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Open Control Systems and Devicenet Applications

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Open Control Systems and Devicenet Applications 1 Open Control Systems and DeviceNet Applications Yoshihiro Miyazaki Industrial Systems Division, Industrial Computer Systems Dept. Hiroaki Fukumaru Omika Control Product Systems Division, Control Systems Development Dept. Recent years have seen significant changes in Japan's manufacturing environment. Even as the country has entered a period of low economic growth, globalization of manufacturing through a shift to overseas production has been on the increase. Within this environment, changes are also taking place in information control systems that today integrate everything from databases to manufacturing lines. The increasing use of personal computers, Ethernet applications and so forth is rapidly making such systems more open while also making them more cost-effective. Additionally, field devices such as sensors and actuators (hereafter devices) are requiring less wiring and consequently are becoming lower in cost with the increasing use of field-level networks(hereafter field networks) to connect them. This paper describes recent trends in technologies being used to increase the "openness" of information control systems. It furthermore introduces and describes the features of "DeviceNet", a field network whose superior real-time performance makes it well suited for application to the FA field. 1.THE TREND TOWARD MORE OPEN and an increasing trend towards internationalization CONTROL SYSTEMS in the sector (Fig. 1). Customer needs have also The manufacturing industry has undergone major changed from the era of mass consumption, with ever- changes in recent years, including a shift towards increasing demand for greater diversity in products slower growth, drastic overhauling of price structures, and shorter lead time in bringing them to the market. Change of Social Structure Standardization/More Openness on Global Scale Nation Hardware Closed competetion → Mega-competetion Enterprise Low Cost PCs Ethernet Pyramid Structure → Flat Structure Standard Manufacturing Windows Components DeviceNet Mass → Variable IEC61131-3 LONWOWKS Production Production Soft ware Intelligent Devices Quick Response Standardization Multivendors to Change Proposal Common Infrastructure from Japan Japan User Needs Multivendor Features Low Price New v Information&Control Open/Defact Standard 10 year Maintenance Single Vendor x Systems PC Architecture, WindowsNT Maintenance x Ethernet,Field Network Open & Dependable Information/Control vApplicability to FA Environment Integrated System x High Reliability,24-hour Operation x Realtime Control, 10-year Support v SE-less Seamless System Architecture Phase Construction x Autonomous Decentralized System Compatibility Keeping Reliable Construction Fig. 1—Environment Around Information&Control Systems 2 Open Control Systems and DeviceNet Applications For manufacturing systems to keep up with these seamless architecture for everything from devices to changes, they need to made more flexible so that they information systems, in which multivendor equipment can respond quickly to changes, and they need to lower works together in a smooth and unified manner, the cost of bringing out products. enabling the system to be changed and improved easily. The computer industry, too, has undergone To achieve such systems, then, requires that the remarkable changes of late. Striking developments FA field adopt and strengthen the newest open have been made in technologies to improve the technologies that have been put to use in OA and other performance, lower the cost, and increase the openness fields. In response to these needs Hitachi has of Local Area Networks (LANs) comprising personal developed a new information control system, adopting computers (hereafter PCs), the Ethernet and so on. "open" and "dependable" as keywords, "dependable" These technologies are rapidly finding more and more being synonymous with "having high reliability". The uses and applications in both the office automation main features of the system are (1) its openness based (OA) and factory automation (FA) fields. on the use of PCs, Ethernet, field networks and so on, Against this background, many have eagerly (2) its applicability to an FA system environment based awaited the development of a manufacturing system on its high reliability and use of real-time technology, that can bring out products at low cost and respond and (3) its seamless system architecture based on quickly to changes in the market, by being able to autonomous decentrilized system (hereafter ADS) freely and immediately adopt the latest technology technology. developments in a multivendor environment. In increasing the dependability of systems, they The rush to incorporate the newest in open should be made more open so that system equipment technologies into the OA field has, however, created from different vendors can work together smoothly problems from the standpoints of both reliability and instead of operating as separate units, so that signals real-time performance. Manufacturing lines cannot be can be transmitted using internationally standardized allowed to go down with the same frequency that protocols, not simply domestic ones. Let us consider ordinary PCs do; they must have the real-time Hitachi's ADS technology as an example of this. When performance that is required of a manufacturing line. the technology was made open at the end of 1996, the They also have to have long-term operability consistent use of its interface specifications enabled multiple- with the operating life of the line equipment. vendor PCs, servers, and controllers to be freely and Manufacturing systems, furthermore, should have a flexibly connected to the standard Ethernet. Small-scale Systems Medium/large-scale Systems Optical/wireless LAN ISDN Control PC Servers Control PC Servers Internet PC PC PC Note PC Ethernet (+ ADS) Ethernet FL-net (Ethernet base) Open Field Network Controller (DeviceNet) Field Network (DeviceNet) Devices Devices ADS:Autonomous Decentralized System (Actuator) (Sensor) Features ( 1 ) Open (PC/AT Compatible,WindowsNT, Ethernet, DeviceNet, IEC61131-3) ( 2 ) Dependable (High Reliability/maintainability, Real-time Performance) ( 3 ) Seamless (Small- to Large-scale, Unified Architecture from Devices to Computers) Fig. 2—New Information&Control System Structure (Example) 3 Furthermore, this technology was proposed by ODVA systems are expected to proliferate rapidly in the future. (Open DeviceNet Vendor Association) for DeviceNet, Regarding interfaces to devices such as sensors a representative example of a field network, and was and actuators, in recent years there has been a rapidly incorporated as a standard specification in Release 2.0. accelerating move away from conventional individual This has made possible the development of seamless parallel wiring to serial wiring that utilizes field system architectures in everything from devices to networks. There are any number of open field networks information systems. that are open networks, and the chips that support them Figure 2 shows an example system structure of are being marketed, but there has been little progress the new information control system. made in unifying them into a single network such as In man-machine systems employing low-cost PCs, Ethernet. Instead, different types of field networks are a great deal of inconvenience is the result whenever a applied to different fields. In the next chapter we server goes down. Thus control PC servers employ a compare the characteristics of DeviceNet, the PC architecture that makes use of high-reliability mainstream field network applied in the FA field, with technology to ensure long-term stable operation. In those of other types of field networks. LANs both information systems and control systems both make use of the standard Ethernet, and an 2. DEVICENET FEATURES Ethernet-based FA control network with added real- DeviceNet is a field network whose superior real- time performance is employed in the high-speed time performance makes it well suited for application connections between controllers. A field network (e.g., to the FA field. The range of devices supported by DeviceNet) is applied in the connections to devices, DeviceNet and other major field networks is shown in and costs are kept low by minimizing the amount of Fig. 4. wiring needed. In Japan, standardization in the FA field is chiefly Sensors Actuators being advanced by the Japan FaOpen Systems High Master/Slave Infrared Analyzer Motor Drive Promotion Group (JOP) of the Manufacturing and Electromagnetic Analyzer Loop Controller Science Technology Center (MSTC) supported by the Machine Vision Inverter Drive Remote I/D Bar Code Reader Ministry of International Trade and Industry. The or- Performance Micro-inverter PROFIBUS ganizational structure of MSTC is outlined in Fig. 3. Flowmeter Control Valve Thermometer Soft Starter Pressure Meter Foundation Fieldbus Encoder Motor Starter Contacter Manufacturing and Science Technology Center (MSTC) Opto-electric Switch DeviceNet Solenoid Proximity Switch Japan FaOpen Systems Promotion Group(JOP) Limit Switch LONWORKS Low FA Open Vision Technical Committee Production System Models Technical Fig. 4—Range of Devices Supported by Field Networks Committee WG1 WG2 Distributed Manufacturing Architecture DeviceNet supports a wide range of devices, from Project Ethenet + ADS Technical Committee switches to drive controllers. A comparison of FA Control Network WG Project FL-net Technical Committee (Ethenet base) DeviceNet specifications with those of other major Open Controller
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