and keyboards. Mesh topologies offer the best way to meet various and increasingly common communications requirements.
Bluetooth Low Energy (LE) was the next
truly distinct Bluetooth technology and was relationship which is reflected in the term “pairing”. Some devices can
optimised to use as little energy as possible, able to operate and have multiple point-to-point relationships with other devices, and can
communicate wirelessly, powered by only a coin-sized battery which form a hub/spoke topology known as a “piconet”.
could often last for years. It’s hard to find a smartphone or tablet that Bluetooth LE devices can also form point-to-point and hub/spoke
doesn’t support Bluetooth LE nowadays. relationships with other devices, as well as work in a connectionless
So, with this in mind, is Bluetooth mesh networking a new flavour of way, broadcasting data which any other device in direct radio range
Bluetooth, or is it a new feature? To be honest, it’s neither. can receive. This is a 1:m topology, where m can be a very large
number. If devices listening to broadcasts are not transmitting data
The Crucial Three themselves, then the broadcasting device has the radio spectrum to
It’s common to find both Bluetooth BR/EDR and Bluetooth LE available itself and there’s effectively no limit to the number of other devices
in devices like smartphones, but they do not rely on each other’s services that can receive and make use of its broadcasts.
and capabilities. Those two Bluetooth flavours work independently of Bluetooth mesh allows us to establish a many-to-many (m:m)
each other, and whilst they’re quite happy to coexist in the same relationship between wireless devices. Furthermore, devices may relay
device, it’s not possible to use Bluetooth BR/EDR to communicate with data to other devices not in direct radio range of the originating
a Bluetooth LE device, or vice versa. device. In this way, mesh networks can span large physical areas, and
In contrast, Bluetooth mesh networking uses, and is dependent contain large numbers of devices.
upon, Bluetooth LE. Bluetooth LE is the wireless communications
protocol stack which Bluetooth mesh makes use of. Motivation for mesh networking
At its most basic level, Bluetooth BR/EDR lets one device connect to Bluetooth mesh networking was created because mesh topologies offer
and communicate with another device, establishing a point-to-point the best way to meet various and increasingly common communications

22 in d u s t r ial et h er ne t b o o k 10.2017
requirements, demanded by applications such as building automation

SOURCE: BLUETOOTH SIG

and sensor networks. These requirements include coverage of large

Technology
areas, the ability to monitor and control a large number of devices, and
optimised low energy consumption, to name but a few.
There are other low-power wireless communications technologies
which support mesh topologies, but these are believed to have
unacceptable constraints and limitations, and are generally not
supported by standard smartphone, tablet and PC equipment. They
are thought to lack optimisation for the problems they are trying to
address, and the products they want to create. Other issues include
low data transmission rates, limited numbers of “hops” when relaying
data across the mesh, scalability limits often caused by the way radio
channels are used, and difficulties and delays when following procedures
to change the device composition of the mesh network.
Creating an industry-standard mesh communications technology
based on Bluetooth LE presented an opportunity to meet the
requirements without the associated limitations and constraints.

Message-oriented communication
Bluetooth mesh networking uses a publish/subscribe messaging system.
Devices may send messages to addresses whose names and meaning
correspond to high level concepts which users can understand, like
“Garden Lights”. This is publishing. Devices can also be configured to
Bluetooth mesh networking uses a publish/subscribe messaging system.
receive messages sent to particular addresses by other devices. This is
subscribing. When a device publishes a message to a particular address,
all the other devices that subscribed to that address will receive a copy Flooding has its pros and cons, but with Bluetooth mesh networking
of it, process it, and react in some way. it has been optimised to retain the strengths while addressing the
Imagine a set of outdoor lights. Each light is configured so that it weaknesses.
subscribes to “Garden Lights” messages. Now, imagine a Bluetooth Flooding doesn’t need particular devices to have special responsibility
mesh light switch sending an “ON” message to the “Garden Lights” to act as centralised routers, the failure of which could render the entire
address. All of the lights in the garden will receive the “ON” message network inoperable. Specific routes being unavailable could also have
and react to it by switching on. a catastrophic impact on the network. This is avoided with a flooding

Messages and device state

Devices in a Bluetooth mesh network have a set of independent state
values, representing some condition of the device. Referring to the
previous example, each light has a state value which represents whether
the device is switched on or off. Changing it, by publishing a message
While you look ahead
of a type whose definition means that it acts upon “on/off” state … we have an eye for the rest.
values, is how a Bluetooth mesh light switch is able to control lights.
Changing a state value modifies a physical condition of the device
itself, like switching it on or off.

Relaying
Mesh networks allow devices to be installed and communicate with each
other across a large area. Consider a large space such as a shopping
centre, airport or office building. With walls and other physical barriers,
it may not be possible to achieve direct radio contact from a device on
one side of a building, to a device installed on the far side of the same
building, or even a device in an adjacent building. Bluetooth mesh
networking solves this problem by allowing some of the devices in the
network to be designated “relays”.
Relay devices retransmit messages that they receive from other
devices, and are able to communicate with devices that are not in radio
range of the device which originally published the message. A message 360° Network Reliability
may be relayed multiple times, over a maximum of 127 “hops”; enough for Smart Factory Automation
to relay a message across an enormous physical area.
• 3 industrial protocols with one-click setup
• 2 installation options: DIN-Rail and Rackmount
Managed flooding • 1-page configuration dashboard
Bluetooth mesh networking uses an approach known as “flooding” to
publish and relay messages. This means that messages are not routed by Moxa Solutions. Protected, easy, intelligent.
a process which results in them being transmitted along a specific path
comprising a sequence of only certain devices. Instead, all devices in www.moxa.com
range receive messages and those which are acting as relays, retransmit
the message to all other devices in range.

1 0. 2017 i n d u str i a l e th e r n e t b o o k 23
ME_AZ_FA_IEB_85x120mm_E_DU010917.indd 1 01.09.17 14:29
 Bluetooth device support
SOURCE: BLUETOOTH SIG

Bluetooth mesh networking may be new, but Bluetooth Low Energy (LE)
Technology

is not, and many of the devices on the market already, including most
modern smartphones and tablets, will be able to access a Bluetooth
mesh network via proxy nodes.
These include a standard Bluetooth Low Energy GATT service which
has two GATT characteristics; Mesh Proxy Data In, and Mesh Proxy
Data Out. Bluetooth LE devices, like smartphones, can use these
characteristics to send and receive data to and from the Bluetooth
mesh network.

Security
Security is mandatory in Bluetooth mesh. Every packet is encrypted
and authenticated.
Replay attacks are prevented by judicious use of sequence numbers.
Man-in-the-middle attacks are protected against by using asymmetrical
cryptography during important procedures. Protection against trash-can
attacks, which exploit discarded devices, is provided for. Security keys
get refreshed when necessary.
Security of the network and security of individual applications such
as lighting, heating or physical building security are independent
Mesh networks allow devices to communicate with each other across a large area. of each other. Different security keys are used for securing network
layer operations such as relaying vs securing the application-specific
approach to mesh networking. This also means there are multiple paths content of messages. A light bulb, for example, has full access to data
by which a message can arrive at its destination. in messages transmitted by light switches, because they have the same
application key.
Optimising the mesh network But while the same light bulb is able to relay messages from the
All packets include a field known as the TTL. This may be used to limit Bluetooth physical access token to the lock in the front door, it is not
the number of hops that a message takes as it is relayed. Heartbeat able to see the application layer content of those messages.
messages, transmitted by devices at intervals, include information
which allows the network to learn about its topology and how many The stack
hops away each of the other devices is. This allows devices to set TTL Bluetooth mesh networking introduces a new protocol stack, which sits
to an optimal value, avoiding messages being relayed an unnecessary on top of Bluetooth LE. Each layer of the stack is responsible for the
number of times. following key functions:
Every device contains a message cache so that it can determine • Bearer Layer: Defines how PDUs are transported using an underlying
whether or not it has seen a message before, and if it has it will LE stack. Currently, two bearers are defined, the Advertising Bearer
immediately discard the message, thus avoiding unnecessary processing and the GATT Bearer.
higher up the stack. Perhaps most interestingly, devices which are very • Network Layer: Defines various message address types and a
power-constrained, such as sensors, may be designated “low power network message format. The relay and proxy behaviours are
nodes”. These nodes work in conjunction with one or more devices, implemented by the network layer.
which are designated “friends”. Friends are not power constrained and • Lower Transport Layer: Where required, the lower transport layer
act on behalf of the low power node, storing messages addressed to it handles segmentation and reassembly of PDUs.
and only delivering them when asked. The relationship between a low • Upper Transport Layer: Responsible for the encryption, decryption
power node and a friend is termed “friendship”. and authentication of application data passing to and from the
Low power devices usually spend the most significant proportion access layer. It also has responsibility for special messages known
of their time not transmitting data. Sensors are a good example of as transport control messages. These include heartbeats and
this. Maybe a sensor only transmits a temperature reading whenever messages related to the “friendship” relationship.
the temperature falls below or above a specified threshold, and this • Access Layer: Responsible for the format of application data,
typically happens twice a day. Such an infrequent transmission schedule defining and controlling the encryption and decryption process
keeps the energy use of this type of device very low. which is performed in the upper transport layer and verifying that
But what if the sensor needs to be able to receive data occasionally? data received from it is for the right network and application,
It will need to keep up to date with the security keys being used in the before forwarding the data up the stack.
network. And maybe those temperature thresholds need to be modified • Foundation Model Layer: Responsible for the implementation of
to use different values according to the season. For a sensor to receive those models concerned with the configuration and management
messages directly, it needs to switch the radio on so that it can receive of a mesh network.
data. Most of the time it will receive nothing, but energy will have been • Model Layer: Concerned with the implementation of models and,
expended nevertheless. the implementation of behaviours, messages, states and so on.
Working with a friend allows the low power node to schedule its use
of the radio to receive messages to whatever frequency makes sense Future of Bluetooth mesh networking
for the device, but importantly, a much lower frequency than it would Bluetooth mesh networking will initially be adopted for applications
have otherwise needed to if it had to “listen” for messages all the time. such as building automation, commercial lighting and sensor networks,
Friends do the heavy lifting for low power nodes. They store but it is anticipated to be adopted across a broad range of industry
messages, and deliver them when explicitly asked to, operating to a sectors and applications.
schedule which they control, and thus can make the most efficient use
of the radio possible. Martin Woolley, Technical Program Manager, Bluetooth SIG.

24 in d u s t r ial et h er ne t b o o k 10.2017
 IIoT edge gateways create

Technology
bridges between domains
Full-blown IIoT deployments based on new automation strategies will implement more effective, direct
communications with the cloud, artificial intelligence and an ability to both boost production flexibility and
improve asset management. Here’s how edge gateways are part of potential solutions.

SOURCE: HILSCHER
IIoT architectural vision.

THE SCOPE AND SCALE OF THE INDUSTRIAL Technology) domains. This platform supports Techniques and protocols are already
Internet of Things (IIoT) is well beyond familiar “on-premise” needs today by offering available for “crossing the edge”. Some are
recent experience. However, realistic solutions new ways to solve “brownfield” challenges, IT-based, e.g. HTTP and web services. In
are already available and interest is rapidly and can interface with cloud-based services, automation, the hard real-time benefits of
growing. In the future, full-blown IIoT opening up IIoT to everyone now. It is also protocols like PROFINET and EtherNet/IP will
deployments will be based on new automation future-proofed in readiness for full-blown IIoT ensure they remain favored options.
strategies. Field devices will communicate opportunities in the future. OPC UA is a technology that can exist on
directly with the cloud, and concepts such as both sides of the divide. A recent arrival to
Artificial Intelligence and “digital twins” will Edge gateways IIoT is the MQTT protocol, actually devised
draw users to greater production flexibility Edge gateways sit at the “edge” of networks 20 years ago as a lean and efficient way of
and improved asset management. New levels and perform a connectivity function. They are transmitting data over long distances for
of profitability will be achieved. similar to the gateways we are familiar with SCADA. Both MQTT and OPC UA will be de facto
Addressing this “full blown” scenario today except that they are used to gather, standards for IIoT.
will not happen immediately. Initially, IIoT process and transfer data between the IT A less familiar but potentially an IIoT
implementations will be associated with plant (Information Technology) and OT (Operations protocol standard is AMQP. This is similar to
upgrades and step improvements. They will Technology) sectors. Edge gateways perform MQTT but has yet to be strongly positioned.
use familiar techniques and have to co-exist tasks such as data collection, aggregation and Various vendors are supplying cloud-based
with current equipment and systems. They will even abstraction. services in support of the Data Management
add value without legacy risk. In effect, an edge gateway is a bridge layers, for functions such as MES and ERP.
This article outlines IIoT capabilities between two domains and that means a good An edge gateway must be able to deal with
as they relate to today’s and tomorrow’s understanding of the technologies used on all of these needs, while interfacing with
automation environments, and introduces each side is important. In the architecture of the established automation networks from
netIOT Edge technology, a new gateway a full-blown IoT deployment, edge gateways where data is aggregated. It has to deal with
computing platform for bridging the IT sit at the juncture of the OT (Data Generation) emerging cloud-based services and remote
(Information Technology) and OT (Operations and IT (Data Management) layers. applications such as analytics, artificial

1 0. 2017 i n d u str i a l e th e r n e t b o o k 25
 SOURCE: HILSCHER
Technology

The netIOT Edge software architecture

intelligence and virtual modelling concepts lost, or where equipment is “closed” to • Node-RED configuration. Node-RED is
such as “digital twins”. reconfiguration, or it’s costly to reprogram, an open-source, visual wiring tool for
Recognizing the importance of upgrading netIOT Edge provides an easy way to gain the Internet of Things. It enables users
brownfield sites, it also supports traditional access to what is really going on in a to easily configure the data flow and
data gathering functions e.g. SCADA, production line. processing functions. There’s more about
visualization, preventative maintenance, etc. Node-RED below.
IIoT gateway technology • The technology can also support IIoT
Potential of IIoT gateways From a hardware perspective, the technology stacks for customer-specific applications.
The netIOT Edge technology is capable of utilizes two processors including a netX
delivering a flexible and versatile solution that ASIC with processor running an embedded Drag and drop flow control
offers unprecedented, sometimes disruptive, Operating System (OS with protocol stacks to Node-RED is a browser-based editor that
opportunities for adding value to plants today support the automation connectivity), and makes it easy to wire together data flows
at little or no risk to existing systems. It is a separate x86-based processor for handling using graphical blocks called “nodes.” “Drag,
more than a simple “gateway” because it is an the IT-oriented functions, running Linux. drop and click” are used to build the flows.
independent computing platform capable not Linux is the world’s most widely used open- The Node-RED project is “open-source” and
only of conventional gateway tasks but also of source operating system and is at the heart supported widely by the IT industry. Flow
acquiring, processing, storing and analysing of millions of applications in all industries, functions are created by selecting “nodes” from
data locally, as well as interfacing that data including manufacturing automation and a user library, dragging them into position on
to cloud-based systems. enterprise management. a screen, and then click-connecting them.
Essentially, netIOT Edge offers a way to Briefly, here’s an overview of the techology: “Nodes” range from basic READ and WRITE
support traditional data gathering applications • Isolation of the automation-facing to advanced rule-based decision-making.
(e.g. historian, visualization, SCADA etc.) network, helping protect it from outside Relevant to the automation industries
while opening up a plant to the full potential attack. It is among the first gateways to are nodes such as serial communications,
of Industrial IoT. The technology is potentially be submitted for IEC 62443 certification. MQTT protocol conversion, and TCP/ UDP
“disruptive” because it can be employed in • Choices for running third party software communications.
both traditional and futuristic roles. It can be applications locally in the IT-facing Currently Node-RED has over 800 “nodes” in
a passive device that simply listens to traffic core. Options include SCADA, polling and its online library. This total is growing rapidly
on a network, or it can be an active device analytics. Third-party add-ons supporting as the global user community contributes to
handling complex functions such as rule- Artificial Intelligence and other cognitive the repository. Hilscher has contributed by
based decision making. applications can also be run. developing an OPC UA node and a node for
netIOT Edge is based on open standards • Collection of additional data from a the Siemens S7 PLC.
that free users from proprietary solutions real-time time Ethernet network with All nodes in the global repository are freely
tied to vendor-specific control systems. For netIOT Edge making non-visible data available to any netIOT Edge user. Many
plants where programming skills have been available for smart applications. common automation nodes are pre-installed

26 in d u s t r ial et h er ne t b o o k 10.2017
 SOURCE: HILSCHER
Technology
Node-RED configuration screens showing how data sources, functions and destinations are selected and linked graphically.

in netIOT Edge on shipment. Other nodes can personnel retire or are laid off. Normally, data sent to a SCADA application
be downloaded as required. With Node-RED Here are ways the technology can enhance is “raw” data. Cirrus Link Solutions’ Sparkplug
the user has access to rich and powerful brownfield sites based on actual use cases: specification adds context and semantics to
functionality that can be easily configured. Direct polling: the gateway is used to poll the the data stream, turning it into meaningful
PLC and pull data from it into local memory. information. Anyone in the enterprise with
Local software execution This can be done over an existing network or, access to a SCADA terminal can see what is
Docker, the world’s leading software for increased security, via an independent happening with the data points.
“container” platform allows third-party Ethernet connection from the netIOT Edge
software applications to be run safely and gateway to the PLC. Once data is in netIOT Greenfield applications
securely. It is supported by an open-source Edge it can be used locally (e.g. a database In parallel with the aspirations of individual
developer community. Everything required application) or streamed to the cloud. OT and IT companies, many collaborative
to make a piece of software run is packaged Active mode: netIOT Edge becomes a part efforts are underway. In Germany, the
into an isolated container. Containers do of the PLC’s network as a slave device, and Platform Industrie 4.0 project is working
not bundle a full operating system, only the the PLC pushes data to it. It’s a fixed solution to realize its strategic vision for the future
libraries and settings required to make the that can be alarm/event driven. Like Direct of manufacturing. In North America, the
software work. This makes for lightweight, Polling, it takes up bandwidth (though not as Industrial Internet Consortium is creating
self-contained systems that guarantee much). Once data is in netIOT Edge it can be specifications and definitions for IIoT
software runs the same, regardless of where used locally or distributed in the usual way. connectivity, and organizing testbeds.
it’s deployed. Containers enhance security Passive mode (or P-mode): Passive mode Major industrial suppliers meanwhile are
since applications are isolated from each other enables netIOT Edge to sit unnoticed on developing initiatives of their own, while
and netIOT Edge’s Linux host system. a network, monitoring any or all activity. IT vendors such as IBM, Microsoft and SAP
Docker aids collaborating on code with Selected events or data streams are extracted (among others) have identified the industrial
co-workers. Docker can manage apps side-by- and delivered to local storage for further space as a key new market. This IIoT strategy
side to get better compute density. Docker processing. P-mode can only READ data; it includes another important component for
enables new features to be deployed fast and cannot WRITE to the network so it is a secure true IIoT functionality. A netIOT interface
with confidence. It opens opportunities for method of monitoring what happens without module and new netX 90 ASIC are designed
making netIOT Edge a powerful partner in an interfering with operations. specifically to be embedded into low cost field
IIoT architecture. The combination of netX Use cases translate into these scenarios: devices. The netIOT Interface also incorporates
ASICs and Intel x86 CPUs, together with Linux, • As a master for polling devices. the netX ASIC, and currently includes on-board
Node-RED and Docker functionality, creates • As a slave collecting data passing support for both OPC UA and MQTT. This will
a computing platform optimized for IIoT. between the PLC and its I/O. enable field devices to communicate directly
Powerful new concepts complement traditional • Edge gateway can read/write data to and with gateway, sending data from the field
functionality to offer opportunities for the from the controller. through an automation network for local
gathering, distribution and processing of data. • As a slave and have the controller push processing, and then onwards into the cloud.
event driven data to it. Smarter field devices will deliver data that
Brownfield applications • As an “invisible” slave reading (only) once was considered unwanted. For example,
Automation systems can range from highly data passing between controller and I/O. an encoder might transmit vibration data
flexible networks managed by skilled engineers • Unit can poll data and read data off the along with motion control information. This
who can “make things happen”, to fixed I/O network simultaneously. added data will enable better monitoring of
installations that are impossible to change SCADA Collaboration: Hilscher has formed an field devices and improved asset management.
without great expense or delay. The pressure agreement with two other companies, Cirrus Using the technology, more effective IIoT
to “do better” is immense and constant yet Link Solutions and Inductive Automation, to architectures can become fully realizable.
staffing levels are under continuous review and jointly market a new approach to SCADA using
skills are slowly disappearing as generations of the edge gateway technology. Technology report by Hilscher.

1 0. 2017 i n d u str i a l e th e r n e t b o o k 27
 Ethernet line extenders for
Applications

control of electrical substations

Secure network technology is helping Electricity North West improve the quality of supply to its customers.
Wolverine Ethernet Line Extenders enable existing cable infrastructure to be used to create a secure Ethernet
IP-based network used for controlling electricity substations in the north west of the UK.

Reutilising IP network cabling

SOURCE: WSTERMO
ELECTRICITY NORTH WEST has
upgraded its data communications The existing communications network
network to an Ethernet IP-based was based on copper cabling. It was
solution to help improve the thought that to support an Ethernet
service provided by its electricity IP-based network, a vast new fibre
distribution network. The optic cable infrastructure would be
modernised, `non-operations’ required. With approximately 11,000
network provides increased reliability km of installed cabling potentially
and bandwidth helping the company needing to be replaced, the size,
to better monitor and control the complexity, time and cost of the
supply of electricity to 2.4 million project was extremely prohibitive.
properties in the UK. Critical to the It was therefore essential to find a
project was the use of Ethernet line solution whereupon the existing cable
extenders, which enable the existing infrastructure could be used, wherever
ageing copper cabling infrastructure possible.
to be used, ensuring the project was Westermo Wolverine Ethernet line
economically viable. extenders presented a solution to
Electricity North West owns, this challenge, as they allow effective
operates and maintains an electricity Ethernet networks to be created over
distribution network in the UK, distances of up to 15 km (depending
Ethernet line extenders allowed effective Ethernet networks to be created
connecting more than five million on cable characteristics), whilst
over distances of up to 15 km.
people to the National Grid. The enabling data rates up to 15.3 Mbit/s.
network covers a diverse range of As part of Electricity North West’s continuous Critically, the SHDSL communications
terrain, from isolated farms in rural areas improvement programme, the company was technology the devices are based upon makes
such as Cumbria, to areas of heavy industry installing new RTUs to replace aging legacy it possible to reuse many types of pre-existing
and urban populations including Manchester. devices and upgrade the communications copper cables. This meant that Electricity
Electricity North West is continuously looking network which connects these devices. This North West could avoid replacing its vast cable
to improve the quality of service provided would help better support existing operations infrastructure, but still upgrade the network.
to its customers. Effectively monitoring and enable new services to be offered such as “Because we have an aging copper cable
and controlling the 500 primary substations CLASS (Custom Load active system services), network we wanted to install and maintain
distributed throughout the region is critical which uses voltage control to manage network redundancy wherever possible to
to achieve this. The substations ensure that electricity consumption at peak times. ensure we have a very resilient and reliable
power can be rerouted should a problem arise, The existing data communications network solution. The Wolverine Line Extenders are
helping to minimise ‘lost minutes’ of supply. was a very large VF serial-based solution, helping us to achieve this whilst still using
which offered limited bandwidth - only the existing cables. As a result, we have
Maximising quality of supply 1200 baud, no redundancy and insufficient installed the devices throughout the entire
“Our main aim is to maximise the quality of resilience. An upgrade to an Ethernet IP-based network.”
supply and minimise lost minutes,” explained solution was required to provide much greater Approximately 750 Wolverine Line extenders
Paul Gornall, who is the network and field reliability, resiliency and bandwidth. It also are being used to connect the RTUs at the 500
operations manager at Electricity North West needed to support the broader range of primary substations back to the SCADA system.
and responsible for telecommunications and enhanced functions and services. Around 250 devices have been installed to
telemetry systems. “It is imperative that we “Ultimately the greater bandwidth, date at sites across the region. The Westermo
demonstrate delivery to the edge of the power reliability and resiliency provided by the Ethernet Line extenders have created a robust
network and to do this we must have a suitable Ethernet IP-based network will help to support network offering greater reliability, security,
communications network that supports these Electricity North West’s current operations resilience and bandwidth.
operational deliverables.” and provide even greater reliability of power “We undertook extensive FAT testing
The data communications network provides supply to our customers,” explained Paul of the Westermo Wolverine and found the
the means of connecting these locations back Gornall. “The upgraded and future-proofed performance to be outstanding. Having
to a centrally located SCADA system. Remote communications network will also enable installed over 250 devices, we continue to be
Terminal Units (RTUs) installed at the primary the company to offer a range of additional extremely pleased with the devices and the
substations route voltages, current, switch services such as CLASS and smart metering, performance of the network as a whole.”
states, temperature of transformers and alarms which will further enhance our ability to serve Using a third-party management tool,
data from connected sensors and equipment. our customers.” Electricity North West is able to continually

28 in d u s t r ial et h er ne t b o o k 10.2017
monitor network performance. When starting important that the communications network the network management tool by helping to

Applications
the project the aim was to attain 2Mb of could support this expansion. The two DSL easily `catch’ SNMP traps (significant events or
bandwidth throughout the network, but using and four 100baseTX ports provided by the issues) from the thousands of sensors, devices
the Westermo devices it has been possible to Wolverine has helped to future proof the and equipment.
achieve, on average, between 4 and 6Mb, and network by ensuring that additional equipment The Wolverine Line extenders and WeConfig
up to 12Mb on some sections of the network. can be easily connected to the network when tool are also being used to monitor and trend
required. the SNR performance of the cable. Cable
Robust data communications degradation, caused by age, erosion and even
The upgrade of the network is being performed Security at edge of network weather can lead to reduced performance
by Electricity North West’s information Enhanced network security was a critical and eventually to line failure. By trending
technology and telephony networking team. part of the network upgrade project. The the performance Electricity North West can
The group found the Westermo devices Wolverine Line Extenders are powered by make informed business decisions on cable
to be very straight forward to install and Westemo’s WeOS operating system, which replacement.
configure and extremely user friendly. The enables complex networking functions to be Electricity North West’s networking team
DIN-rail mounting and 48V power supply easily configured as well as providing unique are also using WeConfig to ensure continued
requirements, typically found in the existing IP security functionality. network performance. The SHDSL diagnostic
housing cabinets at the substations, meant By utilising a firewall on each port, it has function has been used to monitor the effect
that the devices integrated very easily with been possible to distribute firewalls across the of adding new equipment and services. This
the existing set up. network. The advantage of this solution is that information is extremely valuable, providing
The Wolverine’s robust aluminium housing, it helps to prevent a denial of service attack insight as what to expect in the future and
industrial grade components, wide operating that might occur if only a single firewall was preventing potential problems.
temperature range and EMC, isolation and deployed. Firewalls on each port also helps “The relationship with Westermo is also
shock standards approvals meant they were to prevent unauthorised access to the entire excellent. The company is very easy to work
able to cope with the challenging environment network, thereby improving overall network with and extremely responsive to our project
of the substations. This included low ambient security. requirements. Most importantly their products
temperatures and installation in close Westermo’s WeConfig software configuration are very robust, which is exactly what is
proximately to 33KV power lines, which creates tool is being used to configure and monitor required to cope with the demands of the
the possibility of inference and power spikes. the line extenders remotely, which helps harsh environments of primary substation and
The operations network is continually the networking team to save a considerable ensure the network is extremely reliable.”
expanding as new assets such as wind farms amount of time. In addition, during the
and solar farms are constructed. It was network upgrade, WeConfig has supplemented Application report by Westermo.

28. International Exhibition

for Electric Automation
Systems and Components
Nuremberg, Germany, 28 – 30 November 2017
sps-exhibition.com

et
entry tick
Answers for automation Your free
sps-exhib
it io n .c o m /tickets

Electric Automation and Digital Transformation

 OPC UA TSN: universal language
Applications
Technology

for real-time data exchange

The goal of OPC UA is open and easy communication. But now, OPC UA TSN is providing seamlessly shared
information between all kinds of machines, devices and sensors in real-time. It looks to be a foundational
element of machine interoperability and information transparency for the 4th wave of industrial revolution.

THE BABEL FISH IS REMARKABLE, although

SOURCE: TTTECH
sadly it is a fictional creature. Readers of
The Hitchhiker’s Guide to the Galaxy will know
that placing the fish in your ear allows you to
understand anyone, speaking any language,
instantaneously. In the context of Industry
4.0 which sets out to achieve interoperability
and information transparency between all
machines, devices and sensors, the Babel Fish
would be an extremely valuable tool if applied
to the factory floor.
Now, with the combination of two open
technology standards, OPC UA and IEEE TSN,
industrial automation has an equivalent,
entirely non-fictional solution for the
real-time transmission of information between
machines and devices from any vendor. Let’s
take a closer look at the two standards and the
OPC UA PubSub and TSN offers a complete solution for realizing Industry 4.0 concepts for factory automation.
ways in which their integration will benefit
industrial automation users.
devices (the subscribers). The publisher can industrial systems.
OPC UA: data into information provide this information at set time intervals TSN itself comprises a selection of IEEE
OPC UA, standardized and maintained by so subscribers know how often or even when standardized mechanisms that act to
the OPC Foundation, provides a common to expect new machine or production data. guarantee that data streams arrive at their
framework that sets the rules on how to turn Subscription to published data can be altered intended destination on time, no matter
data into information and how to manage that dynamically, enabling devices to receive what else is going on in the communication
information in a distributed environment such new data from additional sensors as systems network. The most important of these TSN
as a “machine to cloud” scenario. expand or change. mechanisms are time-synchronization (IEEE
As the value of data has become increasingly These features are particularly useful for 802.1AS) and scheduled message release
well understood by industrial users via industrial users as they can flexibly use PubSub (IEEE 802.1Qbv). Sharing a common time-base
initiatives like Industry 4.0 there has been a to automate the operation of systems made between communication network elements
rapid rise in the adoption of OPC UA, with all up of multiple devices or machines that were such as Ethernet switches makes it possible
of the major industrial automation vendors not previously interoperable. Many automated to create a dedicated “time sensitive virtual
now implementing it in their products. By industrial systems operate at extremely fast data path” for each data stream as it passes
representing data in a uniform way, OPC UA speeds, these systems require not only the through each switch along the way to its
enables interoperability between devices that regular exchange of data but for the data to destination.
could not previously share data, and gives be provided within just a few milliseconds As OPC UA PubSub now allows for the
users new insight into a wealth of information. (known as real-time). This is where IEEE TSN publishing of data at set intervals, this creates
OPC UA was initially designed to be used fits into the picture. the opportunity to schedule those data streams
within a client-server architecture, with a using the TSN traffic scheduling mechanism.
user (the client) such as a human operator TSN deterministic communications In turn, this means that OPC UA subscribers
or a cloud-based information management IEEE TSN provides an open, standard method can now expect to receive published data at
system requesting information from a device for communicating data in real-time over a guaranteed time with a very high level of
(the server) in a standardized way, e.g. with Ethernet by extending existing Quality precision, with no risk of delays or message
specific methods and controlled by defined of Service mechanisms in Ethernet with loss due to network congestion or high-priority
access rights. The server then provides additional capabilities for latency control, conflicts on the shared network. While OPC UA
appropriate access to the data for the client determinism, and high availability. This is the PubSub relationships need not use or require
in a standard format. With the new PubSub platform upon which industrial users can take such precise and reliable communication in
extension planned for release this year, advantage of the OPC UA PubSub extension to general, it is expected that many machine-to-
OPC UA now has the capacity to be used for implement automated, interoperable systems machine use cases will benefit from this kind
multicasting information too. for real-time applications. The combination of guaranteed networking service, supporting
In this case, a device (the publisher) of OPC UA PubSub and TSN offers a complete vendor independent, real-time interaction in
provides standard format data to a set of other solution for realizing Industry 4.0 concepts in “teams” of machines on the factory floor.

30 in d u s t r ial et h er ne t b o o k 10.2017
 SOURCE: TTTECH
Engineering Tool

Technology
(User Interface)
Legend
OPC UA Configuration
Logical Link
Physical Link Network OPC UA
Device Configuration
OPC UA element
CUC
TSN element
PubSub TSN
Configuration Broker

IEEE 802.1Qcc
CNC
Switched
Endpoint TSN Scheduler Endpoint

OPC UA NETCONF Client

TSN
Client / Endpoint
Input / Output

Input / Output
Server NETCONF/YANG
Application

Application
OPC UA
PubSub IEEE 802.1AS, NETCONF Server
IEEE 802.1AS Client /
TSN LLDP, RSTP TSN Server
NETCONF Switch TSN Switch Endpoint
Server PubSub

OPC UA
Client/Server & PubSub data

To combine OPC UA PubSub data exchange and TSN scheduled communication, a mechanism is required that assigns TSN schedules to published OPC UA data.

Use Case Networking testbed. Here, vendors are able OPC UA PubSub data stream requested via the
Take a packaging line for example. There are to test their latest OPC UA PubSub and TSN broker, the broker then provides configuration
stations along the line executing tasks such supporting products with those from other relevant feedback to the OPC UA publishers
as shrink wrapping. Today, OPC UA is used to industrial automation companies. This and subscribers.
extract uniform information from the various facilitates interoperability and adherence to Initial configuration of the OPC UA
machines in the line, but OPC UA data cannot standards, ensuring that customers are reaping publishers and subscribers is still done via
be shared in real-time between machines along the full benefits of the two technologies. traditional engineering tools. The OPC UA
the line. Real-time communication is restricted PubSub Broker is an automated function that
to Industrial Ethernet fieldbuses that can vary OPC UA PubSub TSN integration resides as a software module hosted on an
by industrial automation vendor, which makes To achieve the marriage between OPC UA Ethernet switch or another networked device
synchronization and interoperability between PubSub data exchange and TSN scheduled like an industrial PC, this means that there
machines very difficult. communication, a mechanism is required that is no additional burden on the user when
OPC UA TSN offers open communication assigns TSN schedules to published OPC UA configuring OPC UA PubSub over TSN. The
with precision timing for synchronization data. This mechanism is currently known as system also allows for dynamic reconfiguration
and interoperability across packaging line the PubSub TSN Configuration Broker. The of OPC UA data streams over the TSN network.
machines from multiple vendors. The PubSub broker can be considered as both a network When new publishers are added to the
extension to OPC UA enables machines at each management function and an API for the OPC network, the brokerage process is repeated
station to publish data in a multicast manner UA layer; it is tasked to interface with OPC UA to instruct the TSN scheduler to look for
and for machines at other stations to subscribe publisher and subscriber devices and the TSN available slots in the schedule and then
to the data that is relevant for their operation. scheduling software. This interface ensures provide feedback to the publishers and
TSN ensures that this data is delivered from that three critical elements are in place: subscribers. The PubSub TSN Configuration
publisher to subscribers with sub-millisecond • The TSN scheduler knows the publishing Broker mechanism is currently being specified
latency and with extremely tight jitter. Using interval of OPC UA data (and in some within the OPC Foundation. When complete,
PubSub and TSN to share OPC UA information cases an offset within the publishing it will provide the link that enables industrial
in real-time means that machines can work in interval). users to easily connect and configure OPC UA
harmony no matter the name printed on the • The OPC UA publishing device knows TSN compliant devices from any vendor.
controller. OPC UA TSN can thus help to improve when the network is ready (configured A guiding principle of OPC UA is the
solutions for packaging line challenges such as according to the schedule) so that it may facilitation of open and easy communication.
product tracking, line speed synchronization, start publishing. OPC UA TSN now provides a way to seamlessly
robot movement synchronization, quality • The OPC UA subscribers are primed to share information from all kinds of machines,
management and track & trace. receive data to which they are subscribed devices and sensors in real-time.
Testing for use cases like this and others within the requisite timeframe.
is currently ongoing within the Industrial Once the TSN scheduler has confirmed that it Simon Brooks, Industrial Product Marketing
Internet Consortium’s Time Sensitive can assign a path through the network to each Manager, TTTech.

1 0. 2017 i n d u str i a l e th e r n e t b o o k 31
 Data integration for cloud-based
Technology
Technology

Industry 4.0 and IoT applications

A layered model and IoT solution stack is creating cloud-based system architectures that leverage a strategic
data integration layer based on OPC UA. The potential benefit is decisive advantages in terms of integration
costs, flexibility and return on investment.

SOURCE: SOFTING
TWO CONCEPTS THAT REPRESENT profound
changes to industrial production in terms
of business models, company organization
and technology are Industry 4.0 and the
Internet of Things (IoT). Common to almost
all I4.0 and IoT solutions is their goal of
breaking down the clear separation of IT
and OT typical to date, both technologically
and organizationally, to ensure the seamless
exchange of data between OT and IT, and the
efficient management of an overall system
encompassing them both.
So what kinds of requirements does data
exchange between the IT and OT layer need
to meet – and how can these be technically
implemented? To answer this question, we can
take a look at a layered model or a ‘solution
stack’ for IoT solutions.

Layers of networking technology

The bottom layer is Operational Technology
(OT), where everything is located that is found
The OPC UA standard is an excellent choice for IT/OT integration and reduce system integration workloads.
at the lowest three levels of conventional
automation pyramids – namely control units,
field devices, sensors and actuators. For some for system architectures that offer more sources – or even omitted entirely, as long
applications, it would be technically possible functionality in the DI layer than simple as communications between the aggregation
to move the control layer to the cloud. The interfaces to the OT layer. server and application are maximally hardened.
model remains applicable in this use case. It should also be noted that there are a Last but not least, an aggregation server
The second layer from the top, Applications, number of reasons (including the volume should also be capable of managing access
represents software packages such as Predictive of data and security issues) why DI layer rights: a maintenance application that is also
Maintenance or Energy Management, which functionality cannot simply be shifted to the used by external personnel receives access to
are relevant for I4.0 and IoT. cloud but must run on premises. Conceptually, machine data only, while an OEE application is
The layer under this one – Platform – can therefore, the DI layer can be categorized as also allowed to access sensitive process data.
represent a single piece of IT infrastructure in a kind of edge computing. Data preprocessing: Data preprocessing
the simplest case to a more complex version within the DI layer serves to reduce data
involving a public cloud plus IoT services such Data integration requirements volumes by providing individual applications
as analytics, storage capacity and security. Turning now to the specific requirements for only with the data each of these applications
Right at the top is the Services layer, which a more ‘heavyweight’ DI layer, these can be actually requires.
often plays a central role in the context of summarized by utilizing the concepts of data Interface abstraction: Depending on the
IoT or monetization strategies and innovative aggregation, data preprocessing and interface solution architecture, a DI layer can also be
business models. abstraction. used to abstract interfaces to a wide range
Data aggregation: With data aggregation, of applications and business processes. This
Data integration layer often combined with options for filtering data, is especially useful considering the relatively
The Data Integration layer (DI layer), located data are consolidated from multiple sources fast-paced, heterogeneous IT sector with its
between Platform and Operational Technology, by deploying a dedicated aggregation server. short innovation cycles and the comparatively
takes on a special meaning in the context of This server then offers appropriate interfaces slow-moving world of OT.
I4.0 and IoT. The question perhaps arises as for the Platform and Application layers. By Basically, the aim here is to identify a
to whether it wouldn’t be simplest to provide keeping to just one or a few aggregation solution architecture that permits changes
all of the data sources of interest in the OT servers, configuration on the application side or installations at the IT/Application layer
layer with an upwards-pointing interface, can be considerably simplified. Depending as flexibly and independently of the OT layer
with which applications (or IoT platforms) on the relevant threat level, security can as possible while in turn enabling changes
could integrate as required. In practical also be pared down in communications within the OT layer without impacting the
terms, however, there are compelling reasons between the aggregation server and the data Application layer.

32 in d u s t r ial et h er ne t b o o k 10.2017
 SOURCE: SOFTING
Technology
Data integration layer between data sources at the automation level and applications.

Data integration and IT security at the application layer and managing industrial PC to perform complex data
What is the relationship of the DI layer to access rights for users. The requirements analysis and preprocessing. Wherever special,
IT security? There’s no ready answer to this of interface abstraction and reductions to customer-specific requirements can’t be met,
question. Security requirements and measures system integration effort can be achieved by Softing’s OPC Toolkits allow customers to
depend on circumstances and assumptions information modeling and the utilization of develop specific servers or clients.
about threat scenarios and should be assessed companion information standards.
and determined in relation to individual The OPC UA standard is also flexible in terms Integrating IT and OT
components within the system. However, some of the choice of protocol. With the publication In an industrial context, I4.0 and IoT solutions
aspects should always be considered. of version 1.04 of the standard (which has are characterized by the technical integration
Protocol selection: A number of models are been scheduled for this year), OPC UA will not of the formerly separate domains of IT and OT.
available here that avoid opening the firewall only support communication via the client/ In some cases, it may well seem appropriate
(such as the publisher/subscriber model). server model but also the publisher/subscriber and advisable to implement technical access
Certificate management: To ensure secure model (with UPD/binary encoding and MQTT/ to important data from the DI layer as quickly
operations over the long term, the cost and JSON as alternative transport layers). as possible or for tactical reasons – driven
effort of maintaining fully-fledged certificate A series of OPC UA-based standard products perhaps by just one application. Nevertheless,
management must be budgeted for. for IT/OT integration are already commercially a system architecture with a strategic DI layer
Use of proven standards: Security and available. OPC UA has also passed rigorous IT between OT and the central platform – e.g.
cryptography are highly complex topics and security testing conducted by the German based on OPC UA – offers decisive advantages
their details are understood by only a few Federal Office for Information Security (BSI). in terms of the costs of integration, flexibility
experts. Security is therefore best achieved and return on investment.
by using standard algorithms that enjoy Data integration tools The question remains of where to locate
widespread acceptance and trust (OPC UA). Softing’s dataFEED product family offers responsibility within the company for
software and hardware products for OPC and designing and implementing this kind of DI
Implementation with OPC UA IoT cloud communication that can be deployed layer. However this is handled, the common
The OPC UA interoperability standard is in a variety of ways. Lean gateways focus differences in perspective between the
very well-suited to the implementation of on connectivity requirements and are used traditionally discrete worlds of OT and IT
a DI layer. In terms of IT security, OPC UA especially where data is processed in the cloud must be overcome, and core expertise must
offers a flexible, three-tiered configuration and the data integration layer is rather “thin” be acquired in both disciplines.
that not only permits the omission of – or where an OPA UA standard interface is
security procedures but can also be used required for legacy components. Dr. Christopher Anhalt, Business Development
for the realization of all-round security by The dataFEED OPC Suite software product can Manager Data Integration, Softing Industrial
encrypting communications, authenticating be integrated with other applications on an Automation.

1 0. 2017 i n d u str i a l e th e r n e t b o o k 33
 Changing face of connectivity
Technology

basis for enhanced automation

A focus on digitalization is moving us toward fully networked and autonomous production. But major
challenges need to be overcome including increased expertise in mechatronic solutions that fully integrate
digital technology, process improvements and speed to market.

SOURCE: TE CONNECTIVITY
THE NETWORK-BASED DATA REVOLUTION,
also known as digitalization, is increasingly
finding its way into the world of mechanical
engineering. This offers opportunities, but also
presents challenges. The key role that sensors
and connectivity play in creating networks in
this area is undisputed. An overview of current
developments is presented here.
The current discussion surrounding Industry
4.0 in Germany is still largely being conducted
on a highly theoretical level. Topics such as
reducing downtimes, increasing productivity
and decreasing manufacturing costs are clear
indicators of the prevailing paradigm of smart
manufacturing. Countless solutions that are
currently being presented continue to focus
more on automation than on the autonomy of
the production process.
As a result, there is still some way to go
before fully networked and autonomous
production exists as a closed loop. This
also has to do with the heavily fragmented
mechanical engineering market, which leads A challenge in digitalization is expertise in mechatronics and integrated electronic product development.
to different levels of digitalization and
connectivity among medium-sized enterprises. trend monitoring serve as a basis for this: in the future resulting from new production
Integration of a fully autonomous value chain new developments are screened, assessed and logistics concepts.
poses significant challenges for mechanical internally and then followed up if appropriate By including measurement specialties in
and plant engineering, a sector that is still at global level and throughout the entire TE the portfolio, the technology offers enhanced
strongly characterized by mechanics. network. Implementing these technologies opportunities to integrate sensors that enable
These challenges arise at three different quickly in functional concept studies provides customers to record data and turn it into
levels. First, relevant expertise in mechatronics an opportunity for discussion with customers usable information in the cloud, for example.
and integrated electronic product development as to whether they are of interest and what The focus here is mostly on topics such as
must first be built up within the company. added value the customers can obtain as a predictive maintenance and avoidance of
Added to this is the procedural necessity to result. unforeseen downtimes. Smaller, hybrid and
digitalize and adapt existing, often mechanics- Internal and external customers can already more cost-effective connection solutions will
based, processes to a greater degree, as well experience the added value of connectivity also be in greater demand.
as installing completely new processes in the and sensing solutions in a real environment
company. And thirdly, manufacturing industry in TE’s Smarter Factory. At the same time, Physical/cyber-physical gap
faces the challenge to bring its innovative employees learn about the challenges to be Apart from sensor technology, connectivity is
products to the market and the customer as faced by connection and sensor technologies a critical underlying technology for networked,
quickly as possible. individualized and autonomous production.
SOURCE: TE CONNECTIVITY

All data to be made available in real time by

Disruptive technologies & business cyber-physical objects, such as the digital
TE Connectivity has been dealing with these twin, has to be recorded and transformed
changes in advanced technology for a long into usable information. Plug connectors and
time now. One focus at the company is on sensors bridge the gap between the physical
disruptive product and process technologies world and this information world.
that will be brought to market maturity in The intelligence of the network is therefore
the next five years. A second focus is on new based on connectivity solutions that make
business models, which may arise as a result virtual shadowing interaction-ready and hence
of increasing digitalization in the industrial valuable. The development extends from the
sector. ARISO technology is a contactless, combined system existing passive connection technology to more
Specially designed technology and for transmitting data and energy. active and more mobile connectivity. Manual

34 in d u s t r ial et h er ne t b o o k 10.2017
 SOURCE: TE CONNECTIVITY
Technology
With the 5G mobile radio standard, real-time capabilities required in M2M communication and precisely controlling processes will be possible without cables.

and standardized processes will therefore be With the fast-approaching new 5G mobile example, a type of “error tolerance” culture
executed increasingly autonomously in the radio standard, the real-time capability exists. Failure is seen there more as an
future through the integration of artificial that is required in machine to machine incentive to do everything better next time,
intelligence and machine learning. communication for precisely controlling something that is also recognized socially.
processes will also be possible without cables. In start-ups in Germany, we are also
Wireless connectivity in practice TE Connectivity sees itself as a pioneer in increasingly witnessing this open development
ARISO is a contactless, hybrid transmission this area, having introduced, in the form of culture, which is more solution- and added-
system that allows electricity, data and ARISO, a contactless, combined system for value-oriented than results-driven. Integrating
signals to be transmitted contact-free over transmitting data and energy in the industrial start-ups like these into existing organizations
short distances. It is designed for wherever sector, demonstrating that electronics including an instant customer network can
traditional plug connectors reach their limits, integrated in machine and plant engineering have a positive and sustainable impact on
owing to space restrictions, vibrations, dust can also be used in the smallest of spaces and development in Germany. A good example
or dirt for example. at component level. of this is Artificial Intelligence (AI). Many
Typical applications include: observers look to the U.S. when it comes to
• Robotics and tool replacement Enhanced automation this technology, forgetting that there are also
• Rotary tables and material transport Germany continues to lead the way when it good and promising providers in the area of
• Connections through walls or liquids comes to reliable and high-quality production AI in Germany, who have been established
Wireless connectivity plays a key role in machines and systems – as proven by the on the market for many years. If these
this regard. It is already used today in the sustained strong demand for these products companies are successfully brought into the
industrial arena, for example, for mobile in the global market. current discussion and existing Industry 4.0
robots in automobile production. Wireless In terms of integration technology and structures with greater intensity, this could
technologies already offer advantages (in its application in mechanical engineering, provide important impetus for automating
Overall Equipment Effectiveness (OEE) for however, some nations are outpacing us with machine and plant engineering in this country.
instance) wherever proprietary systems and their more open and more added-value-driven
communication protocols lead to compatibility mentality. A zero outage culture continues Dr. Thomas Paral is Head of Research and
and interoperability problems. to prevail in Germany, while in the U.S., for Development at TE Connectivity.

1 0. 2017 i n d u str i a l e th e r n e t b o o k 35
 Device connectivity key to
Technology

optimal OEE in Industry 4.0

For factories to enjoy optimal OEE, device connectivity and collecting precise data is essential. Solutions
for factories can upgrade production technology that improves the availability and performance rates of
equipment, as well as the quality of output.

SOURCE: MOXA
Front-end data processing uses complex data formats and large data sizes, along with
local response and selective use of standard protocols. Transparent data collection is
simpler, uses smaller data samples, and typically leverages standard protocols.

A CONVERGENCE OF MARKET DRIVERS is Netherlands in the 1980s. For the Europeans, Each factor is first calculated separately.
reshaping factory automation. The increasing the challenge was to achieve zero defects The availability rate indicates the percentage
demand for customized products is just one and zero loss on their assembly lines by of time a machine is operating fully without
example of how these trends are transforming applying a Japanese approach in a European any downtime. The formula is as follows:
production lines worldwide. In the pursuit of manufacturing environment. running time ÷ planned production time
perfect production at assembly lines, overall According to the OEE Foundation, Arno Koch The performance rate refers to the actual
efficiency effectiveness (OEE) has emerged was charged with the task to standardize OEE output compared to a standard output. The
as the yardstick that tells manufacturers in order to continuously increase production formula is as follows: ideal cycle time x (total
whether they are producing quality products in factories. In 2001, at the behest of count ÷ running time). Both the availability
or components, as fast as possible, and with corporations that applied OEE, Koch initiated and performance rates refer to the status of
fewer interruptions. the “OEE Industry Standard Endeavor,” which the machine.
OEE focuses on three elements including gave rise to the OEE Industry Standard. The third component of the formula, the
availability, performance, and quality to help Nowadays, OEE is the gold standard in most quality rate, reflects directly on the produced
factory managers keep their finger on the manufacturing operations. units. It measures the ratio of products
pulse of production. passing quality control processes against the
How OEE works actual output. It is calculated as follows: good
OEE has come a long way OEE measures effectiveness of manufacturing count ÷ total count
The first reference to OEE dates back to 1982 by using a numerical value. A formula If a machine underperforms according
when Seiichi Nakajima outlined it as an calculates the availability rate, performance to its OEE benchmark, then OEE can help
integral part of Total Productive Manufacturing rate, and quality of output of any given line managers and operators identify the
(TPM) methodology in his book TPM Tenkai. machine or tool to show how many usable problem areas in their factory. Normally,
Developed in Japan in 1971, TPM only came components it has manufactured in a set time one of the three aforementioned factors
to the Western world’s attention when Fuji frame. OEE is calculated as follows: availability needs to be addressed to ensure that a piece
Photo-Film opened three factories in The rate x performance rate x quality rate = OEE. of equipment remains effective in its value

36 in d u s t r ial et h er ne t b o o k 10.2017
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IEB102_p37.indd 37 09.09.1736 16:29

 above example, it can be inferred that any

SOURCE: MOXA
machine that shuts down unexpectedly will
Technology

go undetected for some time due the absence

of a proper machine condition monitoring
system. Therefore, the availability rate is low
due to a long downtime. The challenge is to
provide a reliable communication network to
capture essential production data and reduce
the downtime of the machine.
With respect to performance rates, operators
are under pressure to reduce the changeover
times of machines. As high customization is
a significant value of Industry 4.0, regular
changes in the programming of computer
numerical control (CNC) machines become
necessary. However, because a CNC buffer is
limited, and programs are relatively large, CNC
machines always take a long time to download
new programs. Spending more time on data
transfers means less manufacturing time,
Without reliable redundancy, continuous uptime cannot be guaranteed in production lines. which machine operators cannot afford as they
are pressed to tap their machine’s maximum
stream. Furthermore, it is unlikely that any mixed-model production lines incur minimal potential. For this reason, the stability of data
manufacturing process can run at an OEE value or no losses in time, quality, cost, or quantity. transfers is very important, especially in old
of 100%. Many manufacturers benchmark a machines with serial interfaces.
challenging target; 85% is not uncommon. Why failing OEE benchmarks? The absence of a full-fledged Ethernet
Moreover, OEE is related to the three major Most factories don’t have sufficient access infrastructure often creates bottlenecks with
levels in a factory: the device level, the control to data that is related to their real-time regard to data transfers. Ethernet networks
level, and the information level. This means all production. The dilemma this entails can be provide high bandwidth, allowing for the
the production data needs to be collected from illustrated in the following example. A factory transfer of large volumes of data, which will
machines or sensors and sent via a network to manager oversees 50 CNC machines and has have a positive effect on productivity.
a manufacturing execution system (MES). In set a key performance index (KPI) of 200 When it comes to the quality of products, it
the past, the OEE information was limited to manufactured pieces per week. is clear that not enough safeguards are built
shop floors only. With the advent of Industry The line manager instructs the operators to into a system to catch a defective product in
4.0, the collected data can now be uploaded produce the required quantity and record the the early stages of production. In the past,
to the cloud for big data analytics. production data manually. The recorded data quality control processes were mostly reliant
is passed on daily to an assistant who puts on the human factor, which is usually prone
Importance of OEE in Industry 4.0 it into an enterprise resource planning (ERP) to oversight and error. Defective products were
OEE and Industry 4.0 go hand in hand. In fact, system manually. After one week, the line only removed during quality control processes,
OEE is the outflow from the manufacturing manager learns to his surprise that only 80 which meant that money and time were
industry’s endeavors to address the challenges pieces have been produced— far below the set wasted on faulty items. Safeguards need to
of Industry 4.0. With the rise of Industry KPI. This raises the question of how managers be incorporated in a system to detect defects
4.0, manufacturers soon realized that a high can readily access real-time production data so as soon as possible by sending early warning
degree of flexibility will be required from that they can take faster action and not wait signals. A dependable communication system
their assembly lines as market forces are now one week, for example, to restore production. is vital to achieve zero defects as reliable
dictated by an era of mass customization. A lackluster production usually echoes back production data is the key to assess the
Customers want products tailored for their to any of the three elements of OEE. From the real-time production status.
specific needs and personal tastes, and the
Henry Ford-style business model of mass SOURCE: MOXA

production, which minimizes variation, no

longer meets their demands.
The trend is shifting towards mixed-model
production lines that put out a larger variety
of products, but fewer quantities of a specific
product. Toyota originally developed the
concept of mixed-model production in the
1960s to undo the hold-ups created by line
changeovers. The biggest challenge is not to
compromise efficiency during changeovers in
order to achieve a high degree of variation.
This is where OEE helps manufacturers make
mass customization work for them. As this
kind of manufacturing is more complex and
has more challenges with regard to workflow
and material flow, OEE benchmarks help A serial-to-Ethernet device server with flow-control is used to stop incoming data to prevent data drop.

38 in d u s t r ial et h er ne t b o o k 10.2017
Benefits of Integrated solutions

SOURCE: MOXA
Because OEE conveys a lot of information

Technology
within one number, it is influential. At all
times, OEE must be a yardstick for improvement
and not a rod for handing out punishment. The
best approach is to try understanding what
needs to be changed in the manufacturing
process to get better results on shop floors.
A three-pronged approach that examines the
availability, performance, and quality rates is
suggested. Once the problem areas have been
identified, new technologies can be sought to
address shortcomings in the process.
Solutions improve machine availability: The
idea is to interpret the working status of the
machines at all times to reduce downtime and
improve network availability in order to ensure
maximum uptime.
Predictive maintenance: For many, it is Controllers help categorize production tasks by automatically retrieving the task sequence from an MES.
perplexing how real-time production data can
prevent unexpected downtime. The simple multicast transmission path. In a mixed-model production line, a
answer lies in predictive maintenance—for While the physical network is down, the programmable controller that supports multiple
which you need real-time production data. ring transmission path changes immediately, functions and interfaces, such as serial
During production, machines generate different and traffic in unicast type communication interface, DI/O, and AI/O, is a huge asset. The
types of data, such as machine vibration, can be recovered almost instantly, but not controller helps categorize production tasks
motor current, tool or coolant level. Based for multicast transmission communications. by automatically retrieving the task sequence
on this data, maintenance engineers schedule Consequently, communications may be lost from an MES. For example, tools are identified
tasks (predictive maintenance) to avoid for a long time. A fast-recovery technology by an RFID tag, and the controller retrieves the
unexpected machine downtime. However, the for multicast communication is needed to production method from the MES via RESTful
data presents itself in different forms. One is keep critical systems up and running. V-ON API and notifies all the relevant machines via
streaming data, which is transmitted in large technology, a pioneering technology, enables an industrial protocol, such as EtherNet/IP,
volumes and requires preprocessing before it is a physical network, unicast traffic, and Profibus, or Modbus. Production information
sent to a back-end system. The other is status multicast traffic to recover within milliseconds can be retrieved via an IT protocol, such as
data, which is transmitted in small volumes when there is a failure in a network. RESTful API.
and via a transparent method without any Increased mobility: Increased mobility
preprocessing. on manufacturing floors has become an Solutions improve output quality
Thus, the system has to use different all-important requirement of Industry 4.0. Perfect production is characterized by zero
methods to collect both status and streaming Floor managers need hands-on information defects. Once again, production data is the
data. For status data, the best way is to use at all times, even when they are not at their key to achieve zero defects. Two types of data
transparent data collection. For streaming desks. The most obvious solution is to provide are applicable: stable data (on/off status) and
data, the best method is to use front-end data all real-time production information on their temporary data (generated over short periods
processing to reduce the amount of data sent mobile devices. Real-time notifications and needs to be recorded without missing any
so that only valuable data is sent to the back- about the network status will help increase parts). When the latter is generated, an alert
end system. Downsizing is necessary because availability and shorten downtime. These types should be sent immediately to operators that
there will be too much streaming data to of notifications should also provide the ability an interruption is occurring. As the production
transfer all the raw data to a back-end system. to check detailed information right away. In quality is reflected in this temporary data, the
In terms of front-end processing, a device with addition, an easy-to-use device-locating challenge is to capture this data precisely.
a programmable platform that is designed to function to find the inoperable device in a A ruggedly designed IIoT controller collects
handle different formats of streaming data is network makes engineers’ jobs easier. precise data in harsh environments to keep
the best fit for the job. Sometimes, a math line managers up-to-date about the status of
function is also required in the programming Improved machine performance all devices in the field.
platform to cope with streaming data. If users The focus is to reduce changeover times to The real value of OEE comes from interpreting
only need to process simple status data, then increase the productivity of machines and the losses incurred due to availability,
an I/O gateway or protocol gateway offers the operators. Clearly, reliable data transmission is performance, or quality. By focusing on
best solution. the key here to increase productivity. A serial- these losses, and more importantly, by taking
Reliable redundancy: Without reliable to-Ethernet device server with a flow-control action to reduce these losses, your OEE score
redundancy in a communications network, feature is normally used to stop incoming data will naturally improve. For factories to enjoy
continuous uptime cannot be guaranteed to prevent data drop; otherwise, the dropped optimal OEE, device connectivity is essential in
in production lines. Most PLC networks rely data has to be resent, which results in wasted order to collect precise data. Several solutions
on the Internet Group Management Protocol time and unnecessary costs. To secure data are available for factories to upgrade their
(IGMP) for multicast transmissions. Implicit transmission, the device should provide an production technology in order to improve
communications, usually used to check the on-chip flow-control feature that is able to the availability and performance rates of their
availability of systems that connect PLCs and process the stoppage (Xoff) directly from equipment as well as their quality output.
devices, are based on multicast. However, a UART, which eliminates data loss when a
IGMP requires up to 125 seconds to update a program is changed. Rick Peng is a Product Manager at Moxa.

1 0. 2017 i n d u str i a l e th e r n e t b o o k 39
 IIoT-ready switch technology
Applications
Technology

using MQTT connectivity

Message Queue Telemetry Transport is a machine-to-machine and Internet of Things connectivity protocol
defined in ISO/IEC PRF 20922. It provides lightweight, publish/subscribe messaging designed for connections
with remote locations, where a small code footprint is required and/or network bandwidth is at a premium.

TO ACQUIRE A LARGE AMOUNT OF DATA

SOURCE: KONTEN NETWORKS

from devices, users need a robust network
infrastructure especially for Industrial
Internet of Things (IIoT) applications
implementing effective cloud and/or machine-
to-machine communications. The major target
of the IIoT is to provide reliable, large scale
network variance applications by analyzing
vast amounts of data that are collected from
different devices and connected together
to provide accurate information that drives
better decision-making.
Industrial Ethernet switches are networking
devices designed for harsh environments
such as extreme high/low temperatures,
high humidity or vibration as well as working
effectively in outdoor applications. The
industrial managed Ethernet switch also
provides industrial protocols such as EtherNet/
IP, Profinet, and Modbus to communicate with
industrial machinery. But even with all of
those requirements, security has become the
single most important issue. Users care about
how to protect the connection, and ways to
identify and filter unwanted traffic.

Introducing MQTT MQTT functions built into switches provide a way to monitor the health of the network and basic management of
MQTT, Message Queue Telemetry Transport, the switch such as controlling PoE and ports using mobile devices.
is a machine-to-machine and Internet of
Things (IoT) connectivity protocol. As a a new approach to controlling and monitoring useful for gathering and analyzing statistics,
standard defined in ISO/IEC PRF 20922, industrial switches installed in the factory or the major aim for IIoT. This is a key reason
MQTT is a lightweight publish/subscribe any other harsh environment. why MQTT functions are being implemented
messaging protocol designed for connections in managed Ethernet switches for use in
with remote locations, where a small code Benefits of MQTT switches industrial applications.
footprint is required or network bandwidth is Konten Networks has implemented MQTT By sending information such as traffic
at a premium. technology in its industrially managed statistics periodically to the MQTT broker on
Using the MQTT protocol, messages are Ethernet switches that can be used for IIoT the Internet, mobile devices with an MQTT
exchanged through an MQTT server, always applications. MQTT functions built into the APP that registers the same topic are able
called the Broker, and is in charge of switch provides a convenient way to monitor to acquire data from the MQTT broker, and
distributing messages to interested clients the health of the network and to do basic recognize the traffic status on the switch
based on the topic of a message. With an management of the switch such as controlling along with the status of the whole network.
MQTT broker, there is no need to maintain PoE and ports through mobile devices and Real-time events/alarms, available through
the connection between the publisher and without LAN limitations. Users can deploy MQTT, provide the administrator first-hand
subscriber, so MQTT applications conserve the the industrial Ethernet switches within a LAN, information that can be handled right away,
battery life. but control and monitor them outside of the even though they are not onsite.
MQTT helps in Industrial Internet of Things LAN to reduce the cost of implementing an
(IIoT) applications with its ability to deliver accessible network. MQTT applications
sensor status information to a control center or Data collection is an additional benefit of In automated factories, there are thousands of
administrator using its simple and lightweight MQTT switches as well. The switch can send I/O sensors to control entire applications, and
protocol. It also uses a database built on the statistical traffic information to the broker the data from sensors is valuable for analysis
server that also collects the information from periodically, and trigger alarms by using and statistics. Therefore, how to ensure
all sensors, useful for the analysis of systems events. The MQTT broker maintains or can effective data transmission is the main point
and applications. Nevertheless, MQTT can offer connect to a database and store collected data for any application. All sensors and devices

40 in d u s t r ial et h er ne t b o o k 10.2017
 SOURCE: KONTEN NETWORKS
connected to the network switches transmit

Applications
data that can be used to monitor systems in
the field.
Traditionally, users set system warning
events to notify an administrator when the
configured events are triggered such as lock
down. Users are able to get the notification
passively, but are unable to deal with the
event if they are not on-site. In an alternate
way to monitor network status, switches
with MQTT function in the backbone network
publish the traffic information to the broker
periodically so that users can keep track of the
network traffic.
It is easy to observe when unexpected
network traffic happens. In addition, the event
alarms are published to the broker immediately
once the event is triggered and the users will
be also notified immediately. Apart from alarm
function, there are also other topics for the
MQTT function including system, interface,
and PoE information for all kinds of MQTT
applications.
The surveilance system is also an important
issue in automated factories. IP cameras need
a stable connection and bandwidth to transmit
streaming data. In the industrial environment,
the power input source is a consideration, too.
PoE supported switches are the best solution
for PoE devices, and steady power and stream Industrial Ethernet switches implementing the MQTT protocol can provide an effective link to cloud services.
forwarding is available using industrial
Ethernet switches. devices to work abnormally. The backup connection successfully. This authentication
Switches with MQTT also provide PoE control mechanism plays a significant role in the mechanism helps to filter a part of unknown
and monitoring. Through a MQTT APP on backbone network to preserve the operation of applications. However, this is not robust
mobile devices, users can monitor the power entire application. An ideal backup mechanism enough to protect the traffic transmitting from
consumption for each PoE port. Users are also must unblock any blocked connection the switch to the broker.
allowed to turn on/off the PoE function on immediately when a failure occurs to allow the Another safer way is to transmit data
the specific port via the MQTT APP. It’s also traffic transmitted into another path without through Secure Sockets Layer (SSL). SSL is a
convenient for the administrator to reset packet loss. The recovery time from failure is cryptographic protocol that provides a trusted
the PD as soon as it fails, no matter where the user’s real concern. environment for communication security, and
the device is located. Switches with MQTT For example, the spanning-tree protocol a key pair is required for certification. The
support make a breakthrough in the current (STP) needs around 50 milliseconds to be certification keys work together to establish
LAN conception – keeping MAC Layer devices effective; and it may cause great loss during an encrypted connection, that can protect
in the LAN but controlling them in the WAN. the recovery time of 50 milliseconds. For this transmitted data from sniffing. Industrial
A massive amount of information is reason, the enhanced spanning-tree protocol, Ethernet switches embedded with both MQTT
published by the switches to the server Rapid Spanning-Tree Protocol (RSTP), is authentication and SSL provide a robust and
(broker), not only for the administrator to proposed even though the RSTP still needs secure environment during data transmitting
monitor the entire system but also for the few seconds to recover from failure. By through MQTT function.
server to analyze and gather statistics. The contrast, we recommend another standard ring
port statistics reflect productivity in the protocol, Ethernet Ring Protection Switching Conclusion
product line, the access frequency in the (ERPS), which is defined in ITU-T G.8032 for Switches supporting MQTT functionality can
I/O sensors, and also the streaming from IP backbone redundancy. The recovery time for be very important for IIoT applications. It
cameras. ERPS is less than 50 milliseconds, which makes can save time and reduce network downtime
How to effectively take advantage of this it absolutely the best choice for the backbone by using one management protocol. With the
collected information is the next step for the redundancy protocol. MQTT authentication and SSL function in the
users to plan for in the future. The database For protecting the traffic in the backbone switch, the device can be secured with the
is established by the users who can take total network, the security methods are saved communication.
control of it and analyze the data using their indispensable and the MQTT protocol supports For IIoT, data collected by the MQTT broker
own data analysis tools. authentication using a username and password and saved in a database must be based on
at the application layer. The broker maintains a reliable network. All things considered, a
IIoT backbone redundancy the access list in the configuration file or switch with MQTT functionality is the niche
We usually design networks using a ring imports the password file into the configuration for networks implementing IIoT applications.
topology for redundancy, and one connection file to provide client authentication. Only
blocked by default for backup. If any of the clients with correct username and password Kirs Yao, engineer of industrial networking
connections fail, it will cause the connected in the connection message can build the devices, Konten Networks.

1 0. 2017 i n d u str i a l e th e r n e t b o o k 41
 Cyber-physical systems drive
Technology

industrial network innovations

The evolution of smart machines, production lines and storage systems within networks, known as cyber-
physical systems, is creating solutions required for the manufacturing of the future. Communications and
networking innovation is giving control engineers interoperable, more adaptable options.

THE FOURTH INDUSTRIAL REVOLUTION, foolproof operation, and is called plug-and- Building field-level systems
commonly known as Industry 4.0, is quickly produce. In these models, the computational Today, in industrial environments, the
taking hold where the hallmarks of world- intelligence of each tooling unit or work industrial networking infrastructure for
class manufacturing are responsive, efficient station within a manufacturing line remains automation is contained within switching or
and flexible operations. Made possible by with the tooling unit rather than with a control cabinets, which can take up a great
the connectivity innovation known as the central computer. deal of precious real estate on the factory
Industrial Internet of Things (IIoT), this A second force in the transformation floor. Moving these critical components out
age relies heavily on advanced automation, of industrial environments is the need to of cabinets is essential to reclaiming space
communication and processes that enable optimize space on the factory floor. The for uses more directly tied to improving
humans, machines and components to work miniaturization of components, lines and productivity and is driving the demand for
together seamlessly. related automation equipment has made compact field-level devices and components
The ability to connect smart devices and production lines even smaller. that are also plug-and-produce capable.
share the information produced by them is So, in smart factories, machines take up Control engineers need to evaluate critical
expected to improve existing business models less space, while autonomously exchanging devices for field-level interoperability, size
and enable new ones. It’s a compelling information, triggering actions and and implementation ease. A holistic field-level
vision, and one that requires a well- controlling one another. These cyber-physical solution system will include:
thought-out strategy and plan for building environments are characterized by: Active I/O modules: Active I/O modules
the robust communication networks capable • Distributed control and decentralized directly interface with sensors and actuators
of supporting the cyber-physical integration decision-making and transmit data to and from a programmable
and systems at the heart of it all. • Modular and scalable automation logic controller (PLC) via an industrial
solutions Ethernet network. The newest generations
Changing automation dynamics • Shorter, more flexible production cycles of active I/O modules increase flexibility
Today’s industrial automation systems are • Smaller equipment and production lines and functionality with digital I/Os and IO‐
comprised of distinct and separate levels, • The ability for parallel communication Link ports. Additionally, more evolved I/O
which are represented by the classical of process data with diagnostic and modules provide input and output forcing,
automation pyramid, including: condition monitoring data without which can be executed through an embedded
• Field-level devices such as input/output impacting standard processes web interface.
(I/O) modules, actuators and sensors, This move to field-level intelligence For maintenance personnel and installers,
and operator terminals creates a more decentralized approach to this offers a simpler, more intuitive
• Control-level devices, information-sharing and processing. Critical infrastructure. One device can recognize the
• A process management level charged to taking advantage of this more flexible, condition of other devices and know their
with supervisory control and data effective and productive model are high status. Standard machine-to-machine (M2M)
acquisition (SCADA) and manufacturing performance communications and power and cloud communication protocols such as
execution systems network infrastructures. OPC UA or MQTT, integral to the I/O modules,
• An enterprise-level with business enable such data transfer between devices,
process and enterprise resource planning Communications & power networks as well as to and from the cloud using the
systems, typically located on servers in The IIoT makes it possible for machines to Industrial Ethernet infrastructure.
the IT data center. produce more, do it better and contribute I/O hubs: These hubs extend machine
to process improvement. As innovation in installations by connecting multiple digital
In Industry 4.0, the field-level connects automation continues to evolve, advances in I/Os per IO-Link port. For automation
to the other levels, which migrate to the communications and networking technology applications, the point‐to‐point
cloud, a server farm or even to the field-level capable of supporting sophisticated communication of IO‐Link is utilized for both
as well, via Industrial Ethernet networks. operations are coming online, as well. data and power transfer for distances of up
One fundamental shift in these operations High performing communications and to 20 meters. And in cases where greater
is toward a plug-and-play model that allows power technology is making it possible for distances are involved or more I/O ports are
for near immediate implementation without machines to: needed, solutions are available.
the need for special tools or highly trained • Transfer large amounts of data in Distributed Control Units: DCUs represent
engineers or electricians. Plug-and-play real-time and with minimum delay cyber-physical systems, and can be built
products can simply be connected and turned • Transfer diagnostics data concurrently through integrating programmable logic
on, producing immediate results. and independently with process data control into active I/O modules. In addition
When applied to the entire industrial • Connect many individual devices reliably to simply transmitting input and output data,
automation process, this concept carries and interoperability. such enhanced active I/O modules are capable
an expectation of ease of use and reliable, • Operate in an energy-efficient manner of processing data, from simple logical

42 in d u s t r ial et h er ne t b o o k 10.2017
 SOURCE: BELDEN

Technology
First programmable logic 4. Industrial revolution
controller (PLC), Modicon 084 based on Cyber-Physical
1969
Systems.

3. Industrial revolution
uses electronics and IT to
First production line, achieve further automation
Cincinnati slaughterhouses of manufacturing.
1870

complexity
2. Industrial revolution
follows introduction of
electrically-powered mass
First mechanical loom production based on the
1784 division of labour.

1. Industrial revolution
follows introduction of
water-and steam-powered
mechanical manufacturing
facilities. Time
End of Start of Start of 1970s Today
18th century 20th century
operations to solving more complex control upon industry standards is ideal. Regardless of therefore, capable of operating in different
problems. Through a M2M communication which protocol chosen – PROFINET, EtherNet/ network systems – provide a very good solution
protocol such as OPC UA, the DCU can provide IP or EtherCAT – all field-level devices in to overcome this challenge. For example,
valuable raw or processed data for diagnostics industrial networks should adhere to the same rather than designing machines for European
or condition monitoring purposes. OPC UA can reference architecture and respond to the application, and having to re-design for use
also be employed to control the DCU through same protocol for seamless interoperability. in the United States, multi-protocol settings
e.g. a human machine interface (HMI). Metal vs. plastic housing: There is often allow for a single device type to be utilized.
Ethernet switches: While unmanaged a misconception that metal housing is
switches with 100 Mbps ports are adequate expensive. The thought that plastic is Solutions for Industry 4.0
for most industrial applications today, higher cheaper and lighter prevails. While in reality, Until now, automation architectures have
data rates are expected in the course of the the weight of a module is determined by the been at odds with industrial, operational and
development of time sensitive networks. molding – and all internal moldings are made business architectures, and manufacturers
Connectors and cables: A field-level, plug‐ with a plastic compound. Metal housings make have been hard-pressed to achieve the ideals
and‐produce concept requires connections to the product not only mechanically robust, enabled by an integrated environment.
meet international standards and IP protection but electrically robust, too, as the body Constraints have been imposed by different
classes 65/67/69K, according to DIN EN 60529 or cage protects the internal components or no standards, availability of affordable
for ingress protection. Over‐molded circular from environmental extremes. Additionally, interoperable system solutions, computation
connectors with M8 and M12 threads offer components with metal housings integrate a and respond times, cost and more.
good protection from moisture and dirt. screw-type connector in their construction. The evolution of smart machines, production
With plastic, an additional piece is required lines and storage system that collaborate within
Quality in from the start to make these connections, ultimately making networks known as cyber-physical systems is
When projects move into the implementation plastic more complicated and costly. changing all of that. In these sophisticated
stage, there may be internal and external Single vs. multi-protocol settings: The sheer operations, communications and networking
pressures to select and install a solution very number of different protocols installed, as innovation is giving control engineers
quickly. There are three key areas that should well as the regional dominance of specific interoperable, more adaptable options for
be considered to avoid overlooking critical protocols, requires extra effort when it comes designing and building the solutions required
quality factors: to building globally deployable machines for the advanced manufacturing of the future.
Proprietary vs. standards-based solutions: and equipment. Active I/O modules loaded
Wherever possible, choosing a solution built with multiple protocols in one device – and Thomas Schoepf, Director R&D, Belden.

1 0. 2017 i n d u str i a l e th e r n e t b o o k 43
 Miniaturised connections and
Technology

higher data transfer rates

Ethernet connector technology is responding to marketplace needs with solutions that provide miniaturised
ports and higher transfer rates. Higher performance and appropriate miniaturisation also means that
connector systems are enabling new designs that can expand network usage both upwards and downwards.

ETHERNET IS INCREASINGLY COMMON as a in heights of 9mm and 13mm. This allows

SOURCE: HARTING
communications standard within industrial other connectors of different heights to be
automations but, until relatively recently, used, eliminating the problems of differing
it has been reserved for the top levels of distances.
monitoring and control units. Now, increasing During the first stages, the M8 D-coded
numbers of sensor, camera and other industrial connector will receive the familiar threading
device manufacturers are looking to connect used by pin connectors. However, as HARTING
their products via Ethernet at the top field has experience with a push-pull locking
level. At the same time, field clients are mechanism used on its larger M12 counterpart,
becoming increasingly smaller, while being the M8 will feature this mechanism in the
required to achieve higher data transfer rates. not too distant future. In particular, this
In order to keep pace with changes solution offers easy access when connectors
in connection technology, HARTING has are arranged next to each other within a
recognised this trend toward miniaturisation very confined space. The cable components
and developed new M8 D-coded connector M8 connection technology is opening up new cost- of connector systems must also be modified.
technology for applications from the cloud effective solutions for networking sensors and other HARTING will release an ad-hoc field assembly
right down to sensors. field devices while also achieving higher data rates. connector in the form of a displacement
termination under the name HARAX.
The move to miniaturisation connectors are now becoming too large for To ensure backward compatibility of the
Initially, miniaturisation comes across as many applications. new version of the M8 as a universal solution,
rather an abstract term. Computers that Some modern industrial cameras used for the D-coded version is also standardised.
used to fill up entire rooms now fit in brief identification and positioning, as an example, A universal standard with a protocol in
cases, mobile phones no longer weigh one have grown so small that the power and data accordance with IEEE 802.3, and a connector
pound these days and so it is clear that these connectors are restricting miniaturisation of designed according to the specifications
developments have also occurred in different their enclosures and actually take up most of of PAS IEC 61076-2-114, offers customers
areas. And, of course, this is also apparent in the space in the application. These are the investment security and allow it to be used
industrial automation where camera systems, types of applications where the M8 D-coded with existing active and passive infrastructure.
sensors, switches, I/O boxes and decentralised connector technology is a fit. This applies equally to the automation and
industrial PCs are continually smaller. M8 connectors are used in many applications transportation markets.
However, it’s not just that the size of these at the field level, at least for signal forwarding.
devices is shrinking. They also have to satisfy The new D-coded M8 connector offers a metal Cloud-to-sensor solution
the increased specifications of digitalisation enclosure with continuous shielding and 0.8 Stepping back and considering the entire
and generate significantly more data. The mm diameter contacts, which enable end system of industrial cabling from the outside,
goal with M8 technology, however, is to devices to be supplied with 100 Mbit fast M8 technology is opening up new areas
ensure that the entire spectrum of industrial Ethernet. To avoid having to find extra space for development, which was completely
production equipment can be connected to a for the additional power ports, the D-coded unthinkable just a few years ago. Ethernet
suitable Ethernet network. M8 connector supports PoE and can feed field communication no longer just takes place
Until now, it has been a standard practice clients with power and data simultaneously. between the top level of a company and
to enable device communication at the top field distributors. High-performance and
field level via BUS systems. This required 30% smaller solution appropriate miniaturisation mean that
translating field level signals into control level HMI, which was also the starting signal for connector systems can expand network usage
Ethernet protocols and vice-versa. It is now mass production, was the showcase for a both upwards and downwards.
possible to cut out this step and connect new, universal solution consisting of extruded More and more devices can, and will, be
miniaturised field clients directly via Ethernet. cables and circuit board connectors. This talking to each other in the near future.
This results in higher data transfer rates which offers device manufacturers the right Servers, internal company networks, individual
require modified connector systems. connector system to make the next steps workstation PCs, network nodes, switches,
in miniaturisations a reality. On the circuit machine modules, tools, even products will
New connection options board, the M8 solution is about 30% smaller be communicating with their environment
Among the connector options for data transfer than the previous M12 solution. But if you via RFID. And it’s miniaturised ports enabled
open to customers, there are only two IP67 combine different M8 ports on an I/O box, the by M8 D-coded connector technology that is
protected solutions to consider: an additional sum of the reduced modular spacing leads to helping to make this possible.
RJ45 protected in an enclosure, or a M12 dramatic space savings. On the device-side,
pin connector. Despite being small, these users can choose between two flange sockets Technology report by HARTING.

44 in d u s t r ial et h er ne t b o o k 10.2017
Low profile GNSS antenna requires engineers to find the optimal channel 10/100/1000 Mbps with auto-negotiation and

Product News
and then make adjustments. auto-MDI-/MDX detection, resulting in high
AeroMag takes care of all the settings speeds and configurability.
throughout the wireless network lifecycle, Enclosed in compact housing (50 mm)
which means engineers do not have to perform and designed for DIN rail mounting, this 16
complex wireless configuration and can enjoy port gigabit switch allows control engineers
continuous wireless connectivity for their daily to expand their control panel’s networking
operations. capabilities without taking up more space.
Further benefits include wide operating
Category 6A PROFINET cables temperatures, wide voltage operation of 12 to
60 VDC and LED identification on each port
The economical 16 channel unmanaged
Antenova: Robusta is a very low profile GNSS gigabit switch offers high speed and features
antenna that offers a new patented design that allow for use in a wide variety of industrial
for tracking metal objects and smart city applications.
applications. The antenna operates in the
1559-1609 MHz bands. IO-Link master modules
The REFLECTOR antennas use a patented new
technology where there are two layers, one
electrically isolated from the other, so as to
provide RF shielding to the second layer. This
allows the antenna to radiate effectively in the
direction pointing away from the base material. Belden: New DataTuff Cat6A PROFINET cables
The Robusta antenna has two key features are designed to support the growing demand
that make it a good choice for discrete tracking. for high-volume data transfer from the factory
It is extremely low profile, so it can be mounted floor. These cables transmit data up to 10Gb/s
onto a metal object such as a bicycle frame, and provide the reliable, ruggedized and flexible
and perhaps concealed under a label. Being connections required in environments built for Weidmuller: Two new IO-Link Master modules,
able to operate directly on a metal surface, it the Industrial Internet of Things (IIoT). IP20 and IP67, use the IO-Link open standard
can be used on bicycles, motorcycles, vehicles, The connectivity required by the IIoT is driving (IEC 61131-9) serial communication protocol
containers or other property that needs to be the trend toward more data at lower levels to connect and communicate data to and
tracked and located accurately. of the automation pyramid, including within from sensors and actuators. This increased
individual sensors and actuators, and the need transparency down to the sensor-actuator
Wireless network deployment tool for an easier way to manage critical information. level helps improve diagnostics and efficiency,
Depending on application needs, two types of increase machine availability, and reduce
DataTuff Cat6A PROFINET cables are available: downtime.
Type A (stationary) and Type B (flexing). Both The modules feature simple, user-friendly
are designed in UL-style with polyvinyl chloride web-based configuration and monitoring. This
(PVC), low-smoke, zero-halogen (LSZH) and allows users to conveniently change parameters
polyurethane (PUR) jacket materials. using the web server, and provides for both
The new cables are designed for industrial on-site and remote testing and diagnostics
operations such as automotive, oil and gas, food without the need for additional software.
and beverage, and machine building. Processes and procedures can be simulated
without a connection to the controller for
16-channel unmanaged switch simplified phase commissioning, and faster
service response in the event of unplanned
Moxa: New AeroMag technology is a fast and downtime.
easy-to-use wireless network deployment tool The IP20 master module features an increased
that allows users to easily use wireless networks. power supply, compared with current industry-
During on-site operations, AeroMag scans available IO-Link modules. It provides 500 mA
the on-site environment and sets the optimal per IO channel (type A), compared with 200
Wi-Fi channel for devices. This technology can mA–an increase of 150%.
configure all basic wireless settings in a single
step and eliminates the need to adjust multiple HART Functions for TwinCAT & I/O
device configurations when adding new devices Beckhoff: Full implementation of HART
into existing networks. functionality, both within the company’s
The technology was developed to reduce the I/O system and in the TwinCAT engineering
time engineers spend on configuring devices environment, promotes simple project planning
and optimizing wireless connections. During the and reliable commissioning.
initial setup stage, AeroMag performs all of the TwinCAT software reduces development efforts
basic configuration that is required to establish in process technology because it facilitates the
wireless connections, including setting the application of comprehensive HART functions
SSID, WPA2 password, RF type, and channel. As WAGO: A new 16 channel unmanaged gigabit directly from the engineering interface. In
on-site environments can be unpredictable, the switch is the latest addition to WAGO’s switch this way, the TwinCAT FDT (Field Device Tool)
installation and system operation phase often portfolio. Each of the 16 RJ-45 ports support container enables implementation of any field

1 0. 2017 i n d u str i a l e th e r n e t b o o k 45
 percent or scaled directly in engineering units for new Synergy microcontrollers.
Product News

to show process measurements such as pressure, SSP v1.3.0 also adds Wi-Fi, LTE cellular and
temperature, level, or flow. Bluetooth low energy (BLE) wireless application
Additional settings for display such as span, frameworks that simplify adding or exchanging
zero, input range, display range, and filtering radio frequency (RF) modules in IoT devices.
frequency are easy to program. The free software Low power management is enhanced by adding
allows users to select square root or linear curve the Power Profile application framework to
from the library, or quickly create a custom one make it easy to use the Synergy MCU’s complex
or even import a curve from Microsoft Excel. low-power modes. The Synergy platform also
includes software and development tool support
Network connected lighting for three additional MCU groups: S5D5, S3A6,
device drivers (Device Type Manager, DTM). An and S128. New low-cost S5D5 and S3A6 target
entire HART configuration can be implemented board kits and S128 development kit further
efficiently using a single tool. reduce development cost barriers.
The Beckhoff CommDTM integrates the SSP v1.3.0 integrates NetX Secure to
TwinCAT platform into existing process control safeguard connected IoT device communications
systems. With its help, the DTMs can be over public networks and the Internet.
implemented in any FDT container. This applies Developers can easily deploy NetX Secure to
to all field devices connected to the HART- authenticate the senders and receivers identity,
capable EtherCAT Terminals. These devices can and prevent eavesdropping and tampering with
be configured and parameterized remotely in data sent across the network. NetX Secure uses
the known containers without requiring direct the TLS protocol to achieve socket layer security
PLC access. Molex: The Transcend Network Connected while using the NetX Duo TCP/IP network stack.
New, compact EtherCAT Terminals in the Lighting System provides designers a complete TLS provides security three ways: by
ELX series are also HART-capable. With management system to accelerate deployment establishing secret keys between the client and
intrinsically safe inputs/outputs, they enable of smart LED lighting control using highly secure server, applying hashing algorithms to detect
the direct integration of field devices installed network architectures in commercial buildings, alteration or forgery of packet content, and
in hazardous areas, Zones 0, 1 or 2, into the educational facilities, healthcare facilities, and remote host identity using digital certificates.
automation system. manufacturing and warehouse facilities. The MQTT protocol enables lightweight machine-
The unit is an intelligent, low-voltage, and to-machine (M2M) communication across
Safety programmable loop display low-energy system that powers and controls small IoT edge devices powered by MCUs. This
building objects using Transcend’s Manager combination of TLS and MQTT protocols ensures
software and components. The Internet of Things secure and efficient communication from edge
(IoT) system uses a broad array of intelligent to cloud.
components to feed multi-sensor information
and data to a central host, such as real-time AMS Trex Device Communicator
energy consumption, light status, temperature
and humidity, air quality, occupancy and more.
System components include smart LED drivers,
LED cable harnesses, Power over Ethernet (PoE)
gateways and a range of wireless components,
including sensors, dimmers, switches and zone
Moore Industries: A new SIL 3 capable SLD controllers. Smart LED drivers are compact, DC/
Functional Safety Programmable Loop Display DC LED components that drive LED engines.
for use in Safety Instrumented Systems (SIS) has Powered and controlled by a Transcend PoE
been certified by exida with full functional safety Gateway, these devices feature integrated
approval after rigorous evaluation to ensure power monitoring that allow control of up to
conformance with strict IEC 61508 standards eight devices per gateway, as well as dual input/
for safety-related applications. output connectors for daisy-chaining.
The SLD is part of the FS Functional Safety
Series family and the loop-powered SLD provides Synergy software package v1.3.0
reliable and accurate display of real-time
process status in mA, percent, or any designated
5-character Engineering Units (EGU). Built for
Safety Instrumented Functions (SIF), the SLD Emerson: The AMS Trex Device Communicator
can be taken out of the loop with the –LMD connects field device data with asset
option (Loop Maintenance Diode) without management experts, leveraging Industrial IoT
affecting the integrity of the safety function. solutions to improve reliability decision making.
The display is DTM programmable with user Auto Sync technology makes AMS Trex the
oriented basic configuration for fast and first handheld communicator to automatically
accurate setup. The SLD can be programed with synchronize field data with a facility’s AMS
any FDT compliant host or program such as Device Manager database. By connecting field
PACTware utilizing Moore Industries’ DTM and Renesas: The Synergy software package v1.3.0 data with decision makers, maintenance and
USB communication cable. DTM programmability includes NetX Secure TLS, MQTT connectivity, operations personnel will now have even faster
allows the SLD to be custom scaled to display Wi-Fi/Cellular/BLE Frameworks, and Support access to field changes and an accurate audit

46 in d u s t r ial et h er ne t b o o k 10.2017
trail for compliance and analysis requirements. a single PC, for example, or have an industrial Power Family testing tools

Product
Industry News
Before the AMS Trex, when changes happened PC double as both a real-time controller and an
in the field, information about those changes edge controller that sends preprocessed data to
was often incomplete, inaccurate, or delayed. higher level systems and the cloud via OPC UA.
The communicator eliminates this risk of The hypervisor provides a virtual network
inaccurate data, by logging and timestamping connection that allows applications to exchange
all changes as they occur. With the resulting data between operating systems. Like with the
audit trail, organizations know not only what usual Ethernet interface, this is done using
was changed, but when and by what device, standard network protocols. In place of a cable,
simplifying change-related troubleshooting and there is a reserved memory area that is not
providing easily accessible data for compliance assigned to either operating system.
audits. The user configures the hypervisor and
allocates hardware resources in the Automation
Bode Analyzer Suite V 3.00 Studio software development environment.
The configurations are defined separately for TTTech: The Power Family is a future-proof
each system, providing maximum flexibility in solution for vehicle testing and validation
how resources are utilized. Whereas previous of automotive networks that fulfills all
parallelization solutions were tailored to a requirements for logging modern networking
specific Windows version, B&R’s hypervisor is architectures in vehicles. The product line
completely independent of which operating consists of the data logger PM-200 and several
systems are used. extensions that can be individually combined to
fit any use case.
Open architecture computers The modular concept of the product range
makes it possible to meet high demands of fleet
tests as well as of test runs. The Power Family’s
centerpiece is the PM-200, a scalable and
modular logging solution, capable of logging
OMICRON Lab: With the release of the new Bode Ethernet from standard up to high-level speed.
Analyzer Suite V 3.00, all users of the Vector With increasing data volume and the
Network Analyzer Bode 100 gain access to centralization of ECUs, autonomous driving and
new functions and features. The new software ADAS have a huge impact on vehicle networking
extends the upper measurement frequency of architectures. As a result, they also require
Bode 100 enabling a measurement range from a new generation of testing equipment that
1 Hz to 50 MHz. A total of seven new impedance offers sufficient bandwidth, a rich number of
measurement modes are now offered covering interfaces and is able to deal with the amount
impedance measurements from mΩ to MΩ. of communication happening within a multicore
This enables the user to perform impedance Rockwell Automation: With the new family ECU.
measurements of passive components as well of Allen-Bradley VersaView 5000 industrial
as measuring the input and output impedance computers, thin clients and monitors, Compact wireless terminal
of active circuits such as power supplies. manufacturers can modernize their standalone
Pre-defined measurement modes allow or distributed HMI applications to support smart
first-time users easy and quick access to manufacturing.
various types of Gain/Phase, Vector Network The VersaView 5000 portfolio includes
Analysis and Impedance measurement modes. five products: VersaView 5400 display and
An all-new memory handling allows to copy live nondisplay computers; VersaView 5200 display
measurements into memory traces with one and nondisplay thin clients; and VersaView
mouse click. 5100 monitors. The display options include
an edge-to-edge glass display, a new 22-inch
Operating systems on one device widescreen option, full HD and 10-point
multitouch capabilities to help improve
operator productivity.
When combined with FactoryTalk View Site
Edition software from Rockwell Automation Steute: New components for sWave.NET wireless
in distributed applications, the VersaView network include a compact wireless terminal for
5400 industrial computers can provide cost- intralogistics and production uses.
effective compliance with 21 CFR Part 11. Users receive information via a two-line
The software stores, processes and transmits display and, vice versa, can also send
electronic records and signatures to show information to superordinate control systems
which employees have made changes. This is (WMS, ERP, PDA, etc.) via three freely
critical for highly regulated industries like life configurable buttons. Flexibility is guaranteed,
sciences. for example, by the fact that signals are passed
B&R: New hypervisor software allows Windows The VersaView 5200 thin clients, the first on within the wireless network sWave.NET. This
or Linux to run alongside B&R’s real-time from Rockwell Automation, are designed to be occurs via access points, which work similarly to
operating system. This enables users to the preferred thin client hardware for use with a router and send the wireless signals directly to
combine the control and HMI applications on the company’s ThinManager software. an IP address, where they are then processed by

1 0. 2017 i n d u str i a l e th e r n e t b o o k 47
 the company’s IT system. a dual rate 100/1000 SFP slot. It is perfectly
Product News

New terminals can be integrated in this designed to fulfill industrial applications that
network in just a few steps. This also makes require distance extension and high bandwidth
for simple retrofitting, e.g. to FIFO shelves, capabilities. This small form factor is designed
E-Kanban shelves, picking points or other for saving space in outdoor applications such as
workstations. At the same time, transparency factory automation, security, ITS transportation,
is increased, both at the individual workstation power/utility, water wastewater treatment
and throughout the company, because a plants, and any other extreme ambient weather
constant, bidirectional flow of information is environments.
generated – for example from the picking belt to The new series has a built-in “Link Fault
logistics management or from the Kanban shelf Pass Through” (LFP) and “Far End Fault” (FEF)
to materials handling. In each case, additional function with redundant power input 48~55VDC.
wireless switching devices and command connect to their choice of leading IIoT cloud This product can support DIN-rail as well as wall
systems can be integrated in the sWave.NET platforms. In addition, Red Lion’s embedded mountable orientations and has two operating
wireless network at any time. MQTT client, simplifies implementations with temperature range models.
pre-configured profiles for AT&T M2X, Amazon
USB 3.0 SuperSpeed Hub AWSTM IoT, AutoDesk Fusion Connect and Industrial Ethernet switch
Telenor Connexion.
Customers connect using a simple drop-down
menu to select their cloud platform of choice.
Also, using the RAM Software Development
Kit (SDK), connectivity can be enabled with
additional platforms, including LEC IQ Web
SCADA, Set-Point IPwebcontrol, Skkynet
Skkyhub, and Telit deviceWISE.
The combination of industrial protocol
support, reliable cellular communication
B+B SmartWorx: Adding to its comprehensive and easy-to-connect cloud support provides
line of USB products, the USH304 is its first customers with a seamless IIoT solution.
isolated USB 3.0 SuperSpeed Hub offering both RAM products also provide a powerful event
isolation and super high speeds. engine and an integrated I/O database which
This 4-port isolated USB offers 2,500 VDC streamlines the creation and storage of data
voltage isolation for upstream ports and tags. Other features include multiple serial and
4x downstream USB 3.0 SuperSpeed ports. Ethernet ports and optional I/O, Wi-Fi and an
Isolation usually downgrades USB speed to 12 active GPS to securely monitor and control
Mbps; not the case with this hub. With a transfer remote devices over 4G LTE cellular networks.
speed of up to 5 Gbps, it can be powered via a Korenix: A new Industrial Ethernet switch
USB bus or 10~30 VDC external power source. Gigabit media converter suitable for a wide range of industrial
Users can experience the confidence of isolation automation applications has IEEE 1588
to protect equipment and systems while also compatibility for use in real-time applications
operating power-hungry industrial devices. using industrial protocols such as Ethernet IP
This is opening new doors for increasing and ModBus.
speed in industrial applications, such as The new JetNet 7310G is a Layer 3 managed
security systems, machine vision, product switch with Layer 2 network performance and
programming, and testing and charging at the provides 8 x 35W Power-over-Ethernet (PoE)
end of the production line. Previously, USB Hubs ports, enabling the simple connection of devices
with isolation were limited in bandwidth. Now such as PoE enabled I/O modules, GigE cameras,
with USH304, users can power larger devices WiFi access points and other devices that require
and provide isolation. Additional features of high power levels and industrial cybersecurity
the new USH304 include:ruggedized design features.
for industrial commercial applications; ESD
protection up to ±8 kV (Level 3); and power MICA certified for Microsoft Azure
status and downstream port speed LED HARTING: The MICA industrial computer system
indicators. has been certified as meeting the requirements
of Microsoft’s Microsoft Azure Certified for IoT
Routers support cloud services program.
Red Lion Controls: The RAM industrial routers Microsoft’s certification process places
and cellular RTUs now support the Microsoft certain demands on end devices which work
Azure, Cumulocity and Nokia IMPACT IIoT with Microsoft Azure services. As a result, MICA
platforms. This follows the recent announcement has gone through a series of tests provided by
that Red Lion’s RAM products now support the Antaira: The IMP-C1000-SFP series is a Microsoft in order to evaluate the functionality
MQ Telemetry Transport (MQTT) protocol. compact IP30 rated gigabit Ethernet-to-fiber of the hardware. The results have been validated
The addition of these three platforms moves media converter featuring a 10/100/1000Tx by Microsoft, meaning that MICA meets the
Red Lion RAM products, providing greater Ethernet port that supports IEEE 802.3at high requirements of the programme.
flexibility for industrial customers to quickly power PoE that can supply up to 30 watts and Azure Certified for IoT is also intended to help

48 in d u s t r ial et h er ne t b o o k 10.2017
 The set simplifies the evaluation of the first

Product News
server-on-modules designed in accordance to
PICMG’s COM Express Type 7 standard, poised
to be globally deployed in cloud, edge, and fog
server applications.
Engineers further benefit from reduced
validation efforts of their own carrier board
layouts, as they can re-use the proposed best
practice components and PCB design schematics
for their own dedicated next-gen modular
micro servers. The quick starter set is suited
for the design of Industry 4.0 micro servers
communicating in real-time, redundant fog Online help with documentation is available
speed up IoT projects with Azure by providing servers, and transcoding cloudlets at the edge of during configuration of the safety circuit. Once
a set of available sensors and devices that are carrier-grade infrastructures typically operating it is complete, the tool checks the circuit for
tested for usability and compatibility with the on a massive scale. faults.
Azure IoT Suite. To protect the fully configured safety circuit
MICA (Modular Industrial Computing Optimizing motion control software from unwanted changes, it can be certified.
Architecture) is an edge computing device based Users can edit, alter or add to uncertified
on a modular open computing platform which configurations of your safety circuit at any time.
can be customised as required, including the The configuration can be printed out and used
hardware, software and interfaces. as documentation.
PNOZmulti Configurator Version 10.5 now also
Wireless VR solution has a connection to the visualisation software
PASvisu. All the project-relevant information
from the PNOZmulti project, such as the
diagnostic list and function elements, can be
displayed and referenced in the visualisation
project PASvisu. PVIS OPC Configurator is used
as a communication interface between the
base unit PNOZmulti and the visualisation via
Siemens: A new software version 5.1 for the PASvisu.
high-end Simotion motion control system
includes a facility for simulating user programs. SG gateways
With the Simosim simulation integrated
TPCast: With the TPCAST wireless adapter, into the engineering, users can now test their
European consumers can experience wireless software without connecting any hardware.
virtual reality. The TPCast wireless adapter is Program parts are optimized at an early stage
new in the field of VR, solving one of the biggest of the development phase, which shortens
physical obstacles which is the cumbersome commissioning times later on. The functions of
wiring between the PC and the headset. the object-oriented programming (OOP) have
TPCast is a small device that attaches to the been expanded in software version 5.1 to make
top of the Vive headset and completely replaces the creation of software more flexible. The new,
the need for any cables. With the adapter, highly modular Simotion software simplifies the
users can experience VR much easier and more implementation of motion control applications
effortlessly. The adapter works even if you move ahead of machine commissioning – in favor of a
your head, without any delay or synchronization shorter time-to-market.
issues with the headset. Simosim for simulation in the engineering HMS Industrial Networks: New SG-gateways
enables online accesses and test functions enable data exchange between infrastructure
Modular micro server designs to be executed just as if a real controller was and energy networks based on IEC61850
connected. In addition to the debugging or IEC60870-5-104, and common fieldbus
capabilities, such as the status program, and industrial Ethernet systems. While
breakpoints and traces, and including the communication between devices and systems
complete web and OPC UA server functionality, is typically done with fieldbus and industrial
even axes can be simulated. Ethernet, modern energy networks are based
upon other protocol standards such as IEC61850
Safety circuit configurator and IEC60870-5-104.
Pilz: Safety circuits are easy to create on The gateways address the need for data
a PC using the PNOZmulti configurator. exchange between these two worlds, offering
The configuration tool supports project protocol coverage and easy integration.
design, configuration, documentation and They focus on applications requiring popular
commissioning of Pilz control systems. industrial, building and metering standards
Congatec: The new COM Express Type 7 quick A graphics-based user interface conforms to such as Modbus RTU (master/slave), Modbus-TCP
starter set can serve as the fundamental basis the Windows standard; all elements are available (client/server), PROFIBUS, PROFINET, EtherNet/
for an OEM’s modular micro server designs. for safety circuit as icons or in selection menus. IP, M-Bus, along with digital I/O.

1 0. 2017 i n d u str i a l e th e r n e t b o o k 49
 Wearable technology:
Private Ethernet

Wear do we go from here?

The development of body-borne computers has taken several steps of miniaturization from discrete
electronics to fully integrated designs. While technology progressed pretty steadily, the market acceptance
has seen many ups and downs. Where does wearable technology stand today and where will it go?

STEVE MANN, A PROFESSOR AT THE University had progressed far enough to think about ing,body-borne technology shot to the top of
of Toronto, is generally hailed as the father of wearable computers as more than mere calcu- the agenda. However, the fickle nature of hype
the wearable computer. In 1992 he founded lators. In July 1996, the US Defense Advanced began to show, and Google stopped selling the
the MIT Media Lab’s Wearable Computing Research Projects Agency (DARPA) hosted glass only two years later.
project. the “Wearables in 2005” workshop, bringing That was just around the time when key
together industrial, university, and military societal megatrends (e.g. health-conscious
Early technology visionaries. lifestyles) and evolving form factors enabled
However, wearable computers have been DARPA’s predictions included computer- yet another comeback of wearable technology.
around much longer than that, and even back ised gloves, flower brooches which react to This was largely driven by fitness trackers like
then the Chinese were at the forefront of emotions and body mounted cameras. But just the Fitbit, which shipped 22.5 million devices
technology. The Cheng Dawei Abacus Museum around that time mobile phones became the in 2016.
in Huangshan City shows a ‘Zhusuan’ from the consumer gadget of choice, and wearables took And the market is still changing. Ramon
Qing Dynasty era in the 17th century. a back seat. Llamas, research manager for IDC’s Wearables
team, says: “Wearables are morphing into
Wearable hype multi-purpose devices, fusing together
The book ‘The History of Wearable Technology’ multiple health and fitness capabilities and
PICTURE: CHINACULTURE.ORG

claims that “wearable computing really took smartphone notifications”. This is indicated by
off in 2011 when Google developed the Google the fact that Apple Watch has captured a 16
Glass”. Fueled by global interest and fund- percent share of the entire wearable market.

Win a Fitbit activity tracker Under your skin

Adventurous tech companies are already taking
The ring features a 1.2 centimeter-long, the concept of wearables to the next level, or
abacus that is a fully functional counting rather one level deeper. Instead of wearing
tool. Fingertips are too big for it, but using a the electronics on your skin, they propose to
small pin, the beads can be moved easily and implant it under your skin.
smoothly along the silver rods.
After this, it took around 300 years before a
wearable calculator became again popular. By The Fitbit flex2 not only tracks your steps,
1975 the required electronics had shrunk so distance, calories burned, active minutes,
much that it could be put into a watch casing. but also how long and how well you sleep.
The first such calculator watch was the Pulsar, For a chance to win one, enter our contest

PICTURE: LUCAS CRANACH

made by Time Computer Inc., of Lancaster, PA. at:
www.iebmedia.com/quiz
The winner will be announced November 6.

NFC chips are encased in a biocompatible

glass and injected into the body, usually
between the thumb and index finger. Typical
NFC chips are readable up to 10 centimeters,
have a memory of 888 bytes, and can be over-
written 100,000 times. To find out whether
The watch featured a six digit, red LED this is a useful body modification, Dutch
display. Due to the high power consumption journalist Rene Schoemaker had one implanted
of the LED display, it needed four 5V button Contest sponsored by: in September 2014.
cells to operate. CC-Link Partner Association So far, that’s the last thing we heard from him.
While the ‘Pulsar’ was marketed as a luxury G2A.CCLinkAmerica.org
toy, 20 years later electronics integration CC-Link-G2A.com Leopold Ploner

50 in d u s t r ial et h er ne t b o o k 05.2017

IEB102_p50.indd 50 13.09.1737 11:07

 Is Your Industrial Ethernet Network
Absolutely Secure?

Consider CC-Link IE Field

as your open network solution.

GIGABIT INDUSTRIAL ETHERNET

Enabling seamless data communication from the
plant-level enterprise network to the production floor network

15th
CC-Link Partner Association – Americas
Tel: (847) 478-2423 or (847) 478-2647
®

email: [email protected] I www.CCLinkAmerica.org

IEB102_p51.indd 51 09.09.1736 16:24

 netIOT Edge:
Merging OT and IT in the Real World

netIOT Edge Gateways Merge Production

Operations with IT and Cloud Applications
: Connects operational IoT data to IT and cloud services
for asset management, business analytics, predictive
maintenance, and more
: Collects data as a slave on the I/O network or polls
data from the controller as a master
: Runs parallel TCP/IP and IoT channels over real-time
Ethernet, OPC UA and MQTT
: Ideal for “brownfield” and “greenfield” applications
: Can function in promiscuous mode, with an air Learn more from Hilscher:
gap for secure physical isolation call 1.630.505.5301,
: Integrated tools to support vertical communication email: [email protected] or
to the cloud visit www.hilscher.com,
www.netIOT.com
: Multi-cloud support: IBM Bluemix and Watson;
SAP Cloud Platform; Microsoft Azure, and more

©2017 Hilscher North America, Inc. All trademarks are the properties of their respective companies.

IEB102_p52.indd 52 09.09.1736 16:26