The Wireless Plant of the Future

by Graeme Lane USA Sales - ELPRO Technologies www.elprotech.com

THE WIRELESS ALTERNATIVE TO EXPENSIVE CABLING

Instrumentation & control where is it heading?

No. of tags Information

1950

1970

1990

2010

Instrumentation & control where is it heading?

Proliferation of information systems
4-20mA p Hart Marshalling cables p FF, Ethernet Automation p DeviceNet, Profibus et al Alarm systems p Pagers, SMS, email
3

Instrumentation & control

p Information
The largest constraint to collecting information cost of wiring

p wireless
The largest constraint to sharing information data incompatibility

p cleverer wireless

Instrumentation & control where does wireless fit in now?

FT FI

Signal Cable
Transducer Indicator

105U

105U

FT Transducer

FI

Wireless I/O

Indicator 5

Factory automation where does wireless fit in now?

PLC

Data Cable

PLC

905U

905U

PLC

Radio Modem

PLC

Wireless I/O

Radio modems

Typical industrial plant or factory 1995 2002 2010 no wireless 1 - 2 wireless applications 100 - 200 wireless applications
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Can the radio spectrum handle this?

Current Wireless Developments

Embedded wireless
Bluetooth, Zigbee - low power, limited range, good radio duty factor

Wireless I/O
data bus interface - 900MHz, longer range, good radio duty factor, proprietry systems

802.11+
high data rates - limited range, limited data compatibility, high radio duty factor
8

Instrumentation & control

p Information
The largest constraint to collecting information cost of wiring

p wireless
The largest constraint to sharing information data incompatibility

p cleverer wireless

Introducing .

The WIB Concept

Wireless Instrumentation Backbone

10

The WIB
Wireless Instrumentation Backbone
PlantPlant-wide wireless instrumentation FactoryFactory-wide wireless automation Signal level - measured variables Connectivity - I/O, serial, field bus
11

The WIB Structure

WIRELESS DCS Ethernet, Modbus, 802.11 WIRELESS J-BOX J-BOX Field devices Profibus, Devicenet, HART, Bluetooth

WIRELESS NODE

I/O - discrete, analog, pulse, t/c, RTD

WIRELESS J-BOX WIRELESS J-BOX

Direct transducer connection

Outside world Ethernet, Internet

12

Wireless J-box J-

WIRELESS J-BOX

Connections for direct I/O and/or serial devices / field bus Wireless connectivity to all other J-boxes Converts data into neutral radioradio-friendly protocol

13

Wireless I/O
WIRELESS J-BOX

I/O

- discrete, analog, pulse, t/c, RTD

I/O

- discrete, analog, pulse, t/c, RTD

WIRELESS J-BOX WIRELESS J-BOX

I/O

- discrete, analog, pulse, t/c, RTD

14

Wireless I/O plus field interface

WIRELESS J-BOX

I/O

- discrete, analog, pulse, t/c, RTD

I/O
HART, Bluetooth, Zigbee

WIRELESS J-BOX WIRELESS J-BOX

I/O

- discrete, analog, pulse, t/c, RTD

15

Wireless I/O plus system interface

WIRELESS J-BOX

I/O

- discrete, analog, pulse, t/c, RTD

DCS
Modbus Ethernet 802.11

WIRELESS J-BOX WIRELESS J-BOX

I/O

- discrete, analog, pulse, t/c, RTD

16

PLC connectivity
WIRELESS J-BOX

PLC
Devicenet

PLC
Devicenet

WIRELESS J-BOX WIRELESS J-BOX

PLC
Devicenet

17

Data bus connectivity

PLC
Profibus
WIRELESS J-BOX WIRELESS J-BOX

HMI
Ethernet

PLC
Devicenet

WIRELESS J-BOX WIRELESS J-BOX

I/O
HART

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Connectivity to outside world

PLC
Profibus
WIRELESS J-BOX WIRELESS J-BOX

HMI
Ethernet

PLC
Devicenet

WIRELESS J-BOX WIRELESS J-BOX

Internet CDMA / GSM Email 19

Put it all together = WIB

PLC
Profibus
WIRELESS J-BOX WIRELESS J-BOX

INTERNET
Ethernet

PLC
Devicenet

WIRELESS J-BOX

WIB

WIRELESS J-BOX

I/O

- discrete, analog, pulse, t/c, RTD

I/O

- discrete, analog, pulse, t/c, RTD

WIRELESS J-BOX

WIRELESS J-BOX

I/O
HART

20

Wireless J-box JDesign Features

WIRELESS J-BOX

Efficient radio communications - low density communications, powerful networking Expandability - station level, network level, world level Security - reliability; hackers
21

Efficient radio communications

22

Efficient Radio Comms

ISM bands - 900MHz, 2.4GHz, 5.6GHz Compromise - data rate vs distance in a plant/factory environment
MHz 900 2400 5600 MB/sec 0.1 0.5 - 10 1 - 100 Distance (feet) 3000 300 30
23

Efficient Radio Comms

A low data rate which works is better than a high data rate which doesnt

p 900MHz
Wireless instrumentation does not require a high data rate, but does require RF strength
24

Low density communications

Wired systems - 95% of info transfer is useless - polling, timed transfers

p Exception reporting
Transmit on change - min. comms Transmit immediately on change fastest response
25

Communications Control
Need extra controls to minimize traffic and maximize reliability Contention control - Listen-beforeListen-beforetransmit, priorities, error-correction errorSelf checking - Integrity Poll Adaptive messaging Learn from cell-phone systems cell26

Powerful Networking

27

Powerful Networking
Peer-toPeer-to-Peer Comms
Each node can talk to any other node If any node fails, other nodes continue to operate Multiple comms sessions - e.g. comms A and comms B
905U

905U

905U

B
905U

28

Powerful Networking
Private Cellular system
Auto-routing Roaming
905U 905U 905U

Self-healing

905U 905U 905U 905U

29

Expandability - station level and network level

30

Station Level Expandability

I/O expansion Seamless routing of messages for other stations Connectivity to high speed data buses

905U

905U

905U

905U

31

Network Level Expandability

Expandable Communications - able to communicate to more stations

CONTROL ROOM

CONTROL ROOM

Avoid the Porcupine Affect

If a plant/factory has 100 wireless loops, how many antennas are needed at the control room? 32

Security - failure to operate / mal-operation mal-

33

Is wireless safe?

34

Security
Protection against failure - spread spectrum band - unit addressing and error-checking, reerrorretry features, failure alarms Protection against mal-operation malcrosscross-talk - system addressing, data encryption Failure alarms - self checking system 35 fail to send, fail to receive

Security
Protection against malicious operation Data encryption Frequency encryption PIN protection on configuration files

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The WIB Structure

WIRELESS DCS Ethernet, Modbus, ControlNet WIRELESS J-BOX J-BOX Field devices Profibus, Devicenet, HART

WIRELESS NODE

I/O - discrete, analog, pulse, t/c, RTD

WIRELESS J-BOX WIRELESS J-BOX

Direct transducer connection

Outside world Ethernet, Internet

37

Wireless J-box JDesign Features

WIRELESS J-BOX

Efficient radio communications - low density communications, powerful networking Expandability - station level, network level, world level Security - reliability; hackers
38

Thank you for attending

www.elprotech.com
THE WIRELESS ALTERNATIVE TO EXPENSIVE CABLING