COMPUTER NETWORKS

FOR
MANUFACTURING
Outline:
Introduction
Hierarchy of Computers in Manufacturing
Levels in the Computer Hierarchy
Benefits of the Hierarchical Structure
Local Area Networks
Network Topologies
Access Methods for Local Area Networks
The Transmission Line
Types of Transmission Media
WAN
Wireless LAN

INTRODUCTION

The functional configuration of the integrated
computer system in a manufacturing firm is
discussed.
The configuration is a hierarchical one, similar to
the management structure in the firm.
The hierarchical structure is achieved by using a
local area network (LAN) in the factory.


HIERARCHY OF COMPUTERS IN
MANUFACTURING
The hierarchical arrangement depicted here is a
management oriented structure indicating various
levels of responsibility, some of which are subordinate
to others.
It represents the command structure that exists
between the computers and computer driven devices
in the factory.
The various computers in the hierarchy are tied
together by communication links to form a
distributed computer system.
The individual links provide a computer
communications network to forward data and
information up through the various levels from the
manufacturing operations all the way to the
corporate computer level
In the opposite direction, product designs, process
plans, production schedules, machine commands
and so on, are passed down to the individual
production cells.
The hierarchy allows for the design engineering and
manufacturing engineering functions to be included
within the computer network.
HIERARCHY OF COMPUTERS IN A
MANUFACTURING ORGANISATION
LEVELS IN THE COMPUTER HIERARCHY
At the FIRST LEVEL within the hierarchy are the
computers that are connected directly to the
process, either to monitor or control it.
The computers that make up this level are typically
microcomputers, located in close proximity to the
manufacturing operations they monitor and control.
The computer is dedicated to the process and
performs tasks that serve the process and facilitate
communication with the second level in the
computer hierarchy.
This level also includes the devices used for factory
data collection systems (e.g. bar code readers,
manual data entry terminals, etc.)

The SECOND LEVEL in the hierarchy consists
typically of minicomputers (most recently super
microcomputers) that are located throughout the
plant and report to the larger plant computer at the
third level.
The second level minicomputers are sometimes
referred to as satellites (or area controllers) in the
plant.
Their purpose is to serve in a supervisory capacity,
coordinating and controlling the activities of the first
level computers in the various sections of the plant.
Performance data are collected from the individual
machine tools, production cells, data input terminals,
and inspection stations, and operating commands
are relayed back to the separate process and
workstations.

The THIRD LEVEL in the hierarchical structure is
the central plant computer.
Operating data from the various satellite computers
in the plant are collected and summarized to
prepare periodic (e.g. daily, weekly, monthly)
reports for plant management.
Real time information on the current status of plant
operations (e.g. machine utilization, customer order
progress, inventory levels etc.) can be accessed
from this level by plant personnel with a need to
know.
The manufacturing engineering CAD/CAM system
interface would probably be at this third level in the
organization, since most of its functions would be
implemented in the plant.
o The computer at the plant level would be larger,
more complete data processing system, either a
large minicomputer or a small mainframe.
o Its use must be shared between plant
manufacturing operations and other business
related functions that are performed at the plant
level.
o Payroll, cost accounting, and personnel are
examples of these other functions.

The FOURTH LEVEL is the corporate mainframe
computer.
Data are compiled from the various plants in the
corporation at this level.
Communication with the individual plant computers
can be achieved by means of telephone long lines,
satellites, or other wide area communications
technologies.
The purpose of the corporate computer in the
hierarchy is to summarize plant operations and
performance for the entire corporation.
The CAD/CAM system interface for design
engineering is probably at this level although it may
be at the plant level depending on corporate
philosophy and organization.
In addition, the corporate computer must be shared
with other departments at the corporate level: sales,
marketing, accounting and so on.

BENEFITS OF THE HIERARCHICAL
STRUCTURE
Gradual implementation.
Redundancy.
Reduced software development problem.
Gradual implementation: The hierarchical computer
system can be installed gradually rather than all at
once. the company is not required to make an all-
or-nothing commitment to install a single plant wide
computer. the risk is therefore reduced, and the
expense is spread over a number of years.
Redundancy: The hierarchical structure contains
redundancy. In the event of a computer breakdown,
other computers in system are programmed to
assume the critical tasks of the broken down
computer.
Reduced software development problem: Since the
computers are separated in the pyramidal
arrangement programming for each project can be
handled separately. Once the project is installed,
changes in software are more easily accomplished,
with less chance of disrupting the system.

LOCAL AREA NETWORKS
The computers in the factory communicate with
each other by means of a local area network (LAN).
A local area network is a nonpublic communications
system that permits the various devices connected
to the network to communicate with each other over
distances from several feet to several miles.
The factory devices that can be attached to the
network include computers, programmable
controllers, CNC machines, robots, data collection
devices, bar code readers, vision systems, and so
on.

NETWORK TOPOLOGIES
Physically, the communications network does not
have the hierarchical configuration described.

Instead, there are three common, configurations, or
topologies, used in local area networks.
1. Star network
2. Ring network
3. Bus network
STAR NETWORK
The STAR NETWORK
consists of a central control
station to which each of the
individual devices or user
stations are connected.
For one device to send a
message to another device
in the network, the message
must be routed through the
central station.
The central station therefore
acts as a traffic manager
and controls the
communications flow
between devices.
Many telephone systems in
office buildings are
structured as star
configurations.

RING NETWORK
In the RING NETWORK the
individual stations are
connected in a continuous ring.
Each station has neighboring
station on either side.
For once station to
communicate with any other
station, the message must be
relayed from station to station
address to the message.
Each station along the ring
checks the message to see
whether it is the desired
recipient.
If it is, it loads the message into
memory, if it is not, it forwards
the message to the next station
along the ring.

BUS NETWORK
The BUS NETWORK consists of a single main transmission
line to which the individual devices are attached.
Any devices or station can communicate with any other device
in the network by sending its message through the bus with
the address of the desired recipient.
Each station connected to the bus checks the message and
loads it if the address is its own.

COMPARISON
Among the three topologies, the bus network is the
most appropriate for a factory local area network.
First, the main transmission line of the bus network can
be laid out in a pattern that corresponds closely to the
layout of machines in the factory, thus facilitating
installation of the communications system.
The product flow line layout is the best example of how
the network bus line corresponds to the machine
arrangement.
Second, machines and other devices in the plant are
often being rearranged to match changing production
requirements.
On a bus network, each device can be connected to
the main transmission bus without major disruptions to
the rest of the network.
Third, the bus network is generally easier to maintain
and repair than the star or ring configurations.

ACCESS METHODS FOR LOCAL AREA
NETWORKS
In the star network, the central control station
coordinates the flow of communications from one
station to the next.
In the ring and bus networks, there must also be a
method for controlling the message transmissions
between stations.
This is done using schemes by which the stations
can gain access to the network.
There are two popular access methods for LANs.
1. Token passing
2. Carrier sensed multiple access with collision
detection.


TOKEN PASSING
In the TOKEN PASSING method, a special code,
called the token, is passed along the network at
high speeds from station to station in a
predetermined sequence.
The sequence can be designed to allow stations
with higher priorities to have greater access to the
network.
In operation, a station can transmit the token
passes to the next station in the sequence.
A station wishing to transmit must wait until it is in
possession of the token.
In this way, access to the network in controlled and
coordinated.

The CARRIER SENSED MULTIPLE ACCESS
WITH COLLISION DETECTION (CSMA/CD)
CSMA/CD) method is also called a contention
based method.
With the access scheme, any station wanting to
transmit on the network first listens to determine if
the network is currently being used.
If not, it proceeds to send its message immediately.
If there is current activity on the network, it waits
until the network is free and tries again.
In the contention based access method, there will
be occasions when two (or more) stations attempts
to transmit along the same transmission line at the
same time.

o This results in a collision that cannot properly be
interpreted by any recipient.
o Each station is capable of detecting the high rate of
transmission activity characteristic of a collision, and
stops transmitting.
o The stations each wait a random length of time
(different times for different stations) and then try
again.
o The attempts are repeated until a successful
transmission is accomplished.

The CSMA/CD access method is appropriate for
office networks in which the communications are
likely to consist of large blocks of data, but the
timing of transmissions is not critical.
This is undesirable in manufacturing because the
timing of commands to a machine tool may be very
important in order to control the process in real
time.
In the token passing method, the transmission
between different stations can be coordinated and
predicted quite closely under various loading of the
network.

THE TRANSMISSION LINE
The TRANSMISSION LINE is the message and
data carrying medium that constitutes the physical
distribution element of the network.
The requirements of the transmission media for
factory networks are that
1) They must be capable of a high data transmission
capacity,
2) They must be unaffected by electrical noise in the
environment, and
3) They must be inexpensive to install, service, and
alter.

The data transmission capacity is characterized by
a term called bandwidth.
A large bandwidth means that the medium has a
high data carrying capacity.
Broadband transmission means that many
independent messages can be transmitted
simultaneously over the communications line, each
operating at its own frequency.
Broadband signals are the standard used for cable
television (CATV) transmission.
In broadband transmission, only one signal is
carried over the transmission line at a time.
Each message requires a certain time to transmit,
and no other messages can be carried at the same
time.

Three types of transmission media are used in
local area networks. The three types are
1. Twisted pair wire
2. Coaxial cable
3. Fiber optics lines

TYPES OF TRANSMISSION MEDIA
TWISTED PAIR WIRE
TWISTED PAIR WIRE consists of two (or more)
copper wires that are twisted throughout the length
of the line.
It is an inexpensive transmission medium and is
used widely in conventional telephone
communications.
Its disadvantages are that it is susceptible to
electrical noise in the environment and it has a
relatively low bandwidth.
Because of the electrical noise problem, and the
requirement for message integrity in manufacturing
controls and communications, twisted pair wire is
not a good choice for factory networking

COAXIAL CABLE
COAXIAL CABLE consists of one or more strands
of wire shielded by a metallic sheath surrounded in
turn by insulation.
The metal shield reduces the problem of electrical
noise. Coaxial cable can have a large bandwidth
and is used for either baseband or broadband
communications.
Broadband coaxial cable is considered to be the
most appropriate transmission medium for factory
networks, and is currently the type most frequently
adopted for these applications.
Multiple taps for user stations and other devices are
readily installed or removed, as required.

FIBER OPTICS LINES
FIBER OPTICS LINES consist of several long
continuous optical fibers fibers of glass or other
material capable of transmitting light.
Its principal attributes are that it possesses a very
large bandwidth and it is unaffected by electrical
noise in the surroundings.
In the operation of fiber optics transmission line,
the electrical pulses representing data at the
transmitting station are converted back into
electrical signals at the receiving station.
It is most appropriately used as a high volume data
pipeline between two points where there is no
need for intermediate taps.

WAN
WIDE AREA NETWORK (WAN) is a computer
network that covers a broad area i.e. any network
whose communications links cross metropolitan,
regional, or national boundaries.
WANs are used to connect LANs and other types
of networks together, so that users and computers
in one location can communicate with users and
computers in other locations. Many WANs are built
for one particular organization and are private.
largest and most well-known example of a WAN is
the Internet.

WIRELESS LAN

A wireless LAN or WLAN is a wireless local area
network, which is the linking of two or more
computers without using wires.
WLAN utilizes spread-spectrum or OFDM
modulation technology based on radio waves to
enable communication between devices in a limited
area, also known as the basic service set.
This gives users the mobility to move around within
a broad coverage area and still be connected to the
network.
Advantages
Disadvantages

ADVANTAGES
Deployment
Cost
Expandability
Productivity
Mobility
Convenience

DISADVANTAGES
Security
Range
Reliability
Speed

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