Industrial communication systems

The Industrial Electronics Handbook

S E c o n d E d I T I o n

IndustrIal

communIcatIon systems

© 2011 by Taylor and Francis Group, LLC

The Industrial Electronics Handbook

S E c o n d E d I T I o n

Fundamentals oF IndustrIal electronIcs

Power electronIcs and motor drIves

control and mechatronIcs

IndustrIal communIcatIon systems

IntellIgent systems

© 2011 by Taylor and Francis Group, LLC

The Electrical Engineering Handbook Series

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© 2011 by Taylor and Francis Group, LLC

The Industrial Electronics Handbook

S E c o n d E d I T I o n

IndustrIal

communIcatIon systems

Edited by

Bogdan M. Wilamowski

J. david Irwin

© 2011 by Taylor and Francis Group, LLC

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Industrial communication systems / editors, Bogdan M. Wilamowski and J. David Irwin.

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ISBN 978-1-4398-0281-6 (alk. paper)

1. Computer networks. 2. Data transmission systems. 3. Telecommunication systems. I.

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vii

Contents

Preface..................................................................................................................... xiii

Preambles...................................................................................................................xv

Acknowledgments................................................................................................. xxiii

Editorial Board........................................................................................................ xxv

Editors....................................................................................................................xxvii

Contributors ����������������������������������尓������������������������������������尓������������������������������������尓 xxxi

Part Iâ•…Technical Principles

1 ISO/OSI Model.................................................................................................1-1

Gerhard Zucker and Dietmar Dietrich

2 Media............................................................................................................... 2-1

Herbert Schweinzer, Saleem Farooq Shaukat, and Holger Arthaber

3 Media Access Methods.................................................................................... 3-1

Herbert Haas and Manfred Lindner

4 Routing in Wireless Networks........................................................................ 4-1

Teresa Albero-Albero and Víctor-M. Sempere-Payá

5 Profiles and Interoperability.......................................................................... 5-1

Gerhard Zucker and Heinz Frank

6 Industrial Wireless Sensor Networks............................................................. 6-1

Vehbi Cagri Gungor and Gerhard P. Hancke

7 Ad Hoc Networks.............................................................................................7-1

Sajjad Ahmad Madani, Shahid Khattak, Tariq Jadoon, and Shahzad Sarwar

8 Radio Frequency Identification...................................................................... 8-1

Edward Kai-Ning Yung, Pui-Yi Lau, and Chi-Wai Leung

9 RFID Technology and Its Industrial Applications......................................... 9-1

Vidyasagar Potdar, Atif Sharif, and Elizabeth Chang

10 Ultralow-Power Wireless Communication...................................................10-1

Joern Ploennigs, Volodymyr Vasyutynskyy, and Klaus Kabitzsch

© 2011 by Taylor and Francis Group, LLC

viii Contents

11 Industrial Strength Wireless Multimedia Sensor Network Technology...... 11-1

Vidyasagar Potdar, Atif Sharif, and Elizabeth Chang

12 A Survey of Wireless Sensor Networks for Industrial Applications............12-1

Stig Petersen and Simon Carlsen

13 Vertical Integration........................................................................................13-1

Thilo Sauter, Stefan Soucek, and Martin Wollschlaeger

14 Multimedia Service Convergence..................................................................14-1

Alex Talevski

15 Virtual Automation Networks.......................................................................15-1

Peter Neumann and Ralf Messerschmidt

16 Industrial Agent Technology.........................................................................16-1

Aleksey Bratukhin, Yoseba Peña Landaburu, Paulo Leitão, and Rainer Unland

17 Real-Time Systems.......................................................................................... 17-1

Lucia Lo Bello, José Alberto Fonseca, and Wilfried Elmenreich

18 Clock Synchronization in Distributed Systems............................................18-1

Georg Gaderer and Patrick Loschmidt

19 Quality of Service...........................................................................................19-1

Gabriel Diaz Orueta, Elio San Cristobal Ruiz, Nuria Oliva Alonso,

and Manuel Castro Gil

20 Network-Based Control..................................................................................20-1

Josep M. Fuertes, Mo-Yuen Chow, Ricard Villà, Rachana Gupta, and Jordi Ayza

21 Functional Safety........................................................................................... 21-1

Thomas Novak and Andreas Gerstinger

22 Security in Industrial Communication Systems...........................................22-1

Wolfgang Granzer and Albert Treytl

23 Secure Communication Using Chaos Synchronization................................23-1

Yan-Wu Wang and Changyun Wen

Part IIâ•…Application-Specific Areas

24 Embedded Networks in Civilian Aircraft Avionics Systems........................24-1

Christian Fraboul, Fabrice Frances, and Jean-Luc Scharbarg

25 Process Automation.......................................................................................25-1

Alois Zoitl and Wilfried Lepuschitz

26 Building and Home Automation...................................................................26-1

Wolfgang Kastner, Stefan Soucek, Christian Reinisch, and Alexander Klapproth

27 Industrial Multimedia.................................................................................... 27-1

Javier Silvestre-Blanes, Manfred Weihs, and Víctor-M. Sempere-Payá

© 2011 by Taylor and Francis Group, LLC

Contents ix

28 Industrial Wireless Communications Security (IWCS)/C42........................28-1

Milos Manic and Kurt Derr

29 Protocols in Power Generation......................................................................29-1

Tuan Dang and Gaëlle Marsal

30 Communications in Medical Applications....................................................30-1

Paulo Bartolomeu, José Alberto Fonseca, Nelson Rocha, and Filipe Basto

Part IIIâ•…Technologies

31 Controller Area Network............................................................................... 31-1

Joaquim Ferreira and José Alberto Fonseca

32 Profibus..........................................................................................................32-1

Max Felser and Ron Mitchell

33 INTERBUS.....................................................................................................33-1

Juergen Jasperneite and Orazio Mirabella

34 WorldFip.........................................................................................................34-1

Francisco Vasques and Orazio Mirabella

35 Foundation Fieldbus.......................................................................................35-1

Carlos Eduardo Pereira, Augusto Pereira, and Ian Verhappen

36 Modbus...........................................................................................................36-1

Mário de Sousa and Paulo Portugal

37 Industrial Ethernet......................................................................................... 37-1

Gaëlle Marsal and Denis Trognon

38 EtherCAT........................................................................................................38-1

Gianluca Cena, Adriano Valenzano, and Claudio Zunino

39 Ethernet POWERLINK..................................................................................39-1

Paulo Pedreiras, Stefan Schoenegger, Lucia Seno, and Stefano Vitturi

40 PROFINET......................................................................................................40-1

Max Felser, Paolo Ferrari, and Alessandra Flammini

41 LonWorks........................................................................................................ 41-1

Uwe Ryssel, Henrik Dibowski, Heinz Frank, and Klaus Kabitzsch

42 KNX................................................................................................................42-1

Wolfgang Kastner, Fritz Praus, Georg Neugschwandtner, and Wolfgang Granzer

43 Protocols of the Time-Triggered Architecture: TTP, TTEthernet, TTP/A................43-1

Wilfried Elmenreich and Christian El-Salloum

44 FlexRay...........................................................................................................44-1

Martin Horauer and Peter Rössler

45 LIN-Bus..........................................................................................................45-1

Andreas Grzemba, Donal Heffernan, and Thomas Lindner

© 2011 by Taylor and Francis Group, LLC

x Contents

46 Profisafe..........................................................................................................46-1

Ron Mitchell, Max Felser, and Paulo Portugal

47 SafetyLon........................................................................................................ 47-1

Thomas Novak, Thomas Tamandl, and Peter Preininger

48 Wireless Local Area Networks.......................................................................48-1

Henning Trsek, Juergen Jasperneite, Lucia Lo Bello, and Milos Manic

49 Bluetooth........................................................................................................49-1

Stefan Mahlknecht, Milos Manic, and Sajjad Ahmad Madani

50 ZigBee.............................................................................................................50-1

Stefan Mahlknecht, Tuan Dang, Milos Manic, and Sajjad Ahmad Madani

51 6LoWPAN: IP for Wireless Sensor Networks and Smart

Cooperating Objects...................................................................................... 51-1

Guido Moritz and Frank Golatowski

52 WiMAX in Industry.......................................................................................52-1

Milos Manic, Sergiu-Dan Stan, and Strahinja Stankovic

53 WirelessHART, ISA100.11a, and OCARI......................................................53-1

Tuan Dang and Emiliano Sisinni

54 Wireless Communication Standards.............................................................54-1

Tuan Dang

55 Communication Aspects of IEC 61499 Architecture....................................55-1

Valeriy Vyatkin, Mário de Sousa, and Alois Zoitl

56 Industrial Internet..........................................................................................56-1

Martin Wollschlaeger and Thilo Sauter

57 OPC UA.......................................................................................................... 57-1

Tuan Dang and Renaud Aubin

58 DNP3 and IEC 60870-5..................................................................................58-1

Andrew C. West

59 IEC 61850 for Distributed Energy Resources................................................59-1

Sidonia Mesentean, Heinz Frank, and Karlheinz Schwarz

Part IV Internet Programming

60 User Datagram Protocol—UDP.....................................................................60-1

Aleksander Malinowski and Bogdan M. Wilamowski

61 Transmission Control Protocol—TCP........................................................... 61-1

Aleksander Malinowski and Bogdan M. Wilamowski

62 Development of Interactive Web Pages.........................................................62-1

Pradeep Dandamudi

63 Interactive Web Site Design Using Python Script........................................63-1

Hao Yu and Michael Carroll

© 2011 by Taylor and Francis Group, LLC

Contents xi

64 Running Software over Internet....................................................................64-1

Nam Pham, Bogdan M. Wilamowski, and Aleksander Malinowski

65 Semantic Web Services for Manufacturing Industry....................................65-1

Chen Wu and Tharam S. Dillon

66 Automatic Data Mining on Internet by Using PERL Scripting Language........ 66-1

Nam Pham and Bogdan M. Wilamowski

Part V Outlook

67 Trends and Challenges for Industrial Communication Systems.................. 67-1

Peter Palensky

68 Processing Data in Complex Communication Systems................................68-1

Gerhard Zucker, Dietmar Bruckner, and Dietmar Dietrich

Index..................................................................................................................Index-1

© 2011 by Taylor and Francis Group, LLC

xiii

Preface

The field of industrial electronics covers a plethora of problemsthat must be solved in industrial  practice.

Electronic systems control many processes that begin with the control of relatively simple devices like

electric motors, through more complicated devices such as robots, to the control of entire fabrication

processes. An industrial electronics engineer deals with many physical phenomena as well as the sen￾sors that are used to measure them. Thus, the knowledge required by this type of engineer is not only

traditional electronics but also specialized electronics, for example, that required for high-power appli￾cations. The importance of electronic circuits extends well beyond their use as a final product in that

they are also important building blocks in large systems, and thus, the industrial electronics engineer

must also possess a knowledge of the areas of control and mechatronics. Since most fabrication pro￾cesses are relatively complex, there is an inherent requirement for the use of communication systems

that not only link the various elements of the industrial process but are also tailor-made for the specific

industrial environment. Finally, the efficient control and supervision of factories requires the applica￾tion of intelligent systems in a hierarchical structure to address the needs of all components employed in

the production process. This need is accomplished through the use of intelligent systems such as neural

networks, fuzzy systems, and evolutionary methods. The Industrial Electronics Handbook addresses all

these issues and does so in five books outlined as follows:

1. Fundamentals of Industrial Electronics

2. Power Electronics and Motor Drives

3. Control and Mechatronics

4. Industrial Communication Systems

5. Intelligent Systems

The editors have gone to great lengths to ensure that this handbook is as current and up to date as

possible. Thus, this book closely follows the current research and trends in applications that can be

found in IEEE Transactions on Industrial Electronics. This journal is not only one of the largest engineer￾ing publications of its type in the world but also one of the most respected. In all technical categories in

which this journal is evaluated, it is ranked either number 1 or number 2 in the world. As a result, we

believe that this handbook, which is written by the world’s leading researchers in the field, presents the

global trends in the ubiquitous area commonly known as industrial electronics.

Clearly, the successful operation of any production process is dependent on a well-designed and

reliable communication system. Modern communication systems that are employed within a factory

use a variety of means for sending and receiving information. With time, these systems have become

more and more sophisticated. This book is the most voluminous of the five that comprise the Industrial

Electronics Handbook, and spans the full gamut of topics that are needed for engineers working with

industrial communication systems. A description of the numerous topics covered in this book is out￾lined in the Preambles, and the readers are directed to the relevant parts for further details.

© 2011 by Taylor and Francis Group, LLC

xv

Preambles

Dietmar Dietrich, Dietmar Bruckner, Gerhard Zucker, and Peter Palensky

Institute of Computer Technology

Vienna University of Technology

Vienna, Austria

Process control requires control units and while in the past these were stand-alone elements, they have

now become more and more interconnected. Today, we have networks on multiple layers; for example,

we have networks of processes with their attendant control units as well as networks of process compo￾nents. These communication systems have different requirements, not only on different layers but also

in vastly different areas of automation. It is fascinating to see that automation permeates essentially

every area of our lives. As a result, we are today able to reach any electrical component, wherever it

may be.

This book provides an overview of the many facets of communication that are relevant to industrial

systems. Part I deals with the technical principles that are necessary for communication, including both

wired and wireless communication, the integration of diverse systems, and quality of service aspects.

Part II focuses on the application of communication systems to different domains such as process and

building automation, energy distribution, and medical applications.

Part III describes what appear to be the most important communication technologies. Although

the list is not exhaustive, it does address the most important areas, including wireless communication,

fieldbus systems, and the industrial Ethernet and industrial Internet for building automation and auto￾motive applications. Part IV covers topics related to general integration of Internet technologies into

industrial automation. Finally, Part V peers into the future in an attempt to describe possible upcoming

developments.

Preamble to Part I:╇Technical Principles

Friederich Kupzog

Institute of Computer Technology

Vienna University of Technology

Vienna, Austria

Jürgen Jasperneite

Institute Industrial IT

Lemgo, Germany

© 2011 by Taylor and Francis Group, LLC

xvi Preambles

Thilo Sauter

Institute for Integrated Sensor Systems

Austrian Academy of Sciences

Wiener Neustadt, Austria

Communication is a prerequisite for distributed systems. Such systems can be loosely defined as a group

of individual computer systems that appear to the user as a single coherent system. The spatially dis￾persed nature of industrial processes, on the scale of a factory floor or electric power grid, is actually

often used as a guide forthe design and layout of automation systems. This can be observed, for example,

in network-based control, where the control loop can actually be distributed over different processors

in a network. In this environment, the basic principles of distributed systems apply. However, while the

classic theory of distributed systems has been developed keeping mainly general-purpose computer

systems in mind, industrial automation focuses on dedicated systems with highly specialized hardware

and software.

Therefore, in what follows, the relevant aspects of distributed systems are revisited from the

viewpoint of industrial communication systems. It begins with a discussion of the classic ISO/

OSI model. Although the basic principle of communication layering is very significant for com￾munication in automation processes, not all layers defined in the reference model are of equal

importance.

Furthermore, special attention is given to three different aspects: wireless, integration, and quality of

service. Wireless communication today has a fixed place in many of the application areas of automation.

Wireless-related topics such as wireless sensor networks, low-power wireless communication nodes,

and RFID are discussed in detail. The integration of heterogeneous systems into a coherent applica￾tion environment is another crucial issue that is addressed. Finally, quality of service is revisited for

industrial communication systems, ranging from real-time communication for safety and security to

network-based control.

Group 1.1: Layers

Thilo Sauter

Institute for Integrated Sensor Systems

Austrian Academy of Sciences

Wiener Neustadt, Austria

The design of complex communication systemsis not possible without a structured approach. Therefore,

a layered structure is commonly adopted. A landmark for communication system development was the

definition of the open system interconnection (OSI) model, a generic framework that is presented in

the first chapter of this group (Chapters 1 through 3). Within this model, it is primarily the lower lay￾ers that are important for industrial communications in order to guarantee the performance needed

for a given application domain. Special attention will therefore be given to the large variety of wired

electrical, optical, and wireless communication media, as well as the many methods devised for access

control. For larger networks that are gaining importance in distributed systems, flat network structures

are not adequate for electrical and logical reasons. Therefore, the information flow through the network

has to be controlled by appropriate routing strategies, which has been a topic of interest for researchers

and developers for a long time. Experience with the first industrial communication systems, however,

showed that the OSI model was insufficient to ensure the interoperability that was a major requirement

of industry. A substantial amount of work has been, and still is, devoted to the definition of high-level

profiles that, depending on device type or application domain, further constrain the degrees of freedom

for system developers and implementers.

© 2011 by Taylor and Francis Group, LLC

Preambles xvii

Group 1.2: Wireless

Jürgen Jasperneite

Institute Industrial IT

Lemgo, Germany

The integration of wireless technologies in industrial automation systems is the next step in the evolu￾tion of industrial networking. Wireless technologies have the potential to reduce the life-cycle costs of

machines and plants as well as support future adaptive production concepts, either as an extension to,

or as a replacement for, existing wired networks.

In addition to wireless networking, new applications can be enabled such as wireless monitoring

and control, or asset and personnel tracking. Most of the wireless technologies are standardized in the

IEEE802 family and are driven by consumer market requirements. As a result, they are not designed

to meet the automation-specific requirements such as low latencies or the demand for high service reli￾ability. As a consequence, the basic concepts must be reviewed and sometimes revised. Therefore, it is in

this group (Chapters 4 through 12) that the principles and architectures of wireless sensor networks are

presented. Furthermore, some key functions of wireless networks, such as self-configuration, routing,

energy efficiency, and data security are introduced.

Group 1.3: Integration

Thilo Sauter

Institute for Integrated Sensor Systems

Austrian Academy of Sciences

Wiener Neustadt, Austria

Industrial communication systems, and automation solutions in general, were initially developed

primarily as islands. In recent years, however, the integration of automation systems into a wider

scope has increased its importance and thus requires a technological basis. This group of chapters

(Chapters 13 through 18) is therefore focused on selected integration aspects. The first chapter deals

with vertical integration aimed at providing a transparent data exchange across all levels of the auto￾mation hierarchy, both from a networking and application point of view. A topic receiving increasing

attention is the integration of multimedia technologies in automation, which requires the conver￾gence of telecommunications and data services and poses new challenges for both network and appli￾cation design. The issue of complex heterogeneous networks comprised of wired and wireless as well

as automation and office domains is being addressed by the concept of virtual automation networks.

Finally, software agent technology will be discussed as one way of achieving integration in automa￾tion systems by means of distributing functionalities among a group of autonomous, loosely coupled

entities that may interact to accomplish a task that is difficult to solve in a centralized manner.

Group 1.4: Quality of Service

Friederich Kupzog

Institute of Computer Technology

Vienna University of Technology

Vienna, Austria

In many cases, special requirements have to be fulfilled in industrial communication systems. While

requirements differ to some extent from those in the consumer products domain, the basic principles

© 2011 by Taylor and Francis Group, LLC