The industrial communication technology handbook

THE

HANDBOOK

INDUSTRIAL

COMMUNICATION

TECHNOLOGY

© 2005 by CRC Press

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© 2005 by CRC Press

THE

HANDBOOK

INDUSTRIAL

COMMUNICATION

TECHNOLOGY

Edited by

RICHARD ZURAWSKI

© 2005 by CRC Press

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The industrial communication technology handbook / Richard Zurawski, editor.

p. cm. — (The industrial information technology series ; 1)

Includes bibliographical references and index.

ISBN 0-8493-3077-7 (alk. paper)

1. Computer networks. 2. Data transmission systems. 3. Wireless communication

systems. I. Zurawski, Richard. II. Series.

TK5105.5.I48 2005

670'.285'46—dc22 2004057922

© 2005 by CRC Press

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v

Foreword

A handbook on industrial communication technology! What a challenge! When we know the complexity

of industrial applications, the number of possible solutions, the number of standards, the variety of

applications, of contexts, and of products!

The challenge can be expressed with just a few words: applications diversity, need for networking,

integration of functions, and technologies.

Applications diversity: The applications concerned with industrial communications are known under

the following terms: process control, manufacturing and flexible systems, building automation, transport

management, utilities, and embedded systems, in trains, aircraft, cars, etc. All these applications need

similar services, but in very different environments and also with very different qualities of service.

Need for networking: The need for networking is not new. Since the MAP and TOP projects, in the

field of automation, it is clear that the future of automation is really in distributed systems supported

by distributed (heterogeneous) communication systems. The sharing of information, the necessity of

interoperability, and the necessity of abstraction levels are just some of the reasons why industrial

communication has always been considered a major challenge.

Integration: In all the domains, integration is a key word meaning that all the functions in an enterprise

need to be interconnected, in real time, as much as possible. This is only feasible through the use of

robust communication systems, real-time features, and coherent design of the applications. With the

development of ubiquitous computing and ambient intelligence, industrial communication applications

will become the next challenge.

Technologies: Numerous technologies are available for use at different levels of control and command

and in all the services provided by a company; in addition, they exist for maintenance, supervision and

monitoring, diagnosis, spare parts management, and so on. Specific solutions are frequently dictated by

specific problems. The importance of standards cannot be overemphasized.

Wireless systems, fieldbuses and cell or plant networks, building automation, device buses and appli￾cations, embedded systems, Internet technologies and related applications, security and safety, MAC

protocols, and representative application domains are just some of the topics treated in this handbook.

Methodology considerations for choosing and developing systems are also presented.

This handbook will become the major reference source for this domain. Setting aside some techno￾logical details, the methods and principles presented will be relevant for years to come. Putting together

such a book would not be possible without the cooperation of a great number of authors, all specialists

in their fields and involved in the development of communication systems and applications, as well as

members of the International Advisory Board. The Industrial Communication Technology Handbook is a

must for industrial communication professionals.

Jean-Pierre Thomesse

Institute National Polytechnique de Lorraine

Nancy, France

© 2005 by CRC Press

vi

International Advisory Board

Jean-Pierre Thomesse, LORIA-INPL, France, Chair

Salvatore Cavalieri, University of Catania, Italy

Dietmar Dietrich, Vienna University of Technology, Austria

Jean-Dominique Decotignie, CSEM, Switzerland

Josep M. Fuertes, Universitat Politecnico de Catalunia, Spain

Jürgen Jasperneite, Phoenix Contact, Germany

Chris Jenkins, Proces-Data, U.K.

Ed Koch, Akua Control, U.S.

Thilo Sauter, Austrian Academy of Sciences, Austria

Viktor Schiffer, Rockwell Automation, Germany

Wolfgang Stripf, Siemens AG, Germany

© 2005 by CRC Press

vii

Preface

Introduction

Aim

The purpose of The Industrial Communication Technology Handbook is to provide a reference useful for

a broad range of professionals and researchers from industry and academia interested in or involved in

the use of industrial communication technology and systems. This is the first publication to cover this

field in a cohesive and comprehensive way. The focus of this book is on existing technologies used by

the industry, and newly emerging technologies and trends, the evolution of which is driven by the actual

needs and by the industry-led consortia and organizations.

The book offers a mix of basics and advanced material, as well as overviews of recent significant

research and implementation/technology developments. The book is aimed at novices as well as experi￾enced professionals from industry and academia. It is also suitable for graduate students. The book covers

extensively the areas of fieldbus technology, industrial Ethernet and real-time extensions, wireless and

mobile technologies in industrial applications, linking the factory floor with the Internet and wireless

fieldbuses, industrial networks’ security and safety, automotive applications, industrial automation appli￾cations, building automation applications, energy systems applications, and others.

It is an indispensable companion for those who seek to learn more on industrial communication

technology and systems and for those who want to stay up to date with recent technical developments

in the field. It is also a rich source of material for any university or professional development course on

industrial networks and related technologies.

Contributors

The book contains 42 contributions, written by leading experts from industry and academia directly

involved in the creation and evolution of the ideas and technologies treated in the book.

Over half of the contributions are from industry and industrial research establishments at the forefront

of the developments shaping the field of industrial communication technology, for example, ABB, Bosch

Rexroth Corporation, CSEM, Decomsys, Frequentis, Phoenix Contact, PROCES-DATA, PSA Peugeot-Cit￾roen, PROFIBUS International, Rockwell Automation, SERCOS North America, Siemens, and Volcano. Most

of the mentioned contributors play a leading role in the formulation of long-term policies for technology

development and are key members of the industry–academe consortia implementing those policies.

The contributions from academia and governmental research organizations are represented by some

of the most renowned institutions, such as Cornell University, Fraunhofer, LORIA-INPL, National Insti￾tute of Standards (U.S.), Politecnico di Torino (Italy), Singapore Institute of Manufacturing Technology,

Technical University of Berlin, and Vienna University of Technology.

Format

The presented material is in the form of tutorials, surveys, and technology overviews, combining funda￾mentals with advanced issues, making this publication relevant to beginners as well as seasoned profes-

© 2005 by CRC Press

viii

sionals from industry and academia. Particular emphasis is on the industrial perspective, illustrated by

actual implementations and technology deployments. The contributions are grouped in sections for

cohesive and comprehensive presentation of the treated areas. The reports on recent technology devel￾opments, deployments, and trends frequently cover material released to the profession for the first time.

Audience

The handbook is designed to cover a wide range of topics that comprise the field of industrial commu￾nication technology and systems. The material covered in this volume will be of interest to a wide

spectrum of professionals and researchers from industry and academia, as well as graduate students,

from the fields of electrical and computer engineering, industrial and mechatronic engineering, mechan￾ical engineering, computer science, and information technology.

Organization

material to cover in a nutshell basics of data communication and IP networks. This material is intended

as a handy reference for those who may not be familiar with or wish to refresh their knowledge of some

is the main focus of the book and presents a comprehensive overview of the field of industrial commu￾nication technologies and systems. Some of topics presented in this part have received limited coverage

in other publications due to either the fast evolution of the technologies involved, material confidentiality,

or limited circulation in case of industry-driven developments.

it is intended as supplementary reading for those who would like to refresh and update their knowledge

without resorting to voluminous publications. This background is essential to understand the material

The section on fieldbus technology provides a comprehensive overview of selected fieldbuses. The focus is

on the most widely used in industry and the most widely known. The presentation is not exhaustive, however.

One of the limiting factors was the availability of qualified authors to write authoritatively on the topics.

tion to the fieldbus technology, comparison and critical evaluation of the existing technologies, and the

evolution and emerging trends. This chapter is a must for anyone with an interest in the origins of the

current fieldbus technology landscape. It is also compulsory reading for novices to understand the

concepts behind fieldbuses.

the fieldbus technology. WorldFIP is one of the first fieldbuses, developed in France at the beginning

© 2005 by CRC Press

ing,” “A Perspective on Internet Routing: IP Routing Protocols and Addressing Issues,” “Fundamentals

and “Internet Security.”

Layer Protocols for Data Communications in Industrial Communication Networks,” “IP Internetwork￾in Quality of Service and Real-Time Transmission,” “Survey of Network Management Frameworks,”

This section begins with “Fieldbus Systems: History and Evolution,” presenting an extensive introduc￾The “The WorldFIP Fieldbus” chapter was written by Jean-Pierre Thomesse, one of the pioneers of

The book is organized into two parts. Part 1, Basics of Data Communication and IP Networks, presents

of the concepts used extensively in Part 2. Part 2, Industrial Communication Technology and Systems,

presented in the chapters in Part 2. This part includes the following chapters: “Principles of Lower￾Part 1 includes six chapters that present in a concise way the vast area of IP networks. As mentioned,

Part 2 includes five major sections: Field Area and Control Networks, Ethernet and Wireless Network

Field Area and Control Networks

Technologies, Linking Factory Floor with the Internet and Wireless Fieldbuses, Security and Safety

Technologies in Industrial Networks, and Applications of Networks and Other Technologies.

ix

of the 1980s and widely used nowadays, particularly in applications that require hard real-time con￾straints and high dependability. This is almost a “personal” record of a person involved in the develop￾ment of WorldFIP.

A brief record of the origins and evolution of the FOUNDATION Fieldbus (H1, H2, and HSE) and

system profiles, and integration technologies such as GSD (general station description), EDD (electronic

device description), and DTM (device type manager).

technology behind it, that has emerged as a result of the trend in automation technology toward modular,

reusable machines and plants with distributed intelligence. PROFInet is an open standard for industrial

automation based on the industrial Ethernet. The material is presented by researchers from the Automa￾concept and the driving force for the technology development. The TTP (Time-Triggered Protocol) and

TTA (Time-Triggered Architecture) had a profound impact on the development of safety-critical systems,

particularly in the automotive industry. This is one of the most authoritative presentations on this topic.

The time-triggered CAN (TTCAN) protocol was introduced by Bosch in 1999 with the aim of making

Protocol) -based networks: DeviceNet, a CIP implementation employing a CAN data link layer; ControlNet,

implementing the same basic protocol on new data link layers that allow for much higher speed (5 Mbps),

strict determinism, and repeatability while extending the range of the bus (several kilometers with repeat￾ers); and Ethernet/IP, in which CIP runs over TCP/IP. The chapter also introduces CIP Sync, which is a

CIP-based communication principle that enables synchronous low-jitter system reactions without the need

for low-jitter data transmission. This is important in applications that require much tighter control of a

number of real-time parameters characterizing hard real-time control systems. The chapter also overviews

CIP Safety, a safety protocol that adds additional services to transport data with high integrity.

was written by the chairman of the International P-NET User Organization and the technical director

of PROCES-DATA (U.K.) Ltd., which provides the real-time PC operating system for P-NET.

over 6 million nodes installed, and a broad base of device manufacturers. The chapter also briefly

introduces IP over INTERBUS and looks at data throughput for IP tunneling.

The IEEE 1394 FireWire, a high-performance serial bus, principles of its operation, and applications

and monitoring, and adding new devices to the network, to mention some activities) of fieldbus systems

© 2005 by CRC Press

its technical principles is presented in the chapter “FOUNDATION Fieldbus: History and Features.”

The description of PROFIBUS (PROFIBUS DP) is presented in “PROFIBUS: Open Solutions for the

in the fieldbus field, and it includes material on HART on PROFIBUS DP, application and master and

World of Automation.” This is a comprehensive overview of PROFIBUS DP, one of the leading players

The chapter “Principles and Features of PROFInet” presents a new automation concept, and the

Dependable time-triggered communication and architecture are presented in “Dependable Time￾tion and Drives Division of Siemens AG, the leading provider of automation solutions within Siemens AG.

Triggered Communication,” written by Hermann Kopetz et al. Hermann Kopetz is the inventor of the

CAN suitable for the new needs of the automotive industry. This technology is introduced in “Controller

protocol, including TTCAN.

Area Network: A Survey.” This chapter describes the main features of the Controller Area Network (CAN)

The chapter “The CIP Family of Fieldbus Protocols” introduces the following CIP (Common Industrial

The P-NET fieldbus is presented in the chapter “The Anatomy of the P-NET Fieldbus.” The chapter

The chapter “INTERBUS Means Speed, Connectivity, Safety” introduces INTERBUS, a fieldbus with

in the industrial environment are presented in “Data Transmission in Industrial Environments Using

The issues involved in the configuration (setting up a fieldbus system) and management (diagnosis

IEEE 1394 FireWire.”

x

plug-and-participate concept and its implementations in the industrial environment.

The section on fieldbus technology is concluded by an excellent chapter discussing the pros and cons

of selecting control networks for specific applications and application domains. The material in this

chapter is authored by Jean-Dominique Decotignie. It includes a great deal of practical recommendations

that can be useful for practicing professionals. It is the kind of material that cannot be easily found in

the professional literature.

Ethernet and Wireless Network Technologies

This section on Ethernet and wireless/mobile network technologies contains four chapters discussing the

use of Ethernet and its variants in industrial automation, as well as selected issues related to wireless

technologies. Ethernet is fast becoming a de facto industry standard for communication in factories and

plants at the fieldbus level. The random and native CSMA/CD (carrier-sense multiple access with collision

detection) arbitration mechanism is being replaced by other solutions allowing for deterministic behavior

required in real-time communication to support soft and hard real-time deadlines. The idea of using

wireless technology on the factory floor is appealing, since fieldbus stations and automation components

can be mobile, and furthermore, the need for (breakable) cabling is reduced. However, the wireless

transmission characteristics are fundamentally different from those of other media types, leading to

comparably high and time-varying error rates. This poses a significant challenge for fulfilling the hard

real-time and reliability requirements of industrial applications.

discusses various approaches to ensure real-time communication capabilities, to include those that

support probabilistic as well as deterministic analysis of the network access delay. This chapter also

presents a brief description of the Ethernet protocol.

The practical solutions to ensure real-time communication capabilities using switched Ethernet are

switched Ethernet suitability in the context of industrial automation and presents practical solutions

obtained through R&D to address actual needs.

The issues involving the use of wireless and mobile communication in the industrial environment

wireless links and lower-layer wireless protocols for industrial applications. It also briefly discusses

wireless stations.

and limits of technologies such as Bluetooth, IEEE 802.11, and ZigBee for deployment in the industrial

environments.

Linking Factory Floor with the Internet and Wireless Fieldbuses

The demand for process data availability at different levels of factory organizational hierarchy, from

production to the business level, has caused an upsurge in the activities to link the “factory floor” with

the intranet/Internet. The issues, solutions, and technologies for linking industrial environments with

the Internet and wireless fieldbuses are extensively discussed in this section.

© 2005 by CRC Press

are presented in “Configuration and Management of Fieldbus Systems.” This chapter also discusses the

This section begins with the chapter “Approaches to Enforce Real-Time Behavior in Ethernet,” which

(factory floor) are discussed in “Wireless LAN Technology for the Factory Floor: Challenges and

Approaches.” This is a very comprehensive chapter dealing with topics such as error characteristics of

hybrid systems involving extending selected fieldbus technologies (such as PROFIBUS and CAN) with

The chapter “Wireless Local and Wireless Personal Area Network Technologies for Industrial Deploy￾ment” concludes this section. This chapter discusses from the radio network perspective the potentials

presented in “Switched Ethernet in Automation Networking.” This chapter provides an evaluation of the

xi

discusses new trends involving industrial Ethernet.

protocol. This contribution comes from authors from industry involved directly in the relevant technol￾ogy development.

The means for interconnecting wire fieldbuses to wireless ones in the industrial environment, various

presented by one of the leading authorities of the fieldbus technology.

Security and Safety Technologies in Industrial Networks

Security in the field area networks employed in the industrial environment is a major challenge. The

requirement for process data availability via intranet/Internet access opens possibilities for intrusion and

potential hostile actions to result in engineering system failures, including catastrophic ones if they involve

chemical plants, for instance. These and safety issues are the focus of this section.

provides a comprehensive discussion of the issues involved, challenges, and existing solutions amenable

to adaptation to industrial environments, and outlines a need for new approaches and solutions.

on the existing solutions and supporting technology in the context of PROFIBUS, one of the most widely

used fieldbuses in industrial applications. The material is presented by some of the creators of PROFIsafe.

CIP Safety, a safety protocol for CIP, is presented in the Field Area and Control Networks section in

Applications of Networks and Other Technologies

networks (synonymous with fieldbuses) and their applications to cover automotive communication

technology, building automation, manufacturing message specification in industrial communication

systems, motion control, train communication, smart transducers, energy systems, and SEMI (Semicon￾ductor Equipment and Materials International). This section tries to present some of the most represen￾tative applications of field area networks outside the industrial controls and automation presented in the

Field Area and Control Networks section.

approaches, solutions, and technologies. The automotive industry is a very fast growing consumer of

field area networks, aggressively adopting mechatronic solutions to replace or duplicate existing mechan￾protocols (TTP/C, FlexRay, and TTCAN) and operating systems and middleware services (OSEKTime

illustrating the design of a Steer-by-Wire system.

The newly emerging standard and technology for automotive safety-critical communication — FlexRay

© 2005 by CRC Press

with the Internet/intranet are discussed in “Linking Factory Floor and the Internet.” This chapter also

The issues and actual and potential solutions behind linking factory floor/industrial environments

overview of the use of the ANSI/EIA-852 standard to encapsulate the ANSI/EIA-709 control network

The chapter “Extending EIA-709 Control Networks across IP Channels” presents a comprehensive

design alternatives, and their evaluation are presented in “Interconnection of Wireline and Wireless

Fieldbuses.” This is one of the most comprehensive and authoritative discussions of this challenge,

This section begins with the chapter “Security Topics and Solutions for Automation Networks,” which

The second paper in this section is “PROFIsafe: Safety Technology with PROFIBUS,” which focuses

This is the last major section in the book. It has eight subsections dealing with specialized field area

“The CIP Family of Fieldbus Protocols.”

and FTCom) used in automotive applications. The chapter also presents a comprehensive case study

tems,” which gives an overview of the X-by-wire approach and introduces safety-critical communication

— is presented in the chapter “FlexRay Communication Technology.” The material is among the most

The “Automotive Communication Technologies” subsection has four chapters discussing different

ical/hydraulic systems. This subsection begins with the chapter “Design of Automotive X-by-Wire Sys-

xii

comprehensive and authoritative available at the time of this book’s publication, and it is written by

industry people directly involved in the standard and technology development.

The LIN (Local Interconnect Network) communication standard, enabling fast and cost-efficient

implementation of low-cost multiplex systems for local interconnect networks in vehicles, is presented

The Volcano concept and technology for the design and implementation of in-vehicle networks using

provides insight into the design and development process of an automotive communication network.

Another fast-growing consumer of field area networks is building automation. At this stage, particularly

for office, commercial, and industrial complexes, the use of automation solutions offers substantial

financial savings on costs of lighting and HVAC and can considerably improve the quality of the envi￾ronment. There are other benefits as well. Relevant communication solutions for this application domain

are presented in the subsection “Networks in Building Automation.” This subsection is composed of three

contributions, outlining the issues involved and the specific technologies currently in use.

of the pioneers of the concept of building automation and a technology developer.

The details of the European Installation Bus (EIB), a field area network designed specifically for

contributed by one of the most active proponents of using field area networks in building automation

and a co-founder of one of the largest research groups in this field, the Vienna University of Technology.

introduces the technical aspects of LonWorks networks, one of the main contenders for building auto￾mation. It covers protocol, development environments, and tools.

successful international standard MMS (manufacturing message specification), which is an Open Systems

Interconnection (OSI) application layer messaging protocol designed for the remote control and moni￾MOTIP (MMS on top of TCP/IP) in development and operation of the virtual factory environment. The

chapter also discusses an MMS-based Internet monitoring system.

communication between digital motion controls, drives, input/output (I/O), and sensors. It includes

definitions, a brief history, a description of SERCOS interface communication methodology, an intro￾duction to SERCOS interface hardware, a discussion of speed considerations, information on conform￾ance testing, and information on available development tools. A number of real-world applications are

presented and a list of sources for additional information is provided.

The

IEC 61375, adopted in 1999. It also discusses other European and U.S. initiatives in this field.

© 2005 by CRC Press

in “The LIN Standard.”

by Design.” The material comes from the source:Volcano Communications Technologies AG. This chapter

An excellent introduction to issues, architectures, and available solutions is presented in “The Use of

Network Hierarchies in Building Telemetry and Control Applications.” The material was written by one

building automation purposes, are presented in “EIB: European Installation Bus.” This chapter was

the standardized CAN and LIN communication protocols are presented in“Volcano: Enabling Correctness

“Fundamentals of LonWorks/EIA-709 Networks: ANSI/EIA-709 Protocol Standard (LonTalk)” chapter

toring of devices such as remote terminal units (RTUs), programmable logic controllers (PLCs), numer￾The subsection “Manufacturing Message Specification in Industrial Automation” focuses on the highly

ical controllers (NCs), robot controllers (RCs), etc. This section features two chapters: “The Standard

Message Specification for Industrial Automation Systems: ISO 9506 (MMS),” which gives a fairly com￾prehensive introduction to the standard and illustrates its use; and “Virtual Factory Communication

System Using ISO 9506 and Its Application to Networked Factory Machine,” which shows the use of

The chapter “The SERCOS interface™” describes the international standard (IEC/EN 61491) for

“IEC/IEEE Train Communication Network” chapter presents details of the international standard

xiii

1451 standards for connecting sensors and actuators to microprocessors, control and field area networks,

and instrumentation systems. The standards also define the Transducer Electronic Data Sheet (TEDS),

which allows for the self-identification of sensors. The IEEE 1451 standards facilitate sensor networking,

a new trend in industrial automation, which, among other benefits, offers strong economic incentives.

The use of IEC 61375 (Train Communication Network) in substation automation is presented in

for various application domains.

The last subsection and chapter in the Applications of Networks and Other Technologies section is

introduction to SEMI, providing an overview of the fundamentals of the SEMI Equipment Communication

Standard, commonly referred to as SECS, its interpretation, the available software tools, and case study

applications. The material was written by experts from the Singapore Institute of Manufacturing Technol￾ogy who were involved in a number of SEMI technology developments and deployments.

Locating Topics

To assist readers with locating material, a complete table of contents is presented at the front of the book.

Additionally, each chapter begins with its own table of contents. For further assistance, two indexes are

provided at the end of the book: an index of authors who contributed to the book, together with the

titles of their contributions, and a detailed subject index.

© 2005 by CRC Press

“A Smart Transducer Interface Standard for Sensors and Actuators” presents material on the IEEE

“SEMI Interface and Communication Standards: An Overview and Case Study.” This is an excellent

“Applying IEC 61375 (Train Communication Network) to Data Communication in Electrical Substa￾tions.” This is in an interesting case study illustrating the suitability of some of the field area networks

Acknowledgments

I thank all members of the International Advisory Board for their help with structuring the book, selection

of authors, and material evaluation. I have received tremendous cooperation from all contributing

authors. I thank all of them for that. I also express gratitude to my publisher, Nora Konopka, and other

CRC Press staff involved in the book’s production, particularly Jessica Vakili, Elizabeth Spangenberger,

and Gail Renard. My gratitude goes also to my wife, who tolerated the countless hours I spent preparing

this book.

Richard Zurawski

ISA Corp

Santa Clara, CA

© 2005 by CRC Press