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Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Smart Wireless Wireless GatewaysGateways
The 21The 21stst Century modem Century modem
Frank WilliamsFrank Williams
May 1, 2007
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
The Plant : A complex environment Plant Servers
OtherComputingDevices
Business Management
Area Servers PlantNetworkModules
NetworkGateway
NetworkGateway
Process Management
Subnetwork Gateway
ApplicationModule
HistoryModule
Personal ComputerNetwork Manager
Control Stations
ArchiveReplay Module
AdditionalCN Modules
Fiber Optics
NetworkInterfaceModuleOther Data
Hiway Boxes
MultifunctionControllerExtendedController
BasicController
AdvancedMultifunctionController
LocalProcessors
Subnetwork CONTROL NETWORK
SmartineTransmitters
PLCGateway
OtherSubsystems
PLC
Logic Manager ProcessManager
AdvancedProcessManager
Transmitters
Control Network Extenders
Field Management
sec
msec
1 sec
secs
min
hoursCourtesy: Apprion
Adding wireless
provides opportunities,
but
presents challenges
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
The new competitive reality!Global competition demanding higher productivity
More data, with more intelligence, yielded from more points throughout the plant, or factory.
Basically, a new paradigm in productivity gain :
data availability when and where neededdata availability when and where needed
we have seen this before• 4-20mA Hart• Marshalling cables Foundation Field bus, Ethernet• Automation DeviceNet, Profibus, etc• Alarm systems Pagers, SMS, GSM, E-mail
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Plant or Factory has more wirelessPlant or Factory has more wireless
Wireless Ethernet
Wireless I/O
•Sensors
•Analog / digital
•Pulse / Freq
•Pressure / Flow
Wireless Data
•PLC to PLC
•DCS to Remote
•PLC/DCS to HMI
•Protocol connectivity
Wireless finds new applicationsWireless finds new applicationsWith greater reliabilityWith greater reliabilityAnd more flexible at less costAnd more flexible at less cost
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
The largest constraint to collecting information is …The largest constraint to collecting information is …
the cost/hassle of wiring the cost/hassle of wiring
The largest constraint to sharing information is…The largest constraint to sharing information is… data incompatibility data incompatibility
Plant & Factory Information hurdlesPlant & Factory Information hurdles
wireless wireless
wireless gateways wireless gateways
• $40/linear ft$40/linear ft• mobilitymobility• downtimedowntime
• protocolsprotocols• speedspeed• network structurenetwork structure
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Wireless Network challengesWireless Network challenges
• Reliable information (data) transfer with… - larger amounts of information demanded- more mobile, flexible and greater scalability- networked from different, and more places
• Connectivity to and from high-speed industrial LAN’s - Profibus (12Mbit/s),DeviceNet (500kbit/s), Modbus (1Mbit/s), Ethernet (10/100Mbit/s)- Interconnectivity to different LAN’s - protocol incompatibility
• Security (process as well as business side of things )- hackers, competitors and other perpetrators- jamming or unwanted messages into process- “malicious” damage?- e.g. disgruntled employees
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
SMART Wireless Gatewaysoffer…
• Advances on traditional modem
• Protocol conversion - adds flexibility
• Faster by using efficient wireless protocol
• Better network bandwidth management
• Reliable and secure data transfer
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
““Smart” Radio Modem Smart” Radio Modem
Data bus
Gateways can act as “smart” radio modems to overcome limitations of normal radio modems
Data bus
Data bus
Data protocol only on data bus sideData is converted to a highly efficient wireless protocol on the radio side
The Smart Gateway can now yield tremendous benefit to the User…
SmartGatewa
y
SmartGatewa
y
SmartGatewa
y
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
LAN Speed ProblemLAN Speed Problem
Conventional Radio ModemsNormal radio modems handle data protocols at 9600bit/s, 19.2kbit/s, etc – slow in today’s information-hungry, high-speed environment
RadioModem
RadioModem
--- data bus speed must be reduced to match the speed of the radio modem, affecting the pre-existing bus ---
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
LAN Speed SolutionLAN Speed Solution
Wireless Gateways
Wireless Gateways connect to the LAN at full bus data rate
Existing LAN devices are not affected.
profibus – 12Mbit/s
Modbus – 1Mbit/s
Ethernet – 10/100Mbit/s
Transfer at protocol speed
profibus – 12Mbit/s
Modbus – 1Mbit/s
Ethernet – 10/100Mbit/s
wireless
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Response Time ProblemsResponse Time Problems
ConventionalConventionalRadio ModemRadio Modem
High speed data protocols require fast response - Profibus (11Mbit/s), DeviceNet (1Mbit/s) etc
RadioModem
RadioModem
Master sends a command to the slave - the radio delays the command
Slave responds, but too late
Master device times out and comms stops
X
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Wireless GatewayWireless Gateway
Master sends a command - the Gateway responds, the Master does not time out
The SMART Gateway transmits the information - fast response is maintained by exception reporting wireless protocol
The second SMART Gateway passes on the information:
Communications is successful and continues
A newer approachA newer approach
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Network Structure ConstraintsNetwork Structure Constraints
Conventional Radio ModemsConventional Radio Modems
The Wireless Network has the same network structure limitations as the Host protocol - most are master-slave polling networks
RadioModem
RadioModem
RadioModem
RadioModem
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Wireless network is independent of the data protocol - peer to peer• Multiple masters - no problems
• Slave to slave - easy add
• Path routing – flexible & quick
Network Structure ImprovementNetwork Structure Improvement
User Scalability & flexibilityUser Scalability & flexibility
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Network Bandwidth ManagementNetwork Bandwidth Management
Conventional Radio Modems
Master-slave polling networks become slow as the network size increases
Radio network becomes busy as size increases
RadioModem
RadioModem
RadioModem
RadioModem
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
SMART Wireless Gateways
Gateways use a more intelligent wireless protocol Based on exception reporting (transmitting on a change), plus transfers on demand
Better Bandwidth ManagementBetter Bandwidth Management
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Protocol IncompatibilityProtocol Incompatibility
Modbus
Modbus
DF1
Data bus interconnectivity
Normal radio modems can only connect the same protocol
Profibus
x
x
x
x
RadioModem
RadioModem
RadioModem
RadioModem
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Data bus interconnectivity
SMART Gateways use a “neutral” wireless protocol - different data buses can be interconnected
Modbus
Modbus
DF1
Profibus
Protocol CompatibilityProtocol Compatibility
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
SECURITY
Can Wireless Gateways help against:
• hackers, competitors and other perpetrators• jamming or unwanted messages into process• “malicious” damage?- e.g. disgruntled employees
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
SecuritySecurity
Data bus
Conventional Radio Modems
• Security achieved by data encryption.
• Unable to limit transfer of data or authenticate the transfer.
Data bus
Data bus
Any data can be transferred
RadioModem
RadioModem
RadioModem
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Data bus
SMART Wireless Gateways
Gateways can only transfer known data • Firewall protection to level “7”• Blacklist/white list• AES encryption routine
Data bus
Data bus
Only known approved data can be transferred
SecuritySecurity
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Example - Tank Gauging Example - Tank Gauging Profibus
Ethernet
Profibus
Profibus
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Example - Tank Gauging Example - Tank Gauging Profibus
Ethernet
Add a High Level Switch
Most Gateways have capability for connection of discrete, analog, and pulse I/O
High level switch
High level switch
High level switch
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Profibus
Ethernet
Profibus
Profibus
High level switch
High level switch
High level switch
Devicenet
Modbus + Internet
““Wireless Information Backbone” Wireless Information Backbone”
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
SummarySummaryWireless Gateway = Smart Radio Modem
Overcomes speed limitations with fast data protocols Allows connection at full bus speed Provides peer-to-peer networking for scalability / flexibility Better wireless network bandwidth management Secure data bus expansion – encryption & firewall Data bus interconnectivity - protocol conversion Internet connectivity - web enabled interface Allows formation of Wireless Information Backbone
Think Wireless…Think ELRPOThink Wireless…Think ELRPO© ELPRO Technologies© ELPRO Technologies NORCAL ISANORCAL ISA
Thank you Thank you
Frank WilliamsFrank Williamsfrankw@elprotech.com619.741.3574 – office858.349.1346 – cell