AZ120 Industrial Network Protocols

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1 July, 2009 AZ120 Industrial Network Protocols (Part 1) Industrial Control Alexandra Dopplinger Global Industrial Segment Lead Factory Automation & Drives service names are the property of their respective owners. Freescale Semiconductor, Inc

2 Agenda Factory Automation Market Target Applications Freescale Alignment with Trends Industrial Network Protocols used in Factory Automation Applications Market Overview Freescale and Protocol Vendor Support PowerQUICC, QorIQ, mobilegt, i.mx and ColdFire processors Protocol Description, Solutions and Enablement Industrial Fieldbus Protocols PROFIBUS, CANopen, DeviceNet, Modbus RTU These topics are continued in Industrial Network Protocols (Part 2) Industrial Ethernet Protocols PROFINET, EtherNet/IP, Modbus TCP, EtherCAT Industrial Wireless Protocols ZigBee, WirelessHART, ISA100.11a service names are the property of their respective owners. Freescale Semiconductor, Inc

Drives Industrial Peripherals service names are the property

3 Factory Automation Market Factory Network Industrial Control Industrial Networking Human Machine Interface (HMI) Industrial Drives Industrial Peripherals service names are the property of their respective owners. Freescale Semiconductor, Inc

4 Factory Automation Industrial Control and Networking Factory Automation equipment is ruggedized for harsh environment and communicates with industrial protocols Industrial Control Programmable Logic Control (PLC) Programmable Automation Control (PAC) DCS Process/temperature control Motion/position control Industrial Networking (wired and wireless) Routers and Gateways Managed and Unmanaged Switches Converters and Hubs service names are the property of their respective owners. Freescale Semiconductor, Inc

5 Factory Automation Freescale Alignment with Trends Market Trend Reuse software, hardware, and tools across platforms Reduce power consumption Migrate from fieldbus to standardized Ethernet and wireless Cost-effective safety and security Freescale Alignment with Customer Requirements A history of shipping industrial products 10 to 15 years, with high quality and strong customer support Processor performance from 80 to >3000 DMIPS in harsh environments, from -40C to 85C ambient Increasing enablement to leverage ruggedized Power Architecture, ColdFire and i.mx processor portfolios DSC portfolio for cost-effective and efficient motor control MPU <1 W max, 400 DMIPS and <4 W max, >1000 DMIPS, with power management Many devices support both legacy fieldbus and industrial Ethernet and/or wireless Increasing 3rd party support for key protocols Secure SRAM, on-chip data fusing to protect against IP cloning Hardware encryption to protect against network data hacking Parity, watchdog and ECC protection against soft errors service names are the property of their respective owners. Freescale Semiconductor, Inc

6 Industrial Network Protocols Used in Factory Automation Applications service names are the property of their respective owners. Freescale Semiconductor, Inc

7 World Market Industrial Protocols CAGR Industrial Nodes 13.5 M 24.8 M 13% Market Share (2010) > 20% > 10% < 10% Network Protocols Ethernet PROFIBUS, DeviceNet, AS- Interface, Foundation Fieldbus, CC-Link Others Market share change from 2005 to 2010: Ethernet (all versions) +8% Modbus RTU (non-ethernet version) -3% CAN -2% Others +/- 1% Source: IMS Research, November 2006 service names are the property of their respective owners. Freescale Semiconductor, Inc

8 Most Significant Industrial Network Protocols Field Bus (Discrete or I/O oriented) CAN Most popular fieldbus solution. 23.3M nodes installed by 2007; 24% growth (PTO 2008). Supported by Siemens. CIP application layer on CAN. Very popular and still growing. Supported by Rockwell. Modbus RTU is a widely used fieldbus solution, but losing share. Developed by Schneider. Very popular SAE-sponsored standard but losing share in factory automation market Industrial Ethernet* 1.6 Mu PROFINET nodes installed by 2008; 40% growth (PTO 2009) Supported by Siemens. CIP application layer on Ethernet. Growing fast. Supported by Rockwell. Modbus TCP/IP is a widely used Ethernet solution, but growing less rapidly in many markets (Schneider) May dominate due to technology and ease of use. Predict >1 Mu by Supported by Beckhoff. Standard Ethernet TCP/IP protocols most common of Ethernet-based nodes 6.5 Mu Ethernet TCP/IP nodes installed by 2006; 24 Mu by 2011; CAGR 24.3% Many deterministic industrial Ethernet protocols use a form of IEEE 1588 For clock synchronization through the Ethernet network IEEE 1588 service names are the property of their respective owners. Freescale Semiconductor, Inc

Target Applications Real-time Determinism in Industrial Networks Protocols Motor

Control Sensors Valves Data scanner Inventory Management IRT Deterministic < 1 IRT us

100 matters ms Cycle for Sync Time 1 to 100 ms Cycle Time NRT NRT Non-deterministic

Applications IEEE 1588 Precision Time Protocol VERY Jitter sensitive; Cycle Time does

9 Target Applications Real-time Determinism in Industrial Networks Protocols Motor Drives Motion Control Synchronized Servos Conveyor belts Picker arms PLCs, I/O Control Sensors Valves Data scanner Inventory Management IRT Deterministic < 1 IRT us Jitter < 1 Deterministic ms Cycle Time < 1 ms Cycle Time RT Deterministic 1 Jitter to 100 matters ms Cycle for Sync Time 1 to 100 ms Cycle Time NRT NRT Non-deterministic Jitter > 100 doesn t ms Cycle matter Time > 100 ms Cycle Time IRT Number of Applications IEEE 1588 Precision Time Protocol VERY Jitter sensitive; Cycle Time does not matter RT service names are the property of their respective owners. Freescale Semiconductor, Inc

10 High-End PLC/PAC DMIPS < 2.5 W 5 W > $15 Processors for Industrial Control, Networking and HMI High-End Networking 1000 DMIPS and up 4W - 10 W > $20 MPC8640 MPC8610 MPC8544 MPC8360 MPC837x MPC8536 P2020 QorIQ* P2010 QorIQ P1020 QorIQ* P1011 QorIQ Pin Compatible PLC/PAC and HMI DMIPS < 1.5 W < $10-20 I/O Control DMIPS < 1 W < $10 Process Control ~100 DMIPS < 0.5 W < $5 MPC8314/15 MPC8313 i.mx31 i.mx27l MCF5445x MCF532x MPC5121e/23 i.mx35x i.mx25x MCF5227x MCF5xxx MCF52235 MCF5225x MPC551x* P10xx QorIQ i.mx51x MPC5xxx Power ARM ColdFire LCD Control service names are the property of their respective owners. Freescale Semiconductor, Inc

11 Protocol Vendor Support for Industrial Protocols Industrial Network Protocol ColdFire PowerQUICC DoGav Systems IEEE 1588 service names are the property of their respective owners. Freescale Semiconductor, Inc

12 IXXAT Automation GmbH IXXAT is a German-based leading supplier for embedded communication systems for industrial and automotive applications Established in 1987 with 20 profitable growth years 2006 sales of $16.7M worldwide 70 employees (most are developers) Represented globally in >15 countries Weingarten, Germany and New Hampshire, USA Contact Bill Seitz seitz@ixxat.com 120 Bedford Center Rd., Bedford, NH X102 Download free eval from CPU I/O Application Protocol Stack CAN or Ethernet Interface PowerQUICC Processors IEEE 1588 (available) POWERLINK (under development) CANopen (under development) ColdFire Controllers EtherNet/IP (available) DeviceNet (available) CAN and CANopen (available) IEEE 1588 (available) POWERLINK (under development) service names are the property of their respective owners. Freescale Semiconductor, Inc

13 Real Time Automation RTA is a USA-based leading supplier of industrial protocols and solutions Established in 1999 by John Rinaldi 15 employees in Milwaukee, Wisconsin, USA Focus on networking, control and developers "Media is irrelevant Contact John Rinaldi rinaldi@rtaautomation.com Download eval info from ROYALTY FREE POWERQUICC ETHERNET/IP CLIENT & SERVER ANSI C SOURCE CODE PowerQUICC Processors EtherNet/IP (available) DeviceNet (available) Modbus (available) PROFINET RT (under development) ColdFire Controllers EtherNet/IP (available) DeviceNet (available) Modbus (available) CANopen PROFIBUS/PROFINET service names are the property of their respective owners. Freescale Semiconductor, Inc

14 DoGav Systems Ltd. DoGav Systems Ltd. is an Israel-based software solution provider who has provided microcode support for PowerQUICC >10 years Established years experience in PowerQUICC microcode design services Over 24 years of experience with Freescale/Motorola USA sales based in New York, USA ~5 Employees in Petach Tikva, Israel Contact David Gabbay Nahum St. Petach Tikva, Israel PowerQUICC processor support (CPM & QE) PROFIBUS DPv1 (alpha demo available) service names are the property of their respective owners. Freescale Semiconductor, Inc

15 National Semiconductor National Semiconductor is a USA-based supplier of industrial Ethernet PHYs Represented globally Contact Fred Weber, Product Marketing Manager, Interface Division fred.weber@nsc.com (631) TX RX MII Port A TX RX MII TX RX TX RX Channel A Channel B 10BASE-T 100BASE-TX or 100BASE-FX 10BASE-T 100BASE-TX or 100BASE-FX Port PowerQUICC, i.mx and ColdFire Processors with Ethernet MAC 10/100 Precision PHYTER adds IEEE 1588 Time Sync Protocol NATIONAL DP83640 PHYTER jitter <3 ns Typical competitor PHY has ~20 ns jitter MCF5234 / M5234BCCKIT eval board B MII RMII Latency DP83848 TX_CLK->TD T nS RD->CRS(ON) T nS RD->CRS(OFF) T nS RD->RXD 1 T nS X1->TD T nS RD->CRS(ON) T nS RD->CRS(OFF) T nS RD->RXD T nS service names are the property of their respective owners. Freescale Semiconductor, Inc

16 Industrial Fieldbus Protocols PROFIBUS, DeviceNet, Modbus RTU, CANopen service names are the property of their respective owners. Freescale Semiconductor, Inc

17 PROFINET Trade Organization (PTO) PTO supports PROFIBUS and PROFINET Evolved from original PROFIBUS International (PI) Open standards for factory automation, safety, drives and motion control PROFIBUS International (PI) formed 1989: 25 Regional PROFIBUS Associations since member companies include all major PLC/DCS vendors Siemens, GE Fanuc, Hilscher, Invensys, Yaskawa, Turckwerks Industrial Automation, Softing, Woodhead >400 engineers in 40 working groups Accredited Competence Centers service names are the property of their respective owners. Freescale Semiconductor, Inc

Fieldbus - PROFIBUS World s leading fieldbus >20 million PROFIBUS devices installed Open standard started by Siemens in 1989 RS485-based differential physical signaling PROFIBUS ASIC contains

deterministic ASIC implements communications stack Universal acceptance in Europe Disadvantages Higher cost than other fieldbus options No bus power Traditional master/slave model www.

18 Fieldbus - PROFIBUS World s leading fieldbus >20 million PROFIBUS devices installed Open standard started by Siemens in 1989 RS485-based differential physical signaling PROFIBUS ASIC contains stack and MAC Multiple PROFIBUS versions DP, FMS, PA Supports up to 127 nodes at 1000 Mbps 244 Bytes/Message, 12 Mbaud Master/Slave polling type network Advantages High speed Highly deterministic ASIC implements communications stack Universal acceptance in Europe Disadvantages Higher cost than other fieldbus options No bus power Traditional master/slave model Key Points World s leading fieldbus Very fast ASIC based with RS485 differential physical signaling service names are the property of their respective owners. Freescale Semiconductor, Inc

19 PROFIBUS uses only OSI layers 1-2 and 7 OSI Model Data Unit Layer Function Application Communication Language Host Layers Data Presentation Session Not used Not used Segments Transport Not used Media Layers Packets Network Not used Frames Data Link Physical Addressing (MAC and LLC) Bits Physical Two-wire Interface service names are the property of their respective owners. Freescale Semiconductor, Inc

20 High-End Networking 1000 DMIPS and up 4W - 10 W > $20 Industrial Control, Networking and HMI P102x QorIQ* High-End PLC/PAC DMIPS < 2.5 W 5 W > $15 PLC/PAC and HMI DMIPS < 1.5 W < $10-20 I/O Control DMIPS < 1 W < $10 Process Control ~100 DMIPS < 0.5 W < $5 MPC8360 MPC832x PROFIBUS can run fully on PowerQUICC processors with programmable QUICC Engine controller MPC8360, MPC8323 and QUICC Enginebased QorIQ devices Implement data-link and network layers with programmable QUICC Engine DoGav Systems demonstrated MPC8323 alpha microcode at FTF, Jun/08 All other devices support PROFIBUS by connecting 3 rd -party ASIC P101x QorIQ Pin Compatible Power ARM ColdFire LCD Control service names are the property of their respective owners. Freescale Semiconductor, Inc

Fieldbus CANopen and CAN Industrial automation protocol based on Controller-Area-Network (CAN) Developed by CAN-in-Automation (CIA) user group as a standardized solution for distributed automation

21 Fieldbus CANopen and CAN Industrial automation protocol based on Controller-Area-Network (CAN) Developed by CAN-in-Automation (CIA) user group as a standardized solution for distributed automation systems European standard CENELEC EN (2002) SAE sponsored CAN Protocol J1939 Master/Slave connection set Cyclic/COS data transfer modes Peer-to-peer messaging (not connectionbased) Object oriented Extensive parameter group data definitions Advantages Widely available with protocol stacks and tools for consumer, medical and industrial applications Largely broadcast data at various rates Disadvantages Complex specification Little conformance testing available Key Points Supports exchangeability and interoperability of devices from different manufacturers DeviceNet and CAN share same physical signaling, MAC and bitwise arbitration collision control service names are the property of their respective owners. Freescale Semiconductor, Inc

22 CANopen Reference Model Application Device Profile for Generic I /O Modules CiA DS 401, V 2.1 Device Profile Drives & Motion Control CiA DSP 402, V Interface and Device Profile for IEC Programmable Devices CiA DSP 405, V CANopen Application Layer and Communication Profile ( CiA DS 301, V 4.02 ) and Framework for CANopen Managers and Programmable CANopen Devices ( CiA DSP- 302, V 3.3 ) CAN Data Link Layer ( ISO ) CAN Physical Layer ( ISO ) CAN Bus service names are the property of their respective owners. Freescale Semiconductor, Inc

23 CANopen Device Model Communication Interface Object Dictionary Application Process CAN Bus Server SDOs Client SDOs RPDOs TPDOs Logical addressing scheme for accessing communication and application parameters, as well as data and functions Device functionality - Functions -Data - Parameters I / O Signals Process NMT, SYNC, Emergency, Time Stamp Messages service names are the property of their respective owners. Freescale Semiconductor, Inc

24 Industrial Control, Networking and HMI CAN Support High-End Networking 1000 DMIPS and up 4W - 10 W > $20 High-End PLC/PAC DMIPS < 2.5 W 5 W > $15 CANopen can run fully on these processors with on-chip CAN controller Other devices support CAN by connecting external CAN controller Freescale CAN PHY MCZ33897 PLC/PAC and HMI DMIPS < 1.5 W < $10-20 I/O Control DMIPS < 1 W < $10 Process Control ~100 DMIPS < 0.5 W < $5 MPC5121e/23 i.mx35x i.mx25x MCF532x MCF5227x MCF5xxx MCF52235 MCF5225x MPC551x* P10xx QorIQ MPC51x Power ARM ColdFire LCD Control service names are the property of their respective owners. Freescale Semiconductor, Inc

Fieldbus DeviceNet DeviceNet is CIP Application Layer on CAN Trunk line with drops Supports up to 64 nodes with multiple masters Node removal/insertion under power Cable includes power

data exchange Both sides agree on message contents Explicit messaging transfers specific data Packet contains message identification www.odva.

25 Fieldbus DeviceNet DeviceNet is CIP Application Layer on CAN Trunk line with drops Supports up to 64 nodes with multiple masters Node removal/insertion under power Cable includes power and data 125K, 250K and 500K baud rate Supported by non-profit Open DeviceNet Vendors Association (ODVA) Advantages Standard set of services and messaging I/O messaging is simply I/O data exchange Both sides agree on message contents Explicit messaging transfers specific data Packet contains message identification Key Points Application layer on CAN Two types of messages Explicit and I/O Object-based representation CIP Common Industrial Protocol service names are the property of their respective owners. Freescale Semiconductor, Inc

26 DeviceNet Network DeviceNet Object Model Connection Object ASCII Data Object Modbus Master Object Assembly Object DeviceNet Object Modbus Slave Object Analog IO Object Discrete IO Object Identity Object service names are the property of their respective owners. Freescale Semiconductor, Inc

27 Object Representation Application Layer Semi Devices Pneu Valve AC Drives Application Object Library Position Controllers Other Profilers CIP Application Layer CIP Application Layer Explicit, I/O, Routing Transport Data Link Encapsulation DEVICENET CONTROLNET UPD TCP Future? IP Physical Layer CAN CONTROLNET ETHERNET Future? service names are the property of their respective owners. Freescale Semiconductor, Inc

28 CIP Object Library Register Discrete Input Point Discrete Output Point Analog Input Point Analog Output Point Presence Sensing Parameter Parameter Group Group Discrete Input Group Discrete Output Group Discrete Group Analog Input Group Analog Output Group Analog Group Position Sensor Position Controller Supervisor Position Sensor Position Controller Supervisor Analog Input Group Analog Output Group Analog Group Position Sensor Position Controller Supervisor Position Controller Block Sequencer Command Block Motor Data Control Supervisor AC/DC Drive Acknowledge Handler Overload Soft Starter service names are the property of their respective owners. Freescale Semiconductor, Inc

29 Industrial Control, Networking and HMI DeviceNet Support High-End Networking 1000 DMIPS and up 4W - 10 W > $20 High-End PLC/PAC DMIPS < 2.5 W 5 W > $15 CANopen can run fully on these processors with on-chip CAN controller Other devices support CAN by connecting external CAN controller Freescale CAN PHY MCZ33897 PLC/PAC and HMI DMIPS < 1.5 W < $10-20 I/O Control DMIPS < 1 W < $10 Process Control ~100 DMIPS < 0.5 W < $5 MPC5121e/23 i.mx35x i.mx25x MCF532x MCF5227x MCF5xxx MCF52235 MCF5225x MPC551x* P10xx QorIQ MPC5xxx Power ARM ColdFire LCD Control service names are the property of their respective owners. Freescale Semiconductor, Inc

30 Fieldbus - Modbus RTU 1960s technology Simple, concise communication strings RS232/422/485 physical layer Devices modeled as Registers and Coils Well-defined instruction set 1 Master, 254 Slaves No formal certification info@modbus-ida.org Advantages Open and widely distributed Free tools on the web Clear/concise command set Large installed base Low-cost implementation Disadvantages Low speed - not real time Source/destination network model Very difficult to troubleshoot Key Points All devices in the system should support Modbus Handy configuration tool Most customers can use it Easy access to gateways for other networks service names are the property of their respective owners. Freescale Semiconductor, Inc

31 High-End Networking 1000 DMIPS and up 4W - 10 W > $20 Industrial Control, Networking and HMI Modbus RTU Support High-End PLC/PAC DMIPS < 2.5 W 5 W > $15 PLC/PAC and HMI DMIPS < 1.5 W < $10-20 I/O Control DMIPS < 1 W < $10 Process Control ~100 DMIPS < 0.5 W < $5 MPC5121e/23 i.mx35x i.mx25x MCF532x MCF5227x MCF5xxx MCF52235 MCF5225x MPC551x* P10xx QorIQ i.mx51x MPC5xxx Power ARM ColdFire LCD Control service names are the property of their respective owners. Freescale Semiconductor, Inc

32 Summary Freescale aligns with Factory Automation market requirements Many devices support both legacy fieldbus and industrial Ethernet protocols PowerQUICC, QorIQ, mobilegt, i.mx and ColdFire processors Solutions, enablement and 3 rd party protocol stacks available PROFIBUS, CANopen, DeviceNet, Modbus RTU PROFINET, EtherNet/IP, Modbus TCP, EtherCAT ZigBee, WirelessHART, ISA100.11a Devices are ruggedized with long life and reliability Industrial products ship 10+years, with high quality and strong customer support Processor performance from 80 to >3000 DMIPS, for fanless operation at -40C to 85C ambient Energy Efficiency MPU <1 W 400 DMIPS and <4 W >1000 DMIPS, with power management DSC portfolio for cost-effective and efficient motor control Cost-effective safety and security on-chip Protect against IP cloning, network data hacking and soft errors Part 2 of this presentation continues protocol description, solutions and enablement Industrial Ethernet Protocols: PROFINET, EtherNet/IP, Modbus TCP, EtherCAT Industrial Wireless Protocols: ZigBee, WirelessHART, ISA100.11a service names are the property of their respective owners. Freescale Semiconductor, Inc

33 Thank you for attending this presentation. We ll now take a few moments for the audience s questions and then we ll begin the question and answer session. Q & A service names are the property of their respective owners. Freescale Semiconductor, Inc

Freescale Industrial Control & Networking

April 14, 2011 Freescale Industrial Control & Networking Single Chip Solutions Alexandra Dopplinger, P.Eng. Global Segment Marketing Manager, Robotics & Factory Automation Presenter: Alexandra Dopplinger,