Your Global Automation Partner. Improve Data Communication for IIOT. White Paper - W1021

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Hortense Patterson
5 years ago
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1 Your Global Automation Partner Improve Data Communication for IIOT White Paper - W1021

2 Many companies still wonder when it s the right time to fully adopt and embrace the Industrial Internet of Things, especially if significant software and technology hurdles stand in the way. From immediately improving data communication to enhancing condition monitoring across the plant floor, there are a number of benefits to preparing now for full IIoT implementation in the future. In this white paper, you ll learn more about how to assess your company s networking and data needs for the IIoT, and key technologies and protocols that power these environments. Why now is the time to prepare for the IIOT The IIoT delivers its biggest impact when businesses can extract, connect and analyze data from across their operations, then apply findings for a benefit. Depending on the application and system, benefits can range from improved plant availability, better quality assurance and cost savings to increased efficiency and flexibility. To implement an IIoT strategy and realize these benefits, companies not only need the software to manage and analyze data, but also the hardware components to physically collect and move it. Strategically investing now in hardware components that bring data together can lead to short-term operational benefits on your path to full IIoT adoption. One of these benefits is efficiency gains by bringing all data to a single location. If an engineer has to walk to a remote workstation multiple times a day to review processes and data, it s often more efficient to aggregate and report this data back to a central station. Another advantage is the ability to expand how much data your operation collects and communicates. By updating components to enhance data efficiency, you can begin to analyze and optimize your processes for improved utilization, condition monitoring and traceability. Assessing your company s data system is the first step toward the IIoT IIoT environments require an industrial network to communicate data. If your operation currently relies on individually hardwired devices to communicate data to a PLC, assessing the benefits of moving to a network is a required first step. This starts by auditing your company s technology and capabilities, to establish a benchmark for your system and identify opportunities to improve or enhance data collection. This audit should determine what data is being measured and if any gaps exist in current data measurement processes. Data from sensors and 2

3 other instrumentation devices can be analyzed for potential efficiencies related to the system as a whole. If you are already using an industrial network to connect your system, you can start by asking questions about performance. Is your current network working well, or do you need faster speeds or larger data volumes? How many communication protocols are in place? Are there opportunities to streamline the number of I/O devices and cabling to save costs? If either assessment shows new ways to improve data measurement and communication, it may be the right time to implement a network or change the protocols in place. Exploring protocol options for the IIoT IIoT environments may use multiple protocols to collect and communicate data from devices to PLCs. Legacy fieldbus protocols already in place including DeviceNet, PROFIBUS and CANopen will continue to connect sensors and other devices to PLCs. However, industrial Ethernet is quickly replacing these legacy protocols across the manufacturing landscape. A key driver of this industrial Ethernet adoption trend is a company s data communication and processing needs. Industrial Ethernet protocols can communicate data in megabytes and gigabytes per seconds. Fieldbus protocol speeds are limited to kilobytes per second. This difference can have large-scale consequences for speed and efficiency when datagathering operations grow more complex, such as gathering data from an entire assembly. Another reason for the interest in industrial Ethernet is familiarity. Long used in commercial operations, companies know how industrial Ethernet works, and can more easily tie together and secure networks. With the trend toward industrial Ethernet, many manufacturers have stopped new development for legacy protocol products. If you are looking to install an industrial network or upgrade the network in place, industrial Ethernet is recommended. A few of the many industrial Ethernet protocols available are EtherNet/IP, PROFINET, EtherCAT and Modbus TCP. Working with an industrial networks expert can help you identify which of these options would work best for your company and its applications. Industrial Ethernet PROFIBUS-DP FOUNDATION FIELDBUS PROFIBUS-PA DeviceNet AS-i Upgrading devices and connectivity to improve data communication now and in the future 100 Mbps to 10 Gbps 9.6 kpbs to 12 Mbps kpbs kbps 125 kpbs to 500 kbps up to 167 kpbs Companies can begin to upgrade devices and connectivity once they have identified which network protocols they will use. Even if the 3

4 IIoT is a long-term strategy for your company, these changes can often lead to improved data communication today. Components below the PLC level may need updates depending on protocol compatibility and how data from these devices connects to each other. Each sensor, connector, cable and I/O block must be able to reliably relay data through the system and to the PLC for the engineer to review, interpret and use. New and upcoming technologies are empowering companies to install products that address future IIoT needs while balancing the demands of today s environments. Among these innovations are edge devices, web-based programming environments and industrial Ethernet cables. Edge devices will be essential to IIoT environments. Field Logic Controllers (FLCs) are one type of edge device that companies can incorporate into their operations now. FLCs can operate as standard industrial Ethernet I/O devices. They can also be programmed to carry out local logic, which will be a core capability of IIoT infrastructure. With data communication at the core of IIoT, cabling solutions will continue to adapt to meet future needs. While today s fieldbus and industrial Ethernet cables work in IIoT environments, longterm planning is underway within IEEE to create new industrial Ethernet physical layer specifications. Many industrial automation applications use two-pair industrial Ethernet cable for 100Mbps communication up to 100 meters. Faster industrial Ethernet such as CAT 6 or CAT 6A is used at higher levels within the network where data is aggregated. But for communicating to sensors, instrumentation or other devices at the lower levels, the 100Mbps communication can be excessive. IEEE efforts are focusing on developing a single-pair industrial Ethernet phy, suitable for 10Mbps communication, at lengths up to 1,000 meters. While the data transfer speeds would be slower, the ability to communicate industrial Ethernet down to the device level and across longer distances could prove beneficial for anyone considering IIoT within factory and process automation. FLC programming is another example of an industry-wide trend toward web-based programming, which will also improve companies ability to implement the IIoT. With this approach, engineers can use a web browser to program and upload logic directly to devices. Available on any device and from anywhere, these environments put control in the hands of the user and remove the need to stand at a PLC to program. Mobile capabilities will be essential for allowing data access and remote monitoring from across the globe. Evolving data communication for IIoT In many ways, the goals of IIoT have always been the goals of efficient, effective manufacturing connect all data points across a facility to make sure operations are running smoothly. The IIoT strategy evolves this long-standing approach by the scale of data collection and 4

5 analysis needed. If your company is discussing an IIoT strategy, it s important to weigh the shortterm benefits of industrial networks and data collection as well as the potential long-term gains in efficiency, optimization and cost savings. To learn more about how Turck can connect you with the right components for IIoT, contact us at (800) or tusa.marketing@turck.com. 5

Your Global Automation Partner. The Full Range for Industrial Ethernet

Your Global Automation Partner The Full Range for Industrial Ethernet Turck is a global leader in automation technology. Over 4,000 employees in 28 countries strive to deliver the best sensor, connectivity,