Industrial Ethernet Network

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Why Ethernet
for Industrial Automation?
⚫ International standard  market dominance → Low cost → Ease
of equipment and accessories availability
⚫ High performance on different speeds: 10, 100, 1000 Mbps and
faster with auto adjustable speed and packet buffering
⚫ IP is a routable protocol connects to LAN and WAN: Connects to
subsystems for APC (Advanced Process Control), Critical
Control, ease of integration for business functions like Online
PIMS (Plant Information Management System), Remote
Monitoring and Control, ERP (Enterprise Resource Planning).
⚫ Continuous development
⚫ Multi-protocol carrier
⚫ Can use different physical media: Fiber optics, IP Radio, etc.
⚫ But needs standard application layer to be interoperable

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Is Industrial Ethernet different than
standard Ethernet?
⚫ It is the same Ethernet that works based on CD/CSMA
⚫ Ethernet is initially designed for IT network that is not
time critical
⚫ Industrial applications are very time critical → PCN
(Plant Control Network) must be ‘deterministic’
network
⚫ Harsh industrial environment (extreme temperatures,
high humidity, high vibrations, dust and corrosive
gases, etc.) requires high ratings of equipments
including network accessories
⚫ Extra precautions of disturbance, DOS (Denial-Of-
Service) attacks, hacking of the network, or
unawareness of risk in Industrial applications
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Can we make Ethernet
‘deterministic’ / ‘real-time’?
⚫ Dedicated Control Network
⚫ Avoid collisions by Industrial Switches
⚫ Industrial Protocol
⚫ UDP Real-time Secret
⚫ Deterministic Software

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Dedicated Control Network
⚫ Utilize Dedicated PCN (Plant Control
Network) LAN that is isolated from IT and
other Network by means of Router and
Firewall
⚫ Limit the number of IP Nodes → make
multiple LAN segments when there are to Control Network
many IP Nodes
⚫ Generally, limiting network traffic for
industrial control only. This lightly loaded
PCN will give you real-time performance
because it is free and often unpredictable
traffic on the plant-wide network
⚫ PCN shall only carry small I/O packets and is
therefore lightly loaded. By only using
fraction of network bandwidth we are
assured that data will always arrive quickly FF-H1
⚫ Full-Duplex network ports simply doubling
the throughput bandwidth

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Avoid ‘collisions’ by Industrial Switch
⚫ Hub:
⚫ Simply broadcast each message to all ports. When there is more than one
Node (Device) communicating there will be ‘collision’ and data have to be re-
transmitted randomly → only One transmission at a time. Other Nodes have
to wait until ongoing communication is completed. Though wiring looks to be
in Star topology, but communication still work like in Bus topology
⚫ Switch:
⚫ Will connect Sender port to Recipient port (can be multiple if Publisher –
Subscriber relationship protocol being used).
⚫ Ethernet Switch can make multiple connections at a time (depending on the
Switch throughput bandwidth) just like the way DPBX works
⚫ Use of Industrial Switch that can do fast switching such as ‘cut-through’ or
slower ‘store and forward’ technique with large message buffers will certainly
improve the speed of transmission
⚫ Utilizing Industrial Switch avoid ‘collision’, because the networks is not shared
and therefore multiple communications are possible, i.e. one communication
does not collide with another; Message queue management and performing
automatic speed changes on the appropriate ports.
⚫ Industrial Switch has better rating to be able to work in industrial environment
(extreme temperatures, high humidity, high vibration and shocks, etc.)

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Industrial Protocol
Types of Communication

⚫ Client-Server (Master-Slave)
⚫ Report Distribution (Source-Sink)
⚫ Publisher-Subscriber

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Client-Server (Master-Slave)
Relationship
⚫ A Client polls the Server
which responds to the
request
⚫ Point-to-Point
communication
⚫ Also used by Profibus,
HART and Modbus
⚫ Central control on
Master-Slave: only one
Master on a single
network; Multiple
(limited) concurrent
Client on Client-Server
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Report Distribution / Report by Exception
Source-Sink Relationship

⚫ Source sends out a message to one or more

Receivers (Sinks) acting as temporary Master
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Publisher-Subscriber Relationship

⚫ A Publisher sends a
message to one or more
Receivers (Subscriber).
⚫ Highly efficient as one
communication reaches
several destinations.
⚫ Data reaches all
subscribers at the same
time, enabling
synchronized action,
eliminating jitter.
⚫ Used to link function
blocks over the Fieldbus
(FF-H1 & FF-HSE)
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Industrial Protocol
What is TCP/IP?
⚫ TCP/IP
⚫ IP = Internet Protocol
⚫ TCP = Transmission Control Protocol
⚫ Defines how message is sent → Guarantees message delivery
⚫ It takes large messages that have to be broken up for transmission
and reassembles at the receiving end (even if packets arrive out of
order)
⚫ Smart enough to reduce traffic if network is getting busy (delay
transmission)
⚫ Handles the entire delivery process in reliable manner
⚫ Unfortunately, its priority is simplicity for the user and reliability, but
not timelines of the delivery
⚫ TCP/IP is great, but it was not designed for real-time
systems
⚫ TCP/IP is still widely used in most Industrial Systems that
do not require milisecond response
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Industrial Protocol
UDP Real-time Secret
⚫ UDP = User Datagram Protocol
⚫ UDP is the actual data packet of TCP delivery system; TCP manage
the delivery of UDP packets; Each UDP packet have an IP Address
and travel on the same network and have the same inner content as
TCP messages  UDP is the heart of TCP messages
⚫ When we use UDP messaging directly, we have control when to
send each packet. Since operating variables (PV, SP, MV, Status,
Tag, etc) are basically short messages, TCP capabilities of
reassembling large messages is not required. Even if there is a large
amount of data to move, the OPC Server can break it up to
manageable pieces as it does for every other communication media
⚫ UDP packets do not carry the overhead of TCP stack (memory
usage and firmware complexity); UDP do not require explicit
sessions to be established between sending and receiving station
and they do not have long timeouts associated with TCP sessions
and delivery mechanism
⚫ Industrial Switch will respond to UDP in a much faster manner
making up a real-time network
⚫ FF-HSE uses UDP/IP for time critical operating variables and TCP/IP
for other non-time-criticalhttps://automationforum.co/
parameters
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Deterministic Software
⚫ Fastest network in the world won’t give deterministic performance
unless the application software that is sending messages is
structured for real-time results. Most HMI and similar industrial
application software use deterministic I/O polling and utilize real-
time task scheduling techniques
⚫ Basic schemes used by I/O Drivers, DDE Servers, OPC Servers
in industrial software is to poll I/O in a deterministic fixed
sequence to ensure repeatable and ‘deterministic’ results. This
fixed polling guarantees that collisions will not occur is we use
‘deterministic control network’
⚫ Depending on the communication type being used, i.e. Client-
Server (Master-Slave), Report Distribution / Report by Exception /
Source-Sink or Publisher-Subscriber, determinism varies (the
latter the more deterministic / real-time)

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Network Security

In Industrial Ethernet application

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System Administration Authority
◼ It is known that IT Engineers are more
competent about computers and network; Administered
I&C Engineers are not as expert as IT Workstation By IT
Engineers about computers and networks
Workstation
Workstation
Enterprise Intranet / WAN

➔ tendency that IT Department will take Workstation

over PCS system administration Workstation Workstation

◼ However, IT Engineers have limited LINE OF ADMINISTRATION AUTHORITY

expertise about PCS ➔ mistakes will be

Router/Firewall

very dangerous for the Plant

◼ Administration Rights have to be divided OWS EWS
Supervisory
Control
PIMS
Server
OPAM
Server
Industrial

into different areas:

P ort al
Adm inistered
PCN
By I&C
◼ IT Department shall administer from Router
WAN leg to the entire IT WAN
◼ I&C Department shall administer from Router PCS SIS FGDS Other
Subsystems

PCN leg to the entire Plant Control System

◼ Administration Rights exchange shall be
coordinated between the administration areas
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to make entire system to work as designed
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High Availability
Fault Tolerant
In Industrial Ethernet applications

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Dual Network set
⚫ Device and Workstations
Switch with Dual NIC
failures can
also be
tolerated
Primary Switch Secondary Switch

Redundant Redundant
single port dual port
Linking device Single Linking device
dual port
Linking device

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Loop / Ring Topology
⚫ Ring-topology fault-tolerant
⚫ Proprietary hubs/switches
⚫ Standard wire or fiber
⚫ Hirschmann Rail-family
⚫ Works with and Ethernet device and
Hub
protocol
⚫ Hub works as “splitter”
⚫ Much faster than “spanning tree”
⚫ One wire failure can be tolerated
⚫ Hub failure cannot be tolerated

Hub Hub

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Combo / Redundant-Ring
⚫ Media duplication and complete redundancy in one.

Primary Secondary

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Thank You
Industrial Ethernet Network

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