The Technologies Reshaping Industrial Network Infrastructure Plan Ahead for the Accelerating Convergence of IT and OT Architectures

Technology REPORT

The Technologies Reshaping Industrial Network Infrastructure Plan ahead for the accelerating convergence of IT and OT architectures

Sponsored by Is Your Infrastructure Friend or Foe?

As technology advances and Industry 4.0 becomes a reality, the demands placed on your network and electrical infrastructure will only increase. To stay competitive, you need plant floor solutions that improve production efficiencies, turn operations data into actionable insights, and scale for future growth. From cable management for control panels to fully integrated industrial networks, Panduit solutions turn connectivity into a competitive advantage. To read our white paper on Edge IoT deployments, visit www.panduit.com/edgeiotdeployments.

® INDUSTRIAL NETWORK ZONING | CONNECTIVITY | DISTRIBUTION FRAMES | CABLE MANAGEMENT | WIRING DUCT infrastructure for a connected world

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CONTENTS

Users sound off on industrial networking needs 4

Plan two steps ahead to support network infrastructure needs 9

IIoT, cloud computing changing controlsystem architectures 12

The promise of single-pair Ethernet 14

Edge, cloud or something in between? 19

MQTT getting what it needs to go industrial 24

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Users sound off on industrial networking needs

Feeling ill-prepared for the demands of Industry 4.0, plants and factories are on the look-out for infrastructure technologies that can give business performance a boost

By Keith Larson, Editor-in-Chief, Control p Out of sight, out of mind. quickly escalated for trouble- are the conclusions to be drawn It’s easy to imagine that much shooting, the majority of industry from a just-completed survey of like a typical homeowner’s benign users say they are proactively on Control and Smart Industry readers neglect of the wiring, plumbing the look-out for new networking on their attitudes toward—and and HVAC systems that make infrastructure technologies that can adoption of—industrial networking modern life possible, industry’s boost business performance. Such infrastructure technologies. engineering and operations teams don’t pay much attention to the industrial networking infra- The majority of industry users structure that powers modern manufacturing. That is, until some- say they are on the look-out for thing goes wrong. new networking infrastructure And while it’s likely true that technologies that can boost production problems due to network performance issues are business performance.

Figure 1. Which of the following statements We wait until network performance or best characterizes your organization’s planning reliability issues force us to consider an horizon for new plant-floor networking infrastructure modernization. infrastructure technology?

We evaluate new networking 17% infrastructure option every 10 years or so.

6% We are always on the lookout for networking infrastructure % that can improve the 52 performance of our business.

We evaluate new networking infrastructure option every five years or so. 25%

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SURVEY METHODOLOGY & RESPONDENT DEMOGRAPHICS In January and February of 2019, an email survey was sent to members of the Control and Smart Industry communities. A total of 114 survey responses were received, with industry, company size and job function demographics as follows.

BY INDUSTRY

Discrete manufacturing/ industrial machine builder 14% Process manufacturing Engineering 40% integration services 32%

15%

Other

BY NUMBER OF EMPLOYEES

More than 10,000 Fewer than 100 27% 40%

% 1,000 – 10,000 18 16%

100 – 1,000

BY JOB FUNCTION

IT/networking infrastructure Other (specify) Plant operations Plant 7% management 16% 6%

66%

Engineering

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CRITICALLY IMPORTANT SOMEWHAT IMPORTANT NOT IMPORTANT

Reliability 92% 8% —

Performance 82% 18% —

Conformance with open standards 51% 42% 7%

Ongoing support services 42% 50% 8%

Cost 29% 67% 4%

Turnkey implementation 19% 60% 21%

Figure 2. How important are the following considerations when selecting a network infrastructure solution for manufacturing/production areas?

As indicated in Figure 1, a full Meanwhile, those surveyed important criteria, followed by cost 52% of survey respondents indicate universally agreed that reliability and turnkey implementation. they are “always on the lookout” and performance are far and away We also asked a series of ques- for networking infrastructure the most important consider- tions specifically about wireless technologies that can improve the ations when selecting a network networking infrastructure in pro- performance of their business. infrastructure solution for use in duction environments, starting Another 31% of survey respondents manufacturing/production areas with current technology usage say that they periodically evalu- (Figure 2). Conformance with (Figure 3) and the use cases driving ate their network infrastructure open standards and ongoing sup- the deployment of wireless. Not options every 5 or 10 years (25% port services were the next most surprisingly, Wi-Fi was the most and 6%, respectively). On the other end of the spectrum, 17% of respondents are strictly reactive, Reliability and performance are waiting for network perfor- far and away the most important mance or reliability issues to force considerations when selecting a them to consider an infrastructure modernization. network infrastructure solution

YES NO UNSURE

1. Wi-Fi (wireless LAN) 84% 13% 4%

2. Commercial mobile (4G/LT E) 35% 54% 11%

3. WirelessHART (low-power mesh) 29% 60% 10%

4. Private mobile (4G/LT E) 21% 67% 12%

5. DAS (distributed antenna systems) 14% 75% 12%

Figure 3. If wireless networking is used in your facilities’ production areas, which of the following technologies are in use?

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Figure 4. Which of the following factors are driving the need for wireless communications in your production environments? (Check all that apply.)

40 Percent

0 Mobile worker Mobile equipment Easier to add Personnel tracking Traceability of tools communications communications sensors for for safety purposes and other equipment (e.g., phones, (e.g., forklifts, AGVs) previously tablets, PCs) unmeasured parameters commonly used (84%) followed by wireless in production areas, it’s wireless networking technologies, commercial 4G/LTE (37%) and most often up to engineering lead- including 5G and the recently WirelessHART (29%). Private ership, but IT and operations also completed Wi-Fi 6 specification. 4G/LTE and DAS, or distributed carry sway in some organizations While both of these options are antennae systems, were reported (Figure 5). under evaluation by about a third of in use by 21% and 14% of respon- The final pair of questions in survey respondents’ organizations, dents, respectively. our survey focused on the evalu- implementation of Wi-Fi 6 is being In terms of the use cases driv- ation and pursuit of key emerging actively pursued by nearly twice as ing the deployment of wireless infrastructure, mobile worker con- IT leadership nectivity and the ability to easily add sensors for previously unmea- Engineering sured parameters were most often leadership cited (Figure 4). Mobile equipment 42% 37% communications (as for automatic guided vehicles, or AGVS, and forklifts), traceability of tools and other equipment, and personnel tracking for safety purposes all 23% made the list of important use cases Plant operations for more than 30% of respondents. leadership

Interestingly, when it comes Figure 5. Within your organization, who is the key decision-maker on the use of wireless net- to decision-making on the use of working technology in production environments?

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NOT CONSIDERING UNDER EVALUATION PURSUING IMPLEMENTATION UNSURE

Wi-Fi 6 31% 29% 7% 33%

5G commercial 38% 29% 4% 29%

5G private 42% 23% 1% 33%

Citizens Broadband Radio 52% 11% 3% 34% Service (CBRS)

Figure 6. To what extent has your organization pursued the following emerging network technologies?

many—albeit still relatively few— the task of handling the growing at all.” Two percent reported their respondents’ organizations as 5G demands of Industry 4.0. A slight organizations have no intentions (Figure 6). majority of respondents ranked of using wireless, while 6%— Finally, we asked our survey themselves a middling “somewhat presumably with tongue firmly respondents whether they felt their confident” (Figure 7). in cheek—checked the box for facilities’ current wireless net- Meanwhile, 1 in 5 were either “What’s Industry 4.0?” p working infrastructure was up to “very confident” or “not confident

Don’t use/don’t plan to use wireless What’s Industry 4.0?

2% Very confident 6% 17% 19% Not at all confident 621%% 52%

Figure 7. How confident are you that your organization’s current wireless Somewhat confident 25% infrastructure is capable of handling the demands of Industry 4.0? 52%

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Plan two steps ahead to support network infrastructure needs p As industry builds towards a digitally transformed version of itself, future success will often rely on the foundation of physical network infrastructure put in place today. That means new wireless connectivity to enable mobile workers and coordinate the movements of autonomous intelligent vehicles (AIVs) must work together with the physical network infrastructure that has long been the backbone of industrial connectivity. Because so much is riding on that physical network infrastructure, Lindsey Parker believes it’s important that individuals charged with designing and implementing solutions for this realm understand the long term implications of their decisions. Physical cabling is often expected to last a couple decades or more, says Parker, manager of industrial network business development for Panduit, so it’s critical to satisfy today’s networking infrastructure needs with an eye to how those needs and requirements will change down the road. Lindsey Parker is industrial network business development manager for Panduit. Smart Industry recently caught up with Parker to learn what factors are most important to consider in an industrial network infrastructure solution, and what steps can be taken to future-proof those investments for the bandwidth-hungry in hardened cabling infrastructure applications that are sure to come. and when to use commercial grade will save you money in the long run Q: Panduit has long been a for what you need today but what while ensuring your infrastructure leader in providing the physical you’ll need tomorrow and the day can withstand its surroundings. infrastructure for digital networks after as well. Also, remember that while the as well as electrical power for plant- It’s important to know, for network infrastructure will only floor and production environments. example, what type of media is represent 7-10% of the spending on What have you found are the most suitable for your environment. You a given project, it’s got to be prop- important characteristics that don’t always need an IP67 rated erly configured. That means the industrial end users and OEMs enclosure or an M12 connector, choosing the right topology to pro- seek in a network infrastruc- but in our world, sometimes you vide appropriate performance and ture solution? do. Panduit references the TIA resiliency. ‘Should be good enough’ A: First off, don’t sacrifice per- 1005-A standard for industrial just won’t cut it. Rather, consider formance and reliability over price environments, which provides following a proven approach such and availability. Second, choose guidance through mechanical, as the Converged Plantwide Ether- partners that understand the ingress, chemical/climactic and net (CPwE) reference architecture unique requirements of industrial electromagnetic (MICE) consid- that Panduit worked with Rockwell environments. Third, plan not just erations. Knowing when to invest Automation and Cisco to define

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and validate. Using that archi- such as WiFi 6 actually require infrastructure, which supports tecture as a guide, you can know a lot more access points in order 10-Gb Ethernet. Many plants exactly what performance to expect to deliver that higher speed and operate today operate on Category from your completed solution. bandwidth. And more access points 5e cabling, which is only 1-Gb Eth- Q: While physical cabling cer- mean more cabling! ernet capable. Also, since physical tainly remains the backbone of That same equation applies to infrastructure is likely to outlive the plant-floor automation and infor- the 5G wireless infrastructure radios that are connected to it—con- mation networks, how has the being promoted by the telecom- sider running a second, redundant infrastructure equation changed munications industry. But with Cat 6A cable while you’re at it. with the increased performance the WiFi 6 vs. 5G decision, the Think two steps ahead so that you’re of wireless networks such as those biggest question is not performance better prepared for what’s to come. defined by the WiFi 6 standard but whether you want to own your Q: What types of applications and 5G from the telecommunica- network outright, or enter into a are made possible by the perfor- tions industry? contract to have that infrastructure mance of these new options? A: High-performance wireless is managed on your behalf. A: The biggest impact of these an important technology that can Another implication of the latest new wireless networks is around deliver new capabilities to industry. wireless standards is that they all workforce mobility—basic But it’s important to realize that but require Category 6A cabling information access first, then it doesn’t replace physical network Wireless apps need physical infrastructure, too! When planning for future network infrastructure infrastructure. Rather, the latest requirements, remember that the latest high performance wireless networks need extra access high-speed wireless standards points as well.

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layering in really cool stuff like now. We need it for productivity, these speed- and bandwidth-hun- augmented reality. With AR, safety and communication. gry use cases? you see major improvements in Other technologies like robot- A: Don’t jump right in. You really employee training and the ability ics and AIVs will really benefit need to take a look at your existing to more effectively utilize a remote from wireless technology, too. physical infrastructure to understand workforce. A network engineer in 5G is expected to be the catalyst what your network can support in Chicago can work with someone for autonomous vehicles on the its current state. If it resembles the unskilled in networks in a plant in roads, and I think you can expect cabling that’s out there in most of Iowa to troubleshoot a problem. to see that be the case in the plant, the industrial world, you’re probably A production operator can learn too. And obviously, the whole not ready to plug in WiFi 6 access on the job using virtual work IoT world is founded in wireless points tomorrow. Bring in the right instructions instead of taking communications. We’ll see an people to help you plan out the a training module in front of a abundance of new sensors that physical layer that will be the foun- computer screen and then trying to are lower cost and easier to deploy dation for all of this new technology remember what it said out on the and configure. and then make sure it gets installed production floor. People expect to Q: What advice can you offer properly. Once you’ve done that, your work how they live, and wireless to industrial networking deci- investments in high-performance communication is in our DNA sion-makers seeking to pursue technology will be able to shine. p

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IIoT, cloud computing changing control system architectures

Technologies are changing our view of the venerable Purdue model

By Ian Verhappen, Senior Project Manager of Automation, CIMA+ p The Purdue Enterprise systems, it is my understanding against the function(s) that equip- Reference Architecture that ISA-95, as part of their regular ment needs to perform. incorporated in the ISA-95/ review of the document, is revis- In general, layers A through D IEC 62264 standard, on which iting the architecture model, with will tend to be at the remote site, the majority of control system particular emphasis on Level 1 and which could be anything from a architectures and subsequent Level 0. single point and RTU to a remote standards including wireless, Another ISA standards compressor or pump station com- cybersecurity, safety, etc. are body, ISA-112 SCADA Systems, plete with its own “mini” control based, originated in 1989. Despite also needed an architecture model system with wireless SCADA con- being in use for almost 30 years, many people still believe that it The virtualization of systems is is based on physical layers, when it actually defines the functions changing system architectures to be performed at each level of once more, with the biggest the architecture. At the time the model was developed, and in most impacts at the top and bottom. cases today, it is still true that form follows function, and the various pieces of hardware tend to on which to base their work. The nections to associated well pads, correlate closely to their assigned present version of this model, isolation valves or remote storage function. The IEC 62443/ISA-99 which adds more granularity to facilities, thus making “site n” a cybersecurity zone and conduit the ISA-95 model, is shown in small SCADA system, or at least a concept also tends to encourage the Figure 1. data concentration site on its own. maintenance and separation of each When creating this model, ISA- Similarly, levels F and G identify of the function-based layers. 112 deliberately chose to use letters the typical SCADA components With the changes in processing to show the different layers, in part that reside on the central SCADA and computing capability we’ve to avoid confusion with the Purdue server(s), typically in the main con- seen at the different levels of the model (shown for reference on the trol center. Alarms and Historian enterprise, particularly Level 1, and side) but also to help the commit- have been identified as two typical the introduction of cloud-based tee relate the physical equipment databases residing at this level,

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Figure 1. In this model by the ISA-112 SCADA Systems standards committee, letters are used to label layers to avoid potential conflict with ISA-95 and other similar models. Routers and firewalls between layers are not shown, nor are other system-specific servers, applications and workstation. Remote-hosted external applications (cloud) could not be configured to attach to devices at any level with appropriate firewalls, tunneling and routing.

* Note that although this diagram shows a Purdue level 5, the true Purdue model only has levels 0 to 4 because it did not anticipate external applications. though as indicated by the “data- elements at any level, with, of the biggest impact at the top base” box on the right, they are by course, the appropriate cybersecu- (nonexistent Level 5 at the top no means the only ones; they are rity protocols. of the model) and again at Level just the ones that the committee Lastly, the red lines on either 1, with basic regulatory control believes require particular attention side of level J are intended to show moving closer to the process since, from a SCADA perspective, the clear demarcation between the itself. Because more functionality they will have some unique con- OT (SCADA related systems), IT in these models will reside in straints and items to be considered and public or external networks software versus the hardware- when developing a system. as a reminder to pay particular based representation, the case can The other addition to the pro- attention to the cyber requirements be made that the function-based posed SCADA model is the when crossing between different reference model will become even concept of cloud computing, layers and systems. more important since the physical presently shown as the “external The virtualization of systems hardware could potentially be applications” cloud at the top. per Open Process Automation flattened into fewer layers residing Though a link is only shown to the Forum (OPAF) and arguably in the cloud and a couple virtual databases at the SCADA server, IIoT, is changing control system machines for the hardware above there is the potential to link to architectures once more, with the sensor layer(s). p

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The promise of single-pair Ethernet

New standards tackle the ‘last mile’ of connectivity for manufacturing automation and industrial control

By Bob Voss, Senior Principal Engineer, JECIC Corporate R&D Center, Panduit Jeff Beller, Business Development Manager, Industrial Network Infrastructure, Panduit p Legacy manufacturing and networks. Today’s OT networks Most notably, 2019 was the first industrial control networks must are a composite of Ethernet and year of decline for new fieldbus evolve to address the demands of legacy fieldbus protocols. What nodes, declining by 5% compared Industry 4.0 and IIoT. Single-pair does the industrial network land- to 6% growth in 2018. Fieldbuses Ethernet promises to be the scape look like? In terms of new in the aggregate now account for enabling technology that allows for installed nodes, HMS concluded 35% of the global market, a decline cost-effective migration from many that for 2018 industrial Ethernet of 7% compared to the 7% growth legacy protocols to one common had surpassed traditional fieldbuses seen for industrial Ethernet. protocol and addresses the need for the first time, and this develop- Industrial networks evolve over for a reliable, secure infrastructure ment continued in 2019. Industrial time and this evolution has seen the providing high-bandwidth communication, power and control “The transition to Ethernet to edge devices. Single-pair Eth- ernet (SPE) extends the network continues and is driven by the to incorporate the “last mile” of need for high performance and connectivity creating a seamless Ethernet TCP/IP network fabric integration with IT/IIoT systems.” for the enterprise, from cloud to edge. SPE technology will help to build out the necessary foundation Ethernet continues with a steady gradual “cooling” of fieldbus deploy- so enterprises can better achieve growth rate of 20% and now makes ments driven by the stronger growth their smart manufacturing objec- up 59% of the global market, an of industrial Ethernet. As Andres tives and digitally transform their increase of 7%. Globally, Ether- Hansson, chief marketing officer at businesses. Its availability to the Net/IP is the largest industrial HMS has noted, “The transition to marketplace is projected to begin Ethernet network with 15% of the industrial Ethernet continues and is with early adoption in 2021. market followed closely by PROF- driven by the need for high perfor- INET at 14%. Other significant mance and the need for integration THE STATE OF THE NETWORK Ethernet technologies include between factory installations and More and more manufacturing EtherCAT, POWERLINK and IT-systems/IIoT applications.” The and industrial equipment and Modbus-TCP all of which are arrival of SPE promises to further devices are being connected to showing steady growth. accelerate this transition.

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MEETING THE WORKFORCE experienced workforce will be the enterprise systems for insights CHALLENGE effectively transferred to the new and action. SPE provides a proto- The advent of SPE technology is and inexperienced one coming in. col that the incoming workforce is very timely if seemingly unplanned. As a stop-gap measure, some already familiar with and presents Manufacturers are being both manufacturers have retained ser- a clear and cost-effective migra- pushed and pulled to transform vice organizations to support their tion path. their network infrastructures. operational technology (OT) net- Industries are at a crossroad works. But this still leaves many SPE OVERVIEW where legacy systems are at, or manufacturers vulnerable and at For decades, Ethernet cabling are reaching, end-of-life while risk. This is the push. The pull is has used four twisted pairs of at the same time the workforce the positive business outcomes that copper conductors to carry data versed in supporting these systems smart manufacturing and digital and power. But recent develop- are setting sail into retirement. transformation delivers. Standing ments have changed all that. As Forward-thinking organizations in the way of this, in part, are the a breakthrough technology and have put plans in place to transfer machines and field devices con- paradigm shift, Ethernet can now and retain this knowledge. But nected with proprietary and legacy be deployed over a single balanced for many it is unlikely that the network protocols that that are not twisted-pair, thus single-pair Eth- collective tribal knowledge of this easily synchronized to ‘uptake’ into ernet, or SPE.

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Industry sees SPE technology as a means to achieve a single converged network— cloud to device—and displace the legacy systems that are prevalent.

In recent years, the automotive for 100Mb/s transmission over these industries saw the technol- industry became the first to a single unshielded twisted-pair ogy as a means to achieve a single develop and adopt SPE, in this cable up to 15 meters in length. By converged network—cloud to case for in-vehicle networks. This superposition, the physical layer, device—and displace the legacy innovation was driven by the or PHY, is full duplex so both the systems that are prevalent. Here, increasing number of applications data send and receive transmission higher data bandwidth and power and complexity of features is over the same pair of wires; this delivery requirements are inexora- being added to cars. With each is the engineering breakthrough bly linked. Pursuant to these goals, feature introduced the number that other application domains the IEEE 802.3cg Ethernet Task of subsystems proliferated along will leverage as well. Consider that Force group was formed to study with much higher bandwidth standard Ethernet has a dedicated fieldbus technologies and create a requirements. Current bus pair of wires for each direction. standard for SPE to address the topologies and a fragmented In order to meet the demands for needs of OT networks for manu- network architecture deployed in more bandwidth, industry further facturers and process industry. SPE the vehicles were ill-equipped to evolved and enhanced the technol- is proposed to address the needs meet these demands. The industry ogy to provide for 1 Gb/s operation of Level 0 of the Purdue industrial needed to converge the growing over a single twisted-pair copper control system hierarchy model. It number of disparate systems and cable in an automotive application is here that Ethernet is generally provide higher bandwidth—and all (IEEE 802.3bp-2016). In addi- not present and where instead the within very small spaces. Reducing tion to converging and achieving proprietary and legacy fieldbus sys- the wire count was a driving high-performance in-vehicle net- tems provide the connectivity from force. The industry responded in working, the technology enabled the control system (Basic Control 2015 with the IEEE 802.3bw the industry to reduce compo- Level 1) to the machines and standard for 100BASE-T1 for nent costs and reduce the overall field instrumentation. in-vehicle networks. Moreover, the weight of the vehicle, improving The challenge and opportu- supplier ecosystem worked with fuel economy. nity to transform OT networks is the automakers to develop and The automotive industry’s suc- enormous. The fieldbus landscape commercialize the technology for cess with SPE was the impetus is very fragmented, and variants the benefit of the industry. for manufacturing, process and include AS-Interface, BACnet, The 100BASE-T1 standard is control system industries to inves- CAN, CANopen, CC-Link, the first SPE standard. It provides tigate the technology. Similarly, ControlNet, DALI, DeviceNet,

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Foundation Fieldbus H1, HART, address nearly all fieldbus applica- PoE which requires a separate pair Interbus, IO-Link, LonWorks, tions and enable a standard media for power delivery to the device. Modbus-RTU, Profibus D, Pro- access control, or MAC. This is why PoE technology can’t fibus PA, and others. There is no In general, no device power be used on SPE. PoDL represents overarching standard resulting is delivered by the fieldbus a necessary adaptation of PoE in far too many fieldbus variants. connection. Therefore, local DC for SPE. Oftentimes, facilities will have power supplies are required near SPE and PoDL work together more than one fieldbus in operation the device to meet its power as technologies to provide both to support. Despite the recent con- requirements. Behind the DC simultaneous data transmission and traction of new fieldbus nodes as power supply are many AC device power over the same link. observed by HMS, there remains components to convert machine Also, PoDL can be used to power countless devices connected via mains power to a usable input a device with no data being trans- fieldbus topologies. Consider that to the DC power supply. When mitted. Like PoE, PoDL includes mid-range estimates suggest that this supporting infrastructure communication with devices to globally there are 80 to 100 million can be eliminated control system determine appropriate power levels. new device connections per year. In DC power infrastructure is The 802.3bu standard defines mul- addition, there remains a plethora simplified and costs become lower. tiple voltages and power classes. of 4-20mA instruments hardwired As a result, the SPE standard Currently, the standard supports to analog I/O. includes the provision for optional power levels up to 1.6 amps per The fieldbus protocols are serial power delivery. conductor that can be delivered to communications usually operating devices at the end of a 1km SPE over shielded and twisted two- THE SPE POWER ADVANTAGE link. Provisions for power levels wire cable. In general, the fieldbus It is the provision for remote up to 2 amps per conductor is systems provide very modest data powering of devices connected expected soon. rates and reach. Across the universe with SPE that is the most signif- This technology means that for of fieldbus, the bandwidth ranges icant and transformative aspect many devices, local DC control from 1200 baud to 12Mb/s. The of this technology for industrial power and its associated infra- longest reach ranges from 400m to applications. The IEEE 802.3bu structure will not be necessary, 5,000m. For many of the systems, standard provides for the option which is truly transformative for the data rate falls increasingly to of remote DC power over the the manufacturing and industrial very low levels as the maximum SPE connection. This technology, network edge. reach distance is approached. In Power over Data Line, or PoDL SPE, together with PoDL, determining the requirements for (pronounced “poodle”), is akin to provides an elegant solution for Ethernet, the new solution needs the well-known and well-adopted connecting field devices to the to cover a range of rate and reach Power-over-Ethernet (PoE) tech- factory and plant-wide network. available with fieldbuses with a nology for standard Ethernet. The Protocol translators and gateways single design. The 802.3cg working significant innovation here though are eliminated, greatly simplify- group concluded that the new SPE is that both the data transmission ing the overall network topology standard would be for 10Mb/s data and the power delivery is over the and providing one that is easier to rate and 1,000m (1km) reach to same pair of conductors, unlike maintain. In addition, with remote

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The advent of SPE will significantly evolve the industrial network edge, paving the way for a seamless network fabric that will be the foundation of Industry 4.0 and the IIoT.

power to the device provided by the • Cost-effectively achieve a single, be updated to incorporate SPE and network switch or injector, control seamless network from cloud APL into validated designs with power infrastructure and provi- to edge vertical application focus. sioning is not needed. Further, as • Supply edge devices with data At the Rockwell Automation’s compared to multi-pair Ethernet, and power on a single connection Automation Fair held in Chicago the single-pair Ethernet PHY chip • Gain significant bandwidth at during November 2019, Panduit electronics are much simpler by the edge versus legacy protocols demonstrated a functional SPE design. This, along with much sim- • Simplify edge networks by connection between a human-ma- pler cable and connector designs, eliminating protocol transla- chine interface and a device over a will all result in a network that is tion gateways kilometer (1km) of cable consist- more reliable. • Transform and simplify DC con- ing of 10 in-line connections. The trol power infrastructure demonstration generated much PERSPECTIVES & CONCLUSION • Improve cybersecurity by elimi- excitement and interest from many SPE is a forthcoming transforma- nating legacy protocols who witnessed it. Other industry tive technology that will soon be • Connect miniaturized micro- solution providers at the event also commercially available to manufac- IoT and otherwise constrained demonstrated SPE technologies. turers and industrial plant facilities. form-factor devices In short, the ecosystem is actively For the manufacturing space, a • Connect field instrumentation developing SPE solutions that are precedent, or model for success has in hazardous environments with attractive to the manufacturing and been set by the automakers and Advanced Physical Layer (APL, industrial marketplace. The advent their ecosystem of suppliers with for intrinsic safety) of SPE will significantly evolve the development and adoption of • Lower total cost of ownership for the manufacturing and industrial SPE (100BASE-T1) for in-vehicle the OT network network edge, paving the way for a networks. Other market segments seamless, “cloud-to-edge” network such as rail transportation and Progressing into late 2020 and fabric. This will create the foun- building automation will also begin early 2021, look for product road- dation for Industry 4.0 and IIoT, to adopt SPE networks in the maps and offerings from device, enabling both quantity and time coming years. connectivity and network equip- precision of information for enter- SPE as an enabling technology ment manufacturers. Reference prises to gain more control over for manufacturers and industrial architectures, like Converged and insights into their underlying plants to: Plantwide Ethernet (CPwE), will processes. p

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Edge, cloud or something in between?

By Bob Sperber p Analysts predict the number edge or cloud seldom takes all. Locating data processing on-site of semiconductors shipped for use Rather, an integrated, hybrid archi- made more sense in terms of pro- in IoT applications overall will tecture that features a combination cessing power, cost and time. grow from 30-something bil- of edge and cloud execution prom- “The fact that we analyze at the lion chips today to more than 70 ise the best of both worlds. edge will optimize the traffic that billion annually in the next five crosses the network. If we were to years. Meanwhile, enormous cloud CHIPMAKER, HEAL THYSELF send all data to the cloud, the solu- datacenter campuses continue to Take Intel, for example. The semi- tion would be far too expensive,” proliferate worldwide, and are mea- conductor manufacturer is both says Chet Hullum, Intel’s general sured on an energy consumption creator and user of the technology manager, Industrial Internet of scale once reserved for the power plants that feed them. On the edge, in the cloud and Increasingly, it’s not a question of embedded within the pervasive computing resource availability, networks that weave these digital worlds together, the designer of but where it’s best to solve industrial automation and informa- which types of problems. tion management solutions today has at his or her disposal computing power that was unimaginable that makes the digital industrial age Things. Yet there remains a role for only a few years ago. possible, and it recently completed the cloud: collecting summary-level Increasingly, it’s not a question its first test of a scaleable, edge- data for long-term trend analysis. of computing resource availability, to-cloud predictive maintenance The project has been a success, but rather where it’s best to solve solution for use in its own fabs. based on results including: which types of problems. Often- The project sought to automate • A more-than 97% increase in times the edge wins out for reasons the labor-intensive process of mon- FFU uptime due to early parts of performance and determinism. itoring fan filter units (FFUs) that orders upon potential failure Other times, the cloud carries the purify air for manufacturing. To detection, and rapid replacement. day because new applications can be optimize vibration data collection • 300% reduction in unscheduled spun up more quickly and readily from each FFU and allow quick downtime over manual, labor-in- address problems that are broader in event triggering, Intel leveraged tensive FFU monitoring, which scope than a single unit or facility. its GE Digital factory automa- in turn boosted productivity. Indeed, an informal tour of tion platform and its own Intel IoT • An estimated reduction in cloud industry leaders indicates that the gateways to create an edge solution. traffic of nearly 94%.

www.SmartIndustry.com -19- Smart Industry: Technology REPORT

Hullum calls the foray into edge Intel uses edge analytics together with cloud-based trend analysis to head off failures of fan-filter units in its semiconductor fabs. (Image courtesy of Intel Corp.) computing an “ideal example” of leveraging an IoT gateway at the to attendees of the ABB Customer where you only move data to the “point of ingestion” and optimizing World 2019 event in Houston. cloud as needed,” Neri said. “It’s system scalability. He reports that HPE has long contended that the all about managing that data Intel is now expanding the FFU new digital architecture for indus- effectively, and extracting out- solution to more production lines. try will be a hybrid, edge-centric comes faster. The company is also expanding the one due in part to compliance (data Manufacturers and other indus- edge-based predictive maintenance ownership/privacy), latency and trial organizations have been architecture “to two additional use bandwidth issues. “75% of all data collecting and analyzing data for cases this year,” including one proj- is created at the edge, where we live decades—historically in central- ect to predict pump failures before and work,” Neri said. Meanwhile, ized data centers that can be quite they occur. only 6% of that data is put to use, distant from the factory floor, notes This sort of solution squares and sending it to the cloud can make Bob Voss, senior principal engi- neatly with the Hewlett Pack- matters worse, Neri added, likening neer at Panduit’s Jack E. Caveny ard Enterprise (HPE) view of an the cloud to The Eagles’ Hotel Cal- Innovation Center, the company’s applications architecture that is ifornia: “Once it’s in, it can be really corporate R&D center in the “edge-centric, cloud-enabled and hard to check your data out.” southern suburbs of Chicago. data-driven,” said CEO Anto- “We believe the better solution “Many newer industrial automa- nio Neri, in a keynote address is an edge-to-cloud architecture, tion applications require real-time

www.SmartIndustry.com -20- Smart Industry: Technology REPORT

or near real-time interaction with compute resources,” Voss says. “Due to this requirement, many factories are moving the compute resources closer to—or on to—the factory floor. This opens up a whole other realm of issues when you expose datacenter servers and networking equipment to these harsh environments. Contamination from water, dust and corrosives become potential hazards. Appropriately protective enclosures, equipment and physical infrastructure are required to properly address these issues.”

NEW REVENUE IN NEW SERVICES

Industrial equipment manufac- equipment, employed Software “It’s all about managing that data effectively, and extracting outcomes faster.” HPE CEO turers also are developing new AG’s Cumulocity IoT platform to Antonio Neri subscribes to an “edge-centric, cloud-enabled, data-driven” approach that cloud services enabled by local, launch a subscription-based con- moves data to the cloud “only when needed.” edge-based analytics for assets dition monitoring service for its in the field. Caterpillar, for one, IoT-enabled compressors. Users generation and micro-grids, lith- recently built on cloud services can remotely monitor operational ium ion battery banks will begin to from OSIsoft to offer its own Asset parameters in near real-time, and emerge as a key resource for buff- Intelligence platform to analyze receive notice of fault conditions. ering supply and demand, says the fuel consumption, equipment These instances of remote monitor- Schneider Electric vice president of health and other critical operations. ing, maintenance and management innovation and data center. “With These cloud-based services, which of manufactured assets show how the right amount of information work in conjunction with analytics remote edge analytics can be par- and the right analytics, you can performed locally, helped one oper- layed into cloud-services that bring start discharging these batteries ator of large marine vessels save new value to stakeholders. to cut electric costs or supplement $450,000 in fuel per ship annually Industry players also are looking power when it’s needed.” by optimizing hull-cleaning main- for the killer use case to unlock tenance to reduce drag. The service new analytics-driven services. One EDGE ANALYSIS + CLOUD also helped saved a cruise line new arena that’s got Steve Carlini PERSPECTIVE $1.5 million per ship in reduced excited is electrical energy storage Industry leaders also are seeking fuel consumption. and grid management. As the tra- to push analytics to the next level: Elsewhere, Gardner Denver, ditional, centralized energy grid from predictive to prescriptive. global provider of industrial continues shifting to distributed Currently, 50% of industrial firms

www.SmartIndustry.com -21- Smart Industry: Technology REPORT

have, or are piloting, an industrial Mitsubishi Electric Automation has alternately put edge and cloud strategies to work on a range of manufacturing challenges. One use case for Oracle cloud applications is to increase the accuracy analytics program, while another of pick-and-place robots, improving the visual detection and rejection of off-spec product. (Image courtesy of Oracle.) 48% of companies plan to within the next three years, according to LNS Research. Firms are, how- estimated $5 million a year, with turbines safely beyond baseload ever, finding it difficult to break zero impact on planned outage conditions during periods of peak into the prescriptive realm because schedules. These results are based market prices, and then guides “it takes far more information than on the company’s implementation users how and when to under-fire is available at the edge,” says Dan of GE Digital’s Predix platform to the turbines to recoup the wear Miklovic, LNS Research fellow. bring essential turbine data from incurred during the peak-prof- There’s new value to be found in the edge to the cloud. There, ana- itability hustle. This reportedly systems that can tell operators, “run lytics blend real-time production preserves both expected turbine this bearing at X speed to meet the data, external lifing models for service life and planned mainte- production schedule, then take it turbine components, and periodic nance schedules. offline for service,” Miklovic says. pricing and weather reports “to For leading photovoltaic manu- Now, edge-to-cloud systems are let plant operators know the most facturer First Solar, most analytics targeting such solutions. profitable way operate the turbine,” are performed in the cloud. Beyond NRG Energy, which supplies explains Amy Aragones, senior the on-premise capabilities of its electricity to more than 38 mil- director of product management, Rockwell Automation control and lion U.S. households, credits GE Digital. information management infra- prescriptive analytics with increas- This hybrid edge/cloud solution structure, data from virtually all ing turbine efficiency to save an analyzes how and when to run machines, PLCs, robots and other

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IoT-enabled devices are sent to the CNC machines, the company was many projects at Mitsubishi and cloud for deeper and more broadly able to increase productivity and elsewhere, Eric Prevost, vice pres- based analysis. In one month at pocket savings worth an additional ident and global head of emerging First Solar, four plants send five 50 assemblies per day. technologies for Industry 4.0 at billion manufacturing database “We’re seeing an enormous Oracle, reports working “in coordi- records to the cloud, each contain- increase in the tag values compa- nation with edge-device providers ing approximately 100 data points nies would like to collect from their for many projects.” on equipment performance. legacy machines, like 30 year-old Research from Wikibon predicts Cloud-based services makes lathes,” says Dave Cronberger, the evolution of a coordinated edge/ sense because “We’re not looking infrastructure architect with Cisco cloud network model from sensor at a single piece of equipment at Systems, adding that manufactur- to supply chain. The research firm a single location, we’re looking to ers are showing “a strong belief that modeled a small wind-farm 200 compare all similar equipment at they’re going to gain new insights miles from the cloud data center every one of our locations,” says from their controls and I/O blocks, with IoT-connected security Allen Blackmore, IT domain and learn new things that they cameras, security sensors, sensors architect for global enterprise tech- don’t know currently.” on the wind-turbines and access nology, First Solar. He envisions Mitsubishi Electric Automation sensors for all employee physical analytics on an enterprise-wide has alternately put edge and cloud access points. The result: When an data lake of unstructured data strategies to work on a range of edge network handled 95% of the across manufacturing, sales, manufacturing challenges. When data traffic for video and sensors, finance, and supply chain func- the use case called for real-time total cost was “reduced from about tions—essentially the entire analytics to predict and improve $81,000 to $29,000 over three business—which by its scope nec- electroplating quality or to control years,” about one-third the cost of essarily transcends the limits of an defects in injection molding, they the cloud-only approach. edge-only approach. focused on local execution: “It Given the caveat that every orga- would have cost us a fortune to put nization has unique conditions, the MODERNIZING MADE all our production data into the mainstream belief that the “you PROFITABLE cloud; we’d run out of space in 10 can’t do everything in the cloud” Bringing IoT capability to legacy minutes,” says Timothy Lomax, rings true, says Jason Andersen, assets “is one of the biggest issues strategic alliance manager. vice president of business line that enterprises face,” says Ricardo Elsewhere, Mitsubishi has used management for Stratus Technol- Buranello, vice president of global Oracle’s cloud and business appli- ogies, maker of high availability factory solutions at Telit, an IoT cations to increase the accuracy of edge-computing solutions. “Today, infrastructure provider. But it’s pick-and-place robots, improving from what we understand, the worth the effort, he says, citing the visual detection and rejection of breakeven point seems to be around results achieved at a customer that off-spec product. The project, now 30%,” Andersen says. “Processing manufactures automotive axles. underway, uses the cloud for robot 30% of your data in the cloud will By connecting and analyzing the data, images, data trending and cost about the same as doing it all data from 1,000 formerly isolated artificial intelligence analyses. For at the edge.” p

www.SmartIndustry.com -23- Smart Industry: Technology REPORT

MQTT getting what it needs to go industrial

Lightweight messaging protocol is now the most commonly used above HTTP

By Ian Verhappen, Senior Project Manager of Automation, CIMA+ p Message queuing telemetry encoding, though MQTT topics Only the most recent persistent transport (MQTT), developed are hierarchical, like a filing system message is stored. When a client in 1999, is a publish/subscribe (e.g. sales volume/flow/corrected). subscribes to a topic, any persistent message lightweight protocol Wildcards are allowed when reg- message will be sent to the client. based on TCP that is now the istering a subscription (but not However, unlike a message queue, most commonly used messaging when publishing), thus allowing MQTT brokers do not allow per- protocol above HTTP. The refer- whole hierarchies to be observed sistent messages to back up inside ence architecture is very simple, by clients. the server. and is based on client/server. The client is generally a sensor that “publishes” the information to the MQTT’s publisher/subscriber server (broker) that receives the model enables clients to information and dispatches it to the subscribers. MQTT protocol communicate one-to-one, one- uses a many-to-many paradigm, to-many and many-to-one. and the broker decouples the publisher to the subscriber and acts as a message router with every message MQTT also supports three MQTT brokers can require user- a discrete chunk of data, opaque quality of service levels: “fire and name and password authentication to the broker. MQTT’s publisher/ forget,” “delivered at least once,” from clients to connect, and to subscriber model enables clients to and “delivered exactly once.” ensure privacy, the TCP connec- communicate one-to-one, one-to- To prevent excess traffic when a tion may be encrypted with SSL/ many and many-to-one. device knowingly disconnects, TLS. Every message is published to an MQTT clients can register a As a machine-to-machine address, known as a topic. Clients custom “last will and testament” (M2M)-oriented protocol, MQTT may subscribe to multiple topics. message to be sent by the broker if is designed to be lightweight, and Every client subscribed to a topic they disconnect. it has two drawbacks for very con- receives every message published MQTT also has support for strained devices: to the topic. The MQTT specifica- persistent messages stored on the • Every MQTT client must sup- tion does not dictate any particular broker. When publishing mes- port TCP and therefore, always Topic Namespace, nor does it sages, clients may request that holds a connection open to the dictate any particular payload data the broker preserve the message. broker, which can be a problem

www.SmartIndustry.com -24- Smart Industry: Technology REPORT

Sparkplug provides an open specification for how edge-of-network devices and applications communicate bidirectionally within an MQTT infrastructure.

in high-packet-loss/comput- management that can be applied to properties, metadata and current ing environment. the SCADA/IIoT market sector. To state values. • MQTT topic names are often meet these requirements, the spec- • Issue write/command messages long strings, which make them ification is based on a lightweight, to any EoN/Device metric. impractical for 802.15.4 indus- bandwidth-efficient, low-latency trial wireless environments. payload encoding architecture. The above standards are MQTT-enabled infrastructure all available and open, with These shortcomings are requires that one or more MQTT Sparkplug from Cirrus Link addressed by the MQTT-SN servers be present in the infrastruc- Solutions, while Eclipse Founda- protocol, which defines a UDP ture. Typically, there will be only tion has released an open-source mapping of MQTT and adds one primary SCADA/IIoT host implementation of MQTT broker support for indexing node responsible for monitoring called Mosquitto, while OASIS topic names. and control of a given group of maintains Advanced Message MQTT is an OSI Application MQTT EoN nodes. The SCADA/ Queue Protocol (AMQP). Do they Layer (Layer 7) like HTTP, and IIoT host node is any MQTT define a fully open solution? Not as a carrier, requires tagging such client application that subscribes to quite. But I have also heard rumors as HTML or XML for web pages and publishes messages defined in of an end user-driven group similar to represent the data. MQTT this document. to the Open Process Automation for SCADA applications have The Sparkplug Topic Namespace Forum being discussed to support Sparkplug, which provides an define nine message-type elements: an Open SCADA standard. open specification for how edge- Using these defined messages of-network (EoN) gateways or host SCADA/IIoT applica- REFERENCES native MQTT-enabled end devices tions can: 1. Sparkplug MQTT Topic & and MQTT applications commu- • Discover all metadata and Payload Definition Version nicate bidirectionally within an monitor state of any EoN/ 2.1, Cirrus Link Solutions, MQTT Infrastructure. Device connected to the April 2019. The Sparkplug specification MQTT infrastructure. 2. MQTT Version 3.1.1 Com- defines an MQTT Topic Name- • Discover all metrics, which mittee Specification, OASIS, space, payload, and session state include all diagnostics, April 2014.