Fieldbus Technology: Industrial Network Standards for Real-Time Distributed Control

606 Pages·2003·23.364 MB·English

by  R. Murugeshan (auth.), Dr. Nitaigour Premchand Mahalik (eds.)

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
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© 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
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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 Fieldb us 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 ofP rocess 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 ................................................... 10 0
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