Applying Plantwide Industrial Wireless Communications for Cost Savings. Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Transcription

1 Applying Plantwide Industrial Wireless Communications for Cost Savings Rev 5058-CO900C

2 Abstract New cost savings across multiple industries are now possible by leveraging recent developments in both Integrated Architecture and wireless technology. Learn how you can utilize new technology to reduce costs by applying these technologies in process instrumentation through remote telemetry out-stations, with a focus on the inclusion of Wi-Fi in wired Ethernet architectures. with a productivity project perspective. 2

3 SCADA RTU Drawing ( but can this go wireless? and what about the CIP protocols? Do they matter? and what if this whole thing was on the move? and I know this can. and so can this. Right? 3

4 Agenda Attributes of Industrial Access Point (AP) Benefits of a wireless (or extended) network Wireless Architecture examples / ideas Fixed Orbit Roam Rapid Roam 1. Eliminating Wires and Cables Increase Reliability Replace cables (e.g., moving machinery) Reduce Installation Cost Wireless I/O, Wireless Sensor and mesh networks Reach great distances (SCADA) 2. Enabling Portability and Mobility Mobile HMI (People) AGVs (Equipment) Communications (VoWLAN) 3.Tracking Assets RFID Real Time Location Services 4. Remote Device Monitoring Troubleshooting / Maintenance Instrumenting existing machinery 5. Video Surveillance Security and process monitoring 6. Guest Access No roaming Roaming Fixed Postion Non Operational Relocaiton Operational Relocation (Slow) Rotary Platforms Break Remake Connections (RPI > 400ms) no WLC Seamless WLC required Savings Potential =Medium Tech Appropriate =Low 3 Messaging (controller MSG instructions, Logix tools, FT, HMI) Standard P/C Filling line Safety P/C Standard I/O Safety I/O Fabrication Sync Motion P/C (Virtual Axis) WarehouseN Motion I/O Other (usually minor load) Distribution ARP, ICMP TCP maintenance Web browsing Redundancy (not yet studied) 3=High Psuccess Continued operations ROI thoughts not an equation The Basics: How many exclusive channels are available (depends on geography and site usage)? 2.4GHz band Any microwave generating equipment? 5GHz band Non DFS DFS Channels with no radar Channels with radar sometimes What are the worst case communication requirements within each coverage area (may vary as devices roam/relocate)? Number of devices? Embedded wireless Bridged wireless Total PPS (mostly RPI related) Timeout (often based on response time) Time synchronization tolerance Tolerable jitter in I/O What are the dimension and material compositions of all the coverage areas in a site? Do any obstructions enter and leave the coverage areas? Is fail over coverage required (not seamless redundancy) What devices? APs, WGBs, WLCs? Worst case fail over time? There are questions related to integration that impact the configuration: What are the VLAN requirements? What is the wireless device management method? What is the addressing method? DHCP? Is there a central authentication server? More questions are necessary, but they relate more to the management process: Was a site survey done? Who is responsible for managing wireless? Channel allocation Security Architecture practices etc..

5 Attributes of an Industrial AP / WGB Frequency: 2.4Ghz, 5Ghz, 4/3G, BlueTooth, 900Mhz, etc. Radio (Tx by Rx) - Speed, throughput and beam forming Multiple Input Multiple Output - MIMO (AP and Client) Autonomous / Controller based options to future-proof A/G/N in (you may use all these) Ability to add diagnostics to ICS assist uptime and troubleshooting Related Others: Coexistence, Network size, Security, Transmission Time, Data Coding Efficiency, Power Consumption Performance moving WiFi from Convenience to Mission Critical network 5

6 Benefits Elimination of cable restriction Increase reliability Replace cables (e.g., moving machinery) Wireless I/O, Wireless Sensor and mesh networks Reach great distances (SCADA) Enable portability and mobility Low cost / high density Reduced installation cost ($ per foot) Balance nodes with bandwidth Track assets RFID Mobility Services Engine (Cisco) 6

7 Benefits Remote Device Monitoring Troubleshooting / Maintenance Instrumenting existing machinery Video Surveillance Security and process monitoring Guest Access Vendor Maintenance 7

8 Benefits Ease of deployment ( easy deployment) Security Authentication and Encryption Dynamic network formation Spatial Ad hoc ( like maintenance) Intermittent (like indexing) 8

9 Architecture Fixed & Moveable 2.4 GHz WLC Enterprise Zone Demilitarized Zone Manufacturing Zone Backup comms for uptime Reduction of Trenching / Permits Replacement Media over distance Redundancy Secondary system bandwidth Added I/O for optimization and monitoring Cell / Area Zone WGB (or client) 9

10 Architecture Orbit 2.4 GHz WLC Enterprise Zone Demilitarized Zone Manufacturing Zone Cell / Area Zone Remove slip rings Reduce time for indexing comms connection Throughput with design reversal Overcome design limitations of wired network Provision Guest/ Convenience/ Maintenance access WGB (or client) 10

11 Architecture Roam 2.4 GHz WLC Enterprise Zone Demilitarized Zone Wiring reduction Sensor reduction Network troubleshooting Establishing a new network Manufacturing Zone Cell / Area Zone WGB (or client) 11

12 Architecture Rapid Roam 2.4 GHz WLC Enterprise Zone Demilitarized Zone Manufacturing Zone WLC Cell / Area Zone Bridge (or client) 12

13 Psuccess : the Protocols TCP and Web EtherNet / IP Messaging MSG instructions, Logix tools, HMI Standard P/C Safety P/C Standard I/O Safety I/O Sync Motion P/C (Virtual Axis) Motion I/O RPI 13

14 Psuccess : the Basic Criteria How many exclusive channels are available? This depends on geography and site usage 2.4GHz band (suggest convenience ) Any microwave generating equipment? 5GHz band (suggest mission critical ) Can you establish for mission critical DFS What are the dimension and material compositions of all the coverage areas in a site? Do any obstructions enter and leave the coverage areas? What is the capability of your wired infrastructure? 14

15 Psuccess : the Basic Criteria What are the worst case communication requirements within each coverage area (may vary as devices roam/relocate)? Number of devices? Embedded wireless (Client devices) Bridged wireless (Work Group Bridge) Total Packets Per Sec(mostly Requested Packet Interval (RPI) related) Timeout (often based on response time) Time synchronization tolerance Tolerable jitter in I/O Is fail-over coverage required (not seamless redundancy) What devices? APs, WGBs, WLCs? Worst case fail-over time? 15

16 Psuccess : Integration and Configuration What are the existing wired network configs (VLAN, QoS, etc)? What is the wireless device management method? Autonomous WLC Mixed Dual WLC What is the addressing method? DHCP? Is there a central authentication server? Attributes and YOUR configuration is key to ICS uptime 16

17 Continued Operations 2.4 GHz WLC WLC Enterprise Zone Demilitarized Zone Manufacturing Zone Cell / Area Zone Plan & monitor your network but don t. Add unrequired product Overload existing network Test the wire too Test in environment Provision: frequency, channel, SSID, VLAN, physical space Plan system maintenance Security 2.4 GHz WGB (or client) 17

18 ROI ROI will be mainly a result of reduced downtime and improved throughput NOT (just) savings in media Think about: Safety (video, sensors) Redundant or Back-up systems Perhaps not originally designed into the system but now needed Big data with added I/O Secure Convenience / Maintenance / Guest cell access Zone based access with Location Service Network expansion (pay-as-you-go) Manufacturing networks are growing, what is your long term plan Security (establishment and management) Network operations management. Who owns the air space? 18

19 The Basic Project Evaluation Model Establish team (Eng and IT) Review benefits Group architectures Grade set Project Potential set Tech Alignment Evaluate applied protocols Apply criteria to protocol set Tech Alignment Calculate Psuccess Cost of continued ops ROI 1. Eliminating Wires and Cables 2. Enabling Portability and Mobility 3.Tracking Assets 4. Remote Device Monitoring 5. Video Surveillance 6. Guest Access 3=High Project Potentia =Medium Tech Alignm =Low Messaging (controller MSG instructions, Standard P/C Filling line Safety P/C Standard I/O Safety I/O Fabrication Sync Motion P/C (Virtual Axis) WarehouseN Motion I/O Fixed Postion No roaming Other (usually minor load) ARP, ICMP TCP maintenance Web browsing Redundancy (not yet studied) Non Operational Relocaiton Operational Relocation (Slow) Rotary Platforms Roaming no WLC Seamless WLC required Distribution The Basics: There are questions related to integration that impact the configuration: 19

20 Watch the industrial wireless space! 20