N. P. Mahalik (Ed.) Fieldbus Technology Springer-Verlag Berlin Heidelberg GmbH
ONLINE LIBRARY Engineering
http://www.springer.de/engine/ N. P. Mahalik
Fieldbus Technology
Industrial Network Standards for Real-Time Distributed Control
With 332 Figures and 36 Tables
Springer Dr. Nitaigour Premchand Mahalik
Department of Electronics and Telecommunication Engineering University College of Engineering, Burla Dist.: Sambalpur, Burla Pin: 768 018, Orissa, India
E-mail: [email protected]
ISBN 978-3-642-07284-0 ISBN 978-3-662-07219-6 (eBook) DOI 10.1007/978-3-662-07219-6
Cataloging-in-Publication Data applied for Bibliographic information published by Die Deutsche Bibliothek. Die Deutsche Bibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data is available in the Internet at
© Springer-Verlag Berlin Heidelberg 2003 Originally published by Springer-Verlag Berlin Heidelberg New York in 2003 Softcover reprint of the hardcover 1st edition 2003
The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Typesetting: Camera ready by authors Cover-design: Medio, Berlin Printed on acid-free paper 62/3020 hu - 5 43210 - Dedicated to all my
TEACHERS
Especially to my
Father Sri Abhimanyu Mahalik
School teacher Sri Prabhakar Barik
PhD supervisor Professor P R Moore Preface
Sophisticated and Flexible control is something that may indeed change the auto• mation system in the most dramatic way. Methods of automation and control rep• resent a broad research topic with applications in many disciplines including in• dustrial and production engineering, manufacturing, process control, robotics, instrumentation, home automation and many others based upon the sophistication, flexibility and state-of-the-art technology. Fieldbus Technology (FT), an enabling platform has already emerged in order to cater the need for sophistication and flexibility and as a matter of fact it has becoming the preferred choice for the next generation real-time automation and process control solutions. Technological researches are now dilating instead of diverging. The primary reason is being the fact that the current technological designs is of highly complex and inter-interdisciplinary nature involving synergistic integration of many aspects of engineering knowledge base. The main objective of this book is to provide information on fundamental con• cepts and principles, latest technological developments along with comparisons with regard to FT. It incorporates a collection of research, development, tutorials, case studies type papers based upon selected contributions. The motivation comes from the fact that the research and developments on fieldbus-based system inte• gration are being carried out at many important academic institutions and indus• trial sectors around the world. The technological trend in this domain i.e., the de• sign and development of platform for automation and process control applications has to be disseminated extensively so that the fieldbus revolution can come up quickly to serve the society. It intends to focus on accommodating latest develop• ments in various types of fieldbus systems conforming to different standards such as CAN, LON, P-NET, ProfiBus, Interbus, WorldFIP, SERCOS interface, etc. There has been confusion and arguments on the terms like Fieldbus, Sensorbus, Devicebus, LAN, Ethernet, and so on. The potential authors of the Chapters have exterminated these confusions. The book will undoubtedly enable the readers to understand the underlying technology, philosophy, concepts, ideas, and principles, with regards to not only fieldbus but to Distributed Control Systems (DCS), Automation, Industrial Networking Systems (INS), Integration of Data and Con• trol Network, Web-based monitoring and control, etc. Aspects of digital control network in terms of theory, practice, tools, techniques, platforms, and experimen• tal results have been presented in proper order. The Chapters include comprehen• sive but general description as far as current research and technological develop• ments are concerned. Fundamental methods, initiatives, significant research VIII results as well as references for further study has been presented. Relative merits and demerits of a variety of platforms, which are described at the appropriate places, have been accommodated so that novice as well as advanced practitioners can use that evaluation to guide their choices. Since the book contains fundamen• tals and results, a wider group of people can use it for their reference. The book can serve as the medium of exchange of information and ideas. It can become a reference book at the research levels for many engineering and technological dis• ciplines. A wide range of researchers should be able to find many useful tips and hints from it. All the contributions have been reviewed, edited, processed and placed appropriately in order to maintain consistency so that irrespective of whether the reader is an advanced practitioner or a new comer he or she can get most out of it. Since this book covers many aspects of interdisciplinary subjects, the importance of the book within the automation and process control domain is considered significant.
Nitaigour Premchand Mahalik Contents
1 Fie1dbus and Contemporary Standards ...... 1 1.1 Way for Distributed Control...... 1 l.2 Networks for Industrial Automation ...... 1 1.3 Evolution of Digital Communication ...... 2 l.3.1 Issues of Proprietary Protocol...... 3 1.4 Introduction to HART...... 3 1.4.1 The HART Technology ...... 4 l.4.2 HART Structure based on the OSI Model...... 5 1.4.3 Specific Applications of HART Technology ...... 5 1.4.4 Device Description Language of HART ...... 6 1.4.5 Benefits of HART ProtocoL ...... 6 1.5 The OSI Reference Model for Fieldbus ProtocoL ...... 7 1.5.1 Layer l. Physical Layer ...... 8 l.5.2 Layer 2. Data Link Layer ...... 8 1.5.3 Layer 3. Network Layer...... 8 1.5.4 Layer 4. Transport Layer...... 9 l.5.5 Layer 5. Session Layer...... 10 l.5.6 Layer 6. Presentation Layer...... 10 l.5.7 Layer 7. Application Layer...... 10 1.6 History of Fieldbus ...... 10 1.6.1 Ease of Configuration and Modularity for Expansion ...... 12 1.6.2 Ethernet for Industrial Automation ...... 12 1.6.2.1 Industrial Ethernet ...... 12 1.6.2.2 HI, H2 and HSE ...... 13 1.6.2.3 Leverage Between HI and HSE ...... 13 1.6.2.4 Future ofHSE with Fieldbus Standards ...... 14 l.7 Need to Replace 4-20 rnA Standard ...... 14 l.7.1 Network Topology ...... 15 1.7.2 Differentiating Features of Fieldbus Technology ...... 16 1.7.3 Founders of Fieldbus Technology ...... 16 l.7.4 Fieldbus Network ProtocoL ...... 16 1.7.4.1 Physical Layer ...... 17 1.7.4.2 Communication Layer ...... 17 1.7.4.3 User Layer ...... 18 1.7.5 Simple PID Control with Function Blocks ...... 19 1.7.6 Popular forms of Digital Communication ...... 20 x
1.7.6.1 Communication Robustness ...... 20 1.7.7 Triumvirates for the Fieldbus ...... 20 1.8 Vendor Groups for Niche Automation ...... 21 1.9 Category of Fieldbus Networks ...... 21 1.9.1 Enterprise Network ...... 23 1.10 Factors to Consider in the Choice ofa Network ...... 24 1.11 Introduction to Commonly used Fieldbus Standards ...... 25 1.12 Fieldbus Comparison Matrix ...... 26 1.13 Single, Open, Interoperable Fieldbus ...... 29 1.14 Integration Aspects of HSE with FF ...... 29 1.15 HART Protocol and FF ...... 31 1.16 The FF Organisation ...... 31 1.17 HIST ...... 32 1.17.1 Popularity ofFF Vis-a-vis Network Users ...... 32 1.17.2 Integration for ERP and MIS ...... 33 1.18 Benefits of Fieldbus Technology ...... 33 1.18.1 Increased Financial Returns ...... 34 1.19 Case Study ...... 36 1.20 References ...... 36
2 Industrial Ethernet Protocol Wars: Fieldbus Revisited ...... 39 2.1.lntroduction ...... 39 2.2.1 Competition Moves to Upper Layers ...... 40 2.2.2 Architectures include Traditional Device Networks ...... 41 2.3 EtherNetilP takes CIP to a Higher LeveL...... 42 2.3.1 Device Profiles & Object Library Fall Under ODV A SIG...... 44 2.3.2 EtherNetilP Connector Offered to lAONA & EIA/TIA ...... 45 2.4 Web-based Architecture with Safety ...... 45 2.4.1 IDA Modeled after IEC 61149 Function Block ...... 45 2.4.2 European Machine Control Suppliers Lead ...... 45 2.4.3 IDA: The PROFInet Alternative ...... 46 2.5 PROFInet is not PROFIbus over Ethernet ...... 47 2.5.1 The PROFInet Architecture ...... 48 2.5.2 Strategy for PROFlnet ...... 49 2.6 Foundation Fieldbus HSE Expands ...... 50 2.6.1 Will HSE be Used at the Field Level?...... 51 2.6.2 Flexible Function Blocks Expand HSE's Scope ...... 51 2.7 lAONA Seeks Common Ground ...... 52 2.7.1 lAONA Working Groups ...... 53 2.7.2 Need for Deliverables Alters Market Perception ...... 54 2.8 OPC Jumps into the Fray ...... 54
3 Real-time Characteristics of the Foundation Fieldbus Protocol...... 57 3.1 Introduction ...... 57 3.2 Foundation Fieldbus Protocol ...... 59 3.3 Execution and Communication Configuration TooL ...... 62 Contents XI
3.3.1 Motivation ...... 62 3.3.2. Process Control Strategies ...... 62 3.3.3 Characteristics of Process Control Strategy ...... 63 3.3.3.1 Priority Messages and Function Block Precedence ... 64 3.3.3.2 Idle Transmission Interval ...... 65 3.3.3.3 Periodicity ofProcess Control Strategy ...... 65 3.3.3.4 Temporal Consistencies ...... 66 3.3.3.5 End-to-end Constraints ...... 66 3.3.4 Fieldbus Messages ...... 67 3.4 Releases and Deadlines of Messages ...... 68 3.4.1 Static x Dynamic Scheduling ...... 69 3.4.2 Description of the Proposed Algorithm ...... 69 3.4.3 Steps of Proposed Algorithm ...... 70 3.4.3.1 First Step ...... 71 3.4.3.2 Second Step ...... 72 3.4.3.3 Third Step ...... 73 3.5 Results ...... 73 3.5.1 Case Study 1...... 74 3.5.2 Case Study 2 ...... 74 3.5.3 Case Study 3 ...... 75 3.5.4 Case Study 4 ...... 78 3.6 Validating Foundation Fieldbus Applications ...... 79 3.6.1 Temporal Behavior Analysis Framework ...... 80 3.6.2 Timing Requirements Specification ...... 83 3.6.3 Events Logging ...... 83 3.6.4 Timing Requirements Validation ...... 84 3.6.5 Visualization ...... 85 3.6.5.1 Case Study 1 ...... 86 3.6.5.2 Case Study 2 ...... 87 3.6.5.3 CaseStudy3 ...... 88 3.7 Conclusions ...... 90 3.8 Acknowledgments ...... 91 3.9 References ...... 91
4 Components Based DCS Design Method ...... 95 4.1 Introduction ...... 95 4.2 Overview of Components-based Distributed Control Systems ...... 96 4.2.1 Concept of Component in Different Areas ...... 97 4.2.2 Concept of Component in Distributed Control System ...... 98 4.2.3 Structure of Component ...... 99 4.2.4 Composition of Component...... 100 4.2.5 A Component Image ...... 100 4.2.6 Physical Part ...... 101 4.2.7 I/O Function Database ...... 102 4.3 The Concept of a Distributed Control System Image ...... 102 4.4 Design of Components-based Control System ...... 103 XII
4.4.1 Basic rules for Decomposing ...... 104 4.4.1.1 TaskAssignment ...... 105 4.4.1.2 Assignment of Closely Coupled Parts ...... 106 4.4.1.3 One Control Algorithm to One Component ...... 106 4.4.1.4 Synchronization for Control Encapsulated ...... 106 4.4.1.5 Component Reuse ...... 107 4.4.2 Components Library ...... 107 4.4.3 Fieldbus ...... 107 4.4.4 Toolbox ...... 108 4.4.5 Procedure ...... 109 4.4.6 Decomposing a System into Components ...... 109 4.4.7 Design of Reusable Components and Setting Library ...... 110 4.4.8 Design of the Distributed Control System Image ...... 110 4.4.9 Building, Management and Monitoring DCS ...... 110 4.4.10 Reference Model for a Component...... 111 4.4.11 Prototype for Basic Components ...... 112 4.4.11.1 Communication Module ...... 112 4.4.11.2 Microcomputer Module ...... 113 4.4.11.3 Application Program Module ...... 113 4.4.11.4 Interface Module ...... 113 4.4.11.5 Physical Module ...... 114 4.4.12 Functions of a Component ...... 114 4.4.12.1 Local Computation ...... 114 4.4.13 DCS Design ...... 116 4.4.14 Defining DCS ...... 116 4.4.15 Design and Editing the System Image ...... 117 4.4.16 Composition of the System Image Database ...... 117 4.4.16.1 Component Database ...... 117 4.4.16.2 Device Database...... 118 4.4.16.3 Network Variable Connection Database ...... 118 4.4.16.4 System lriformation ...... 118 4.4.16.5 Producing the Database...... 118 4.5 Components based Semi-Autonomy Vehicle (SAV) ...... 118 4.6 Reference ...... 120
5 Fieldbus for Control and Diagnostics ...... 123 5.1 Introduction ...... 123 5.2 Fieldbus for Control Applications ...... 124 5.2.1 Pilot Plant ...... 124 5.2.2 Description of the DeltaV System ...... 126 5.2.3 Foundation Fieldbus Technology ...... 127 5.2.4 System Hardware and Software ...... 128 5.2.5 Configuring Fieldbus loops in the DeltaV ...... 130 5.2.6 Defining the Software Control Strategy ...... 130 5.2.7 Downloading the Control Strategy ...... 131 5.2.8 Commissioning the Fieldbus Instruments ...... 131 Contents XIII
5.2.9 Configurations of the DeltaV System ...... 131 5.2.9.1 MMI Screens/or the Controllers ...... 134 5.2.10 Discussion ...... 135 5.3 Control Valve Diagnostics ...... 135 5.4 Summary ...... 138 5.5 Acknowledgement...... 140 5.6 References ...... 140
6 Control of Flexible Conveyor Systems for Automated Assembly ...... 141 6.1 Introduction ...... 141 6.2 Materials Handling Systems (MHS) in FAS ...... 141 6.3 Control of Contemporary Conveyor Systems ...... 142 6.4 Requirements for FCS in the Control of F AS ...... 144 6.5 Object-oriented Modelling ofFCS ...... 146 6.6 Functional Model of the FCS ...... 149 6.7 Industrial Distributed Control Networks ...... 150 6.8 Contemporary Programmable Logic Controllers ...... 151 6.9 Fieldbus Control Networks ...... 152 6.10 Intel Bitbus Control Network ...... 154 6.11 Real-time Control System for FCS ...... 156 6.11.1 The Definition File Format ...... 156 6.11.2 Device Control Section ...... l56 6.11.3 Control Rules Section ...... 156 6.11.4 Product Routing Section ...... 157 6.11.5 LEX and YACC File Translator ...... 158 6.12 A Field-Level Message Control System (FMCS) ...... 158 6.12.1 The System Architecture ...... 158 6.12.2 Bitbus Master Tasks ...... 161 6.12.3 Interoperability ofFMCS with the Cell Controller ...... 162 6.12.4 Graphical Platform for the Design & Setup of FCS ...... 163 6.13 Conclusion ...... 166 6.14 References ...... 166
7 Control Networks and the Internet...... 171 7.1 Introduction ...... 171 7.2 The Embedded World ...... 173 7.3 Extending the Internet...... 175 7.4 Control Networks ...... 176 7.5 LONWORKS® Technology ...... 179 7.6 Conclusion ...... 181 7.7 References...... 181
8 The SERCOS Interface™ for Digital Motion Control...... 183 8.1.The SERCOS Interface ...... 183 8.1.1 SERCOS Interface™ is a Standard ...... 183 8.1.2 How it Works? ...... 184 XIV
8.1.3 Ideal for Distributed Multi-axis Control Systems ...... 184 8.1.4 Advantages ...... 185 8.2 Brief History of the SERCOS Interface ...... 185 8.2.1 Traditional Control Architecture ...... 186 8.2.2 Interface Point for Analog Drives ...... 187 8.2.3 Problems Inherent in ±IO V Interface ...... 187 8.2.4 Digital Drive Challenges ...... 188 8.2.4.1 Parametric Adaptation ...... 188 8.2.4.2 Diagnostic Information ...... 188 8.2.4.3 Drift Offset ...... 189 8.2.5 Next Generation Interface Criteria ...... 189 8.2.6 A New World Standard ...... 189 8.2.7 Not Just for Machine Tools ...... 190 8.3 What the SERCOS Interface is Not...... 190 8.4 How the SERCOS Interface Communicates ...... 192 8.4.1 SERCOS Interface Topology ...... 192 8.4.2 Communications Structure ...... 192 8.4.2.1 Fiber Optics ...... 192 8.4.2.2 Fiber Optic Transmitters/Receivers ...... 194 8.4.3 SERCOS Interface ASICs ...... 194 8.4.4 Timing ...... 195 8.4.5 Interface Placement...... 195 8.4.6 SERCOS Interface IONs ...... 196 8.4.7 System of Units &Variable Format...... 198 8.4.7.1 SERCOS Interface Cycles ...... 198 8.4.8 Cyclic Operation ...... 198 8.4.8.1 Telegram Format ...... 199 8.4.8.2 Telegram Sequence ...... 199 8.4.9 Master Synchronization Telegram ...... 200 8.4.9.1 Amplifier (Drive) Telegram ...... 201 8.4.9.2 Master Data Telegram ...... 202 8.4.9.3 Service Channel ...... 203 8.4.9.4 Example of Cyclic Operation ...... 204 8.4.10 Error CorrectionlDiagnostics ...... 205 8.4.11 System Safety ...... 205 8.5. SERCANS ...... 206 8.6. SoftSERCANS ...... 206 8.6.1 Performance ...... 207 8.6.2 Field Experience ...... 207 8.6.3 Other Software Motion Products ...... 208 8.7 Speed and Determinism Considerations ...... 208 8.8 Comparison to Competitive Interfaces ...... 209 8.8. I Proprietary Digital Technologies ...... 209 8.8.2 MACRO ...... 209 8.8.3 Servo Communications based on FireWire ...... 209 8.8.4 SERCOS Interface ...... 211 Contents XV
8.9. General-Purpose Motion and Machine Tool Features ...... 212 8.10 Confonnance Testing ...... 212 8.11 SERCOS Interface Developer's Kit...... 213 8.12 Support Organizations ...... 213 8.13 Future Technical Advancements ...... 213 8.14 Acknowledgements ...... 214 8.15 References ...... 214
9 Control of Fieldbus-based Systems Via the Internet...... 215 9.1 Introduction ...... 215 9.2 Evolution of Control Systems and Fieldbuses ...... 215 9.2.1 Expanding the DCS/FCS with the Internet...... 218 9.2.2 Monitoring of the DCS/FCS via the Internet ...... 220 9.2.3 Software Architecture ...... 222 9.2.3.1 Software Platform ...... 224 9.2.3.2 HTTPServer ...... 224 9.2.3.3 Communication Protocol ...... 224 9.2.3.4 User Interface Access Security Sockets ...... 225 9.2.3.5 Access Security ...... 225 9.3.2.6 Sockets ...... 225 9.2.4 Evaluation of Application ...... 225 9.2.4.1 Interactivity ...... 227 9.2.4.2 Automated Alarms ...... 227 9.2.4.3 Wireless Internet Technologies ...... 228 9.3 Knowledge-based Control via the Internet...... 228 9.3.1 Hardware Architecture ...... 231 9.3.2 Software Architecture ...... 231 9.3.3 Advantages ...... 232 9.4 Example: Vibration Monitoring and Control...... 233 9.4.1 Operational Principles ...... 233 9.4.2 System Configuration ...... 233 9.4.3 Inferencing Process ...... 235 9.4.4 Experiments ...... 238 9.4.4.1 Generation of the Vibration Signature ...... 238 9.4.4.2 Inferencing Process ...... 238 9.4.4.3 Tests ...... 239 9.4.5 Learning Mode ...... 240 9.4.6 Monitoring Mode ...... 241 9.5 Conclusions ...... 243 9.6 References ...... 244
10 CORBA-based Middleware for the CAN ...... 245 10. I Introduction ...... 245 10.2 Related Work ...... 246 10.3 Hardware Model and Software Abstraction ...... 247 10.3.1 Functional Control Unit ...... 248 XVI
10.3.2 Embedded Control Network ...... 248 10.3.3 Two Abstract Communication Channels ...... 249 10.3.3.1 Invocation Channels ...... 249 10.3.3.2 Connections ...... 249 10.3.4 CORBA-based Middleware Configuration ...... 250 10.3.4.1 Group Object reference ...... 251 10.3.4.2 CAN-based Transport Protocol ...... 251 10.3.4.3 Publisher/Subscriber Scheme ...... 251 10.3.4.4 Compact Common Data Representation ...... 252 10.3.4.5 Embedded Inter-ORB Protocol (EIOP} ...... 252 10.4 CAN-based transport Protocols for Middleware ...... 252 10.4.1 Defining the Protocol Header...... 252 10.4.2 Protocol for Subscription-based Communication ...... 254 10.4.2.1 Global Binding Database ...... 254 10.4.2.2 Channel Announcement and Subscription ...... 254 10.4.3 Protocol for Point-to-point Communication ...... 255 10.5 Programming Models of Two Communication schemes ...... 257 10.5.1 Anonymous Publisher/Subscriber Communication ...... 257 10.6 Client/Server Communication ...... 259 10.7 Extending Embedded Inter-ORB Protocol...... 260 10.7.1 Compact Common Data representation ...... 261 10.7.2 EIOP Messages ...... 262 10.7.3 Optimizing EIOP Message Headers ...... 263 10.8 Experiments and Performance Results ...... 265 10.8.1 Performance Metrics ...... 265 10.8.2 Protocol Processing Latency ...... 265 10.8.2.1 Static Memory Footprint ...... 266 10.8.3 EIOP Protocol Processing Latencies ...... 266 10.8.4 Static Memory Requirement ...... 266 10.9 Conclusion ...... 267 10.10 References ...... 268
11 A Synchronous Model for Fieldbus Systems ...... 271 11.1 Introduction ...... 271 11.2 The Synchronous Model...... 272 11.3 Distributed Systems Concepts ...... 272 11.3.1 System Model...... 274 11.3.2 Communication for Periodic Fieldbus Systems ...... 274 11.3.3 Analysing Adapted Synchronous Network Model...... 276 11.3.4 Pulse Generation (Network Period Time) ...... 277 11.3.5 Pipelined Computations ...... 279 11.3.6 Interleaved Computations ...... 280 11.3.7 Consumption and Network Behavior ...... 280 11.4 Applications of Synchronous Model...... 281 11.4.1 Framework 1 ...... 283 11.4.2 Framework 2 ...... 284 Contents XVII
11.4.3 Application of the Frameworks ...... 285 11.4.3.1 Deriving Message Deadlines ...... 285 11.4.3.2 Message Scheduling ...... 286 11.4.3.3 Peiformance Evaluation ...... 286 11.4.3.4 Period Time Optimization ...... 288 11.5 Computerized Numerical Controller...... 288 11.5.1 Computerized Numerical Controller Architecture ...... 289 11.5.1.1 Placement ofthe Fieldbus within the CNC...... 291 11.5.1.2 Requirements on the Fieldbus ...... 292 11.5.2 Phoebus II x Fieldbus ...... 292 11.5.3 Mapping Adapted Synchronous Model on a Fieldbus ...... 292 11.6 Conclusions ...... 294 11.7 References ...... 294
12 Advanced Functions for Fieldbus Cased Integrated Control Systems ...... 297 12.1 Introduction ...... 297 12.2 Integrated Control Systems ...... 298 12.3 Intelligent Field Devices (IFD) ...... 299 12.4 The Role of Fieldbus in an Integrated System ...... 302 12.5 From the signal list to the Device List ...... 304 12.6 Evaluating the Fieldbus Load ...... 305 12.7 Maintenance and Diagnostics ...... 308 12.7. 1Real-time Diagnostic ...... 308 12.7.2 Off-line Diagnostic ...... 309 12.8 Conclusions ...... 310
13 Real-time Communication Using Foundation Fieldbus ...... 311 13.1 Introduction ...... 311 13.2 A Brief Description ofFF ...... 312 13.3 The Structure and Mechanism ofDLL...... 313 13.3.1 Media Access Sub-Layer...... 313 13.3.2 Data TransferSub-Layer ...... 315 13.3.2.1 Data Transfer for PIS VCR ...... 315 13.3.2.2 Data Transfer for CIS VCR ...... 315 13.3.2.3 Connection less Data Transfer for RDVCR ...... 315 13.3.3 Token and VCR ...... 316 13.3.4 Protocol ofFF DLL...... 316 13.4 Frame Structure and Communication Time ...... 318 13.4.1 Scheduled Communication ...... 319 13.4.2 Unscheduled Communication ...... 319 13.4.3 Client/Server VCR Communication ...... 320 13.4.4 RD VCR Communication ...... 321 13.5 The Scheduled of Hard Real-time Communication ...... 321 13.5.1 Periodic Message Model & Precedence Constraints ...... 322 13.5.2 Heuristic Scheduling Algorithm ...... 324 13.6 The Scheduled of Soft Real-time Communication ...... 328 XVIII
13.7 Conclusion ...... 329 13.8. References ...... 330
14 Foundation Fieldbus and Its Interoperability ...... 333 14.1 Introduction ...... 333 14.2 What is Fieldbus? ...... 333 14.3 End-user Requirement...... 334 14.4. Foundation Fieldbus ...... 334 14.4.1 Interoperability ...... 335 14.4.2 Reasons for Non-interoperability ...... 336 14.4.3 Building Interoperability ...... 337 14.4.4 The Steps ofImplementation oflnteroperability ...... 338 14.4.5 Interoperability in Foundation Fieldbus ...... 338 14.5 Foundation Fieldbus Model...... 338 14.5.1 Function Block ...... 339 14.5.2 Predefined Function Blocks ...... 340 14.5.3 Application based on Function Blocks ...... 341 14.5.4 Object Dictionary (OD) ...... 341 14.5.5 Object Description ...... 342 14.5.6 The Structure ofOD ...... 343 14.5.7 OD Directory and Use ofOD ...... 343 14.5.8 Device Description (DD) ...... 344 14.5.9 Structure ofDD ...... 345 14.5.10 Development ofDD ...... 345 14.5.11 Use ofDD ...... 347 14.6 Interoperable Fieldbus Device Testing ...... 348 14.7 Interoperations Cross the Levels via OPC ...... 349 14.7.1 What is OPC? ...... 349 14.7.2 Why Was OPC Created? ...... 349 14.7.3 OPC Standard Benefits ...... 350 14.7.4 OPC Architecture ...... 351 14.7.5 Using OPC in an Industrial Information System ...... 351 14.7.6 OPC Specification Types ...... 352 14.7.7 Dependence on the Programming Language ...... 353 14.7.8 The Future ofOPC ...... 354 14.8 Conclusion ...... 354 14.9 Reference ...... 354
15 Distributed Real-time Control Systems Using CAN Bus ...... 357 15.1 Introduction ...... 357 15.2 The Need for Time-triggered Approach in CAN ...... 359 15.3 Clock Synchronisation ...... 461 15.3.1 Basic Concepts ...... 362 15.3.2 Fault Model...... 363 15.3.3 Clock Synchronisation Algorithms ...... 363 15.3.3.1 Structures ...... 364 Contents XIX
5.3.3.2 Clock Synchronisation Blocks ...... 364 IS.4 CAN-Oriented Algorithms ...... 36S IS.S Measuring Message Latency in CAN ...... 367 IS.S.1 Experimental Set-up ...... 368 IS.S.2 The Clock Skew ...... 369 IS.S.3 Measuring Message Latency ...... 370 15.5.3.1 Defining the Measured Latency ...... 370 15.5.3.2 Messages Used in the Experiment ...... 371 15.5.3.3 Message Latency with Standard CAN ...... 374 15.5.3.4 Latency with Time-triggered Approach ...... 37S IS.6 Control of a Three-motor Based Actuator ...... 376 IS.6.1 Control Problem ...... 377 IS.6.2 Controller Design ...... 377 IS.6.3 Timing Diagram ...... 379 IS.6.4 Experimental Results ...... 380 IS.7 Conclusions ...... 381 IS.8 References ...... 382
16 Network Architecture for Home Automation ...... 387 16.1 lntroduction ...... 387 16.2 Two Major Protocols in Home Network Industry ...... 389 16.2.1 LonTalk ...... 389 16.2.2 IEEEI394 ...... 389 16.2.3 Comparison of Idiosyncrasies ...... 390 16.3 Design Requirements for Practical Home Networking ...... 391 16.3.1 Accommodating Devices ...... 392 16.3.2 Middleware in Node-Level consumer Devices ...... 392 16.3.3 Configurable Network Hardware Architecture ...... 392 16.3.4 Asynchronous Messaging System ...... 392 16.3.S Resource Repository based on Tuple-Space ...... 393 16.3.6 Minimizing Overhead ...... 393 16.4 Conceptual Overview of Proposed Architecture...... 393 16.4.1 Network Configuration: IEEE1394 Backbone ...... 39S 16.S Overall Architecture of Proposed Middleware ...... 396 16.S.1 Network Managers ...... 397 16.S.2 Device Manager...... 397 16.S.3 Device Proxy ...... 397 16.S.4 Resource Repository and Repository Manager...... 398 16.S.S Priority-based Event Channel...... 398 16.S.6 Real-time Driver for Backbone Protocol Adaptor...... 399 16.S.7 Priority-based Event Channel...... 399 16.S.8 Event Message Format, Producer & Consumer...... 399 16.S.9 PreProcess Module ...... 400 16.S.10 Priority Queues and Dispatcher...... 400 16.S .11 Resource Repository and Manager...... 400 16.5.11.1 Space based Resource Repository ...... 401 xx
16.5.11.2 Replicated Model ...... 401 16.6 Implementation and Evaluation ...... 403 16.6.1 Performance Evaluation ...... 404 16.7 Case Study ...... 405 16.7.1 Data Structure on Consumer Devices ...... 405 16.7.2 Graphical User Interface Editor Agent...... 407 16.7.3 Home Network Management Agent...... 408 16.8 Conclusion and Future Work ...... 410 16.9 Acknowledgement ...... 411 16.10 References ...... 411
17 Electromagnetic Compatibility of Fieldbus Communication ...... 413 17.1 Introduction ...... 413 17.2 EMC of Distributed Systems ...... 413 17.2.1 Communication Channel...... 414 17.2.2 EMS of Communication Channel...... 415 17.2.2.1 Physical Layer ...... 415 17.2.2.2 LinkLayer...... 416 17.2.2.3 Application Layer ...... 417 17.2.2.4 Summary ...... 417 17.3 Improvement of Communication Immunity ...... 417 17.3.1 Source of the Disturbance ...... 418 17.3.2 Disturbance Coupling ...... 418 17.3.2.1 Capacitive Coupling ...... 419 17.3.2.2 Inductive Coupling Model ...... 420 17.3.3 Origination of Communication Errors ...... 421 17.3.3.1 Receiver Errors ...... 421 17.3.3.2 Optocoupler Errors ...... 422 17.3.3.3 Link Layer Controller Errors ...... 422 17.3.4 Design of the High Immunity Communication Interface ...... 423 17.3.3.1 Selection ofComponents ...... 423 17.3.3.2 Construction ...... 424 17.3.3.3 Protection Devices ...... 425 17.4 Measurement of the EMS of Communication ...... 426 17.4.1 Generation of Disturbing SignaL ...... 426 17.4.1.1 Generator Requirements ...... 426 17.4.1.2 Selection ofthe Generator ...... 427 17.4.2 Method of Measurement...... 429 17.4.2.1Criteria ofImmunity ...... 429 17.4.2.2 Physical Arrangement of the Test ...... 430 17.4.2.3 Measurement, Results, and Evaluation ...... 431 17.5 Practical Results ...... 431 17.6 Conclusion ...... 433 17.7 References ...... 433 Contents XXI
18 Communication Protocols for Application in Agricultural Vehicles ...... 335 18.1 Introduction ...... 435 18.2 Requirements for Embedded Networks in Agricultural Machines ...... 436 18.3 CAN - Controller Area Network ...... 437 18.4 CAN - based Protocols in Agriculture ...... 439 18.4.1 ISO 11783 ...... 439 18.4.2 Agricultural Bus System: LBS ...... 441 18.4.3 ISOBUS ...... 441 18.4.4 Application Example: A Planter Monitor ...... 442 18.5 Wireless Networks ...... 444 18.5.1 IEEE 802.11 ...... 445 18.5.2 IEEE 802.15 (Blue tooth) ...... 445 18.5.3 GSM ...... 445 18.5.4 HomeRF ...... 446 18.5.5 ZigBee ...... 446 18.6 Discussion ...... 446 18.7 References ...... 448
19 P-NET: European Fie1dbus Standard ...... 451 19.1 Introduction ...... 451 19.2 Design Criteria ...... 451 19.3 Access to the Bus ...... 452 19.4 Resultant Speed ...... 453 19.5 Multi-net Operation ...... 454 19.6 Distributed Contro1...... 455 19.7 Channel Structure ...... 455 19.8 Process Objects ...... 457 19.9 SCADA & Data Logging using VIGO Manager ...... 458 19.9.1 VIGO Overview ...... 458 19.9.2 PRO-View ...... 460 19.9.2.1 Background...... 461 19.9.2.2 Dynamic Elements ...... 461 19.9.3 PRO-Log ...... 462 19.10 Conclusions ...... 465
20 The INTERBUS ...... 467 20.1 Introduction ...... 467 20.2 Why Fieldbus Technology? ...... 467 20.2.1 Selecting a Fieldbus System ...... 468 20.2.2 Different Data and Devices ...... 469 20.2.3 Variety of Devicesl Integrating All Devices ...... 469 20.2.4 General Technical Requirements ...... 470 20.2.4.1 Security ...... 471 20.2.4.2 Expansion ...... 471 20.2.4.3 Diagnostics ...... 471 XXII
20.2.4.4 Product Availability ...... 471 20.3 Introduction to INTERBUS ...... 471 20.3.1 Topology and Structure ...... 472 20.3.2 Topology Flexibility ...... 472 20.3.3 Basic Elements ofINTERBUS ...... 473 20.3.4 Data Transmission with INTERBUS ...... 474 20.3.4.1 Master/Slave Structure ...... 474 20.3.4.2 Cycle Time and Calculation ...... 475 20.3.4.3 PCP Transmission ...... 475 20.3.4.4 Transmission Reliability ...... 476 20.3.4.5 Determinism ...... 476 20.3.4.6 Optimum EMC Behavior ...... 476 20.4 Automation with INTERBUS ...... 476 20.4.1 CMD: One Tool, All Control Systems ...... 477 20.4.2 Process Data preprocessing ...... 477 20.4.3 Provision of Operating Data ...... 477 20.4.4 Operation and Maintenance ...... 478 20.4.4 Clear Error Diagnostics ...... 478 20.4.5 Preventative Error Removal; Reducing Downtimes ...... 478 20.4.6 Evaluation of Optical Fiber Paths ...... 478 20.4.7 Diagnostic Tools ...... 479 20.5 Automation Components Detail ...... 479 20.5.1 Electrical Isolation of Different Media ...... 479 20.5.2 Combined Systems ...... 479 20.6 Field Components ...... 480 20.6.1 Standard Interface ...... 480 20.6.2 INTERBUS Implementation ...... 480 20.6.3 PCP Functions ...... 481 20.6.4 ID Code for Unique Identification ...... 481 20.6.5 INTERBUS Implementation ...... 482 20.7 All Control Systems: One Bus - INTERBUS ...... 482 20.7.1 Control System Functions with INTERBUS ...... 482 20.7.2 Master/slave Method ...... 482 20.7.3 INTERBUS Master...... 482 20.7.4 PLC or PC Card ...... 483 20.8 Standardization and Security ...... 483 20.8.1 Product Compatibility ...... 483 20.8.2 INTERBUS Certificate ...... 483 20.8.3 Configuration and Startup ...... 483 20.84 Software and Interfaces ...... 484 20.8.5 The Web Enabled Factory ...... 484 20.8.6 Open Control Foundation ...... 484 20.8.7 Distributed Intelligence ...... 485 20.8.8 Ethernet TCP/IP ...... 485 20.8.8 Into the Future with INTERBUS ...... 485 20.8.9 Communication Protocols ...... 485 Contents XXIII
20.8.10 Solutions for All Manufacturers ...... 485 20.9 INTERBUS club - A Strong Community ...... 486 20.9.1 INTERBUS is Internationally Standardized ...... 486
21 Channel Backlog Estimation in LonWorks® ...... 487 21.1 Introduction ...... 487 21.2 MAC Sub-Layer of the LonTalk Protocol...... 488 21.3 Predictive p-persistent CSMA ...... 489 21.4 Interface to Link Layer and Physical Layer ...... 490 21.5 Petri-Net Token pLayer...... 490 21.6 Predictive p-persistent CSMA Model...... 492 21.7 No Propagation Delay, No Backlog Estimation ...... 492 21.8 Propagation Delay, No Backlog Estimation ...... 495 21.9 Propagation Delay, Backlog Estimation ...... 497 21.10 Conclusion ...... 499 21.11 References ...... 499
22 The WorldFIP ...... 501 22.1 Overview ...... 501 22.2 Physical Layer ...... 502 22.3 Data Link Layer...... 504 22.3.1 Communication Objects ...... 504 22.3.2 Communication Mode ...... 506 22.3.3 Bus Redundancy ...... 509 22.4 Application Layer ...... 509 22.4.1 Local Read/Write ...... 510 22.4.2 Reception/Transmission Indications ...... 510 22.4.3 Remote ReadlWrite ...... 510 22.4.4 Resynchronization ...... 511 22.4.5 Validity of Variables ...... 511 22.4.5.1 Asynchronous Refreshment ...... 512 22.4.5.2 Asynchronous Promptness ...... 513 22.5 Network Management ...... 514 22.5.1 Local and Remote Services ...... 515 22.5.2 Multi-AEs ...... 516 22.5.3 List ofSM MPS Services ...... 516 22.5.4 SM MPS Services and PDUs ...... 517 22.5.5 SMS ...... 517
23 Some Studies on CAN Fieldbus ...... 519 23.1 Introduction ...... 519 23.2 CAN Physical Layer...... 520 23.3 Error Detection ...... 523 23.4 Message Transfer ...... 524 23.5 Data Frame ...... 524 23.6 Remote Frame ...... 525 XXIV
23.7 Error Frame ...... 526 23.8 Overload Frame ...... 526 23.9 InterFrame Spacing ...... 526 23.10 Fault Confinement ...... 527 23.11 Bit Timing ...... 527 23.11.1 Clock Synchronization ...... 528 23.11.2 Bus Failure Modes ...... 528 23.12 Conclusions ...... 529 23.13 References ...... 529
24 Fault Correcting and Temporally Predictable Fieldbus Communication .... 531 24.1 Introduction ...... 531 24.2 Time Synchronisation and Event Handling 532 24.2.1 Time Synchronisation of Slave Nodes ...... 532 24.2.2 ASIC for Event Handling ...... 534 24.3 Signal Encoding ...... 534 24.3.1 Signal Encoding for Particular Telegram Parts ...... 535 24.3.2 Waveform and Frequencies for Proper Detection ...... 537 24.3.3 Frequency Detection by FFT ...... 539 24.3.4 Simulation of Frequency Detection ...... 540 24.3.5 Experiments with Various Disturbances ...... 541 24.3.6 The Goertze1 Algorithm ...... 542 24.3.7 Results of Frequency Detection ...... 542 24.4 Security of Telegram Transfers ...... 543 24.4.1 Hamming Encoding of Data Nibbles ...... 543 24.4.2 Decoding Secured Data Nibbles ...... 544 24.5 Overview on Signal and Data Encoding ...... 544 24.6 Conclusion ...... 546 24.7 References ...... 547
25 Application of Fieldbus Technology in Mechatronic Systems ...... 549 25.1 Introduction ...... 549 25.2 Spindle Systems Review ...... 551 25.3 Dynamic Modelling ofHSSS ...... 552 25.3.1 Identification ...... 553 25.4 Mechanical Design and Dynamic Curves ...... 558 25.4.1 Q-point Curves ...... 561 25.4.2 Thermal Deformation and Bearing Surroundings ...... 562 25.4.3 Bearing Friction ...... 564 25.4.4 Electromagnetic Balancer...... 564 25.5 Diagnostics and Prognostics ...... 566 25.5.1 Formulation ...... 568 25.5.2 Experiment ...... 569 25.6 SEA Scheme ...... 571 25.6.1 Machine Evolution and Sustainability ...... 571 25.6.2 SEA Variables and LSV ...... 571 Contents XXV
25.6.3 Methods of Realization and Results ...... 572 25.7 Approach to Design Control Systems ...... 574 25.7.1 DCS Realizing PlatfoTIn ...... 575 25.8 Remote Monitoring and Control ...... 579 25.8.1 The Need for Interfacing DN with CN ...... 579 25.8.2 Realization Study ...... 580 25.9 Conclusions ...... 581 25.10 References ...... 581 Authors
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