FIELDBUS Engineering Technology

8/11/2019 FIELDBUS Engineering Technology

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FIELDBUS


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What is a Fieldbus?

A Fieldbus is an industrial computer network forreal-time distributed control.

A complex automated industrial system usuallyneeds an organized hierarchy of controllersystems to function.

Human Machine Interface (HMI)at the top,Programmable Logic Controllers (PLCs)in the

middle, and the Fieldbusat the bottom. The Fieldbus links the PLCs to the components

which actually do the work such as sensors,actuators, electric motors, console lights,switches, valves, and contactors.


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What is a Fieldbus?

Fieldbusis a generic term that describes a new digitalcommunications network that is being used in industry toreplace the existing 4-20 mA analog signal standard.

The network is a dig i ta l, bi-direct ional, mult i -drop ,serial -bus communication netwo rkused to linkisolated field devices, such as controllers, transducers,actuators and sensors. Bi-direct ionalmeans it is a duplex port; the data can

be transmitted in two directions at the same time.Mult i -dropis also referred to as multi-access and it

can be interpreted as a single bus with many nodesconnected to it.

Serial-busmeans the data is transmitted seriallyaccording to RS232 or RS485 protocol. Profibus usesRS485 protocol.


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What is a Fieldbus?

Fieldbus works on network structures such as daisy-chain, star, ring, branch, and tree network topologies.

Previously computers were connected using RS-232 by

which only two devices could communicate. This is the equivalent of the currently used 4-20 mA

communication scheme which requires that each devicehas its own communication point at the controller level

The fieldbus is the equivalent of the current LAN-type

connections, which require only one communication atthe controller level and allow multiple (100's) of analogand digital points to be connected at the same time.

This reduces both the length of the cable required andthe number of cables required.


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History & Current State

In 1999 a committee formed the IEC 61158standard with eight different protocol sets:

FOUNDATIONFieldbus H1

ControlNet

PROFIBUS

P-Net

FOUNDATIONFieldbus HSE

Interbus

SwiftNet

WorldFIP


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History & Current State

Recent additions or planned additions to IEC61158 include but are not limited to:

PROFINET IO EtherCAT

Both FOUNDATION Fieldbus and Profibustechnologies are now commonly implemented

within the process control field, both for newdevelopments and major refits. In 2006, Chinasaw the largest FF systems installations atNanHai and SECCO, each with around 15,000

fieldbus devices connected


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Who uses Fieldbuses?

Those who plancomplex automated

industrial systems


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Where are Fieldbuses Used?

In complex automatedindustrial systems

where an organizedhierarchy of controllersystems is needed.

In manufacturing

plants where manyinstruments need tobe connected.


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What are Fieldbuses Used For?

When fieldbuses work in the factory, the purposehas been to reduce installation cost by moving

the I/O interface from the programmable logiccontroller (PLC) to a remote I/O unit mountedclose to the machine on the factory floor.

Factory automation fieldbuses are fast and

deterministic. (Deterministic means themaximum worst-case time to obtain data acrossthe fieldbus is accurately predictable and is notsubject to chance.)


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When are Fieldbuses Used?

When the advantages of Fieldbuses,discussed on the next slide, are needed

When the disadvantages of Fieldbuses, onthe slide after that, do not hinder use


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Advantages of Fieldbus

A major advantage of fieldbus is the capitalexpenditure (CAPEX) savings associated with

cable elimination; multiple devices share wire-pairs in order to communicate over the busnetwork and savings are also available throughspeedier commissioning.

Ongoing maintenance and process controlsystem performance are significantly enhancedthrough fieldbus systems, which results inoperations expense savings (OPEX).


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Disadvantages of Fieldbus

Disadvantages of fieldbus compared to the 4-20 mAanalog signal standard:

Fieldbus systems are complex, so more training

needed The price of fieldbus components is higher

Fieldbus test devices are more complex

Device manufacturers have to offer different versions

of devices due to different fieldbus standards. Thiscan add to the cost of the devices and increases thedifficultly of device selection.

Standards may predominate or become obsolete,increasing the investment risk.


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Costs

(CAPEX) Savings (OPEX) Savings Cost of Devices Investment Risks

Engineering costs Equipment costs Installation costs Commissioning costs Maintenance costs Operating costs Inventory costs Retooling costs

Figure 1. Typical Modern Industrial System


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Requires Supporting

Technology? YES Fieldbus Components:

Bus Terminal

EtherCAT

Fieldbus Box

Lightbus

PC Fieldbus Cards

Switches

And more

http://www.beckhoff.com/english.asp?embedded_pc/cx1000_2.htm


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References

http://en.wikipedia.org/wiki/Fieldbus http://www.isa.org/InTechTemplate.cfm?Section=Article_

Index1&template=/ContentManagement/ContentDisplay.

cfm&ContentID=60680 http://www.us.profibus.com http://www.easydeltav.com/video/product/foundation_fiel

dbus.asp http://www.fieldbus.org/images/stories/newsroom/newsle

tter/200702/ http://www.beckhoff.com/english.asp?embedded_pc/cx1

000_2.htm http://ethernet.industrial-networking.com/articles/

articledisplay.asp?id=79
http://en.wikipedia.org/wiki/Fieldbushttp://www.isa.org/InTechTemplate.cfm?Section=Article_Index1&template=/ContentManagement/ContentDisplay.cfm&ContentID=60680http://www.isa.org/InTechTemplate.cfm?Section=Article_Index1&template=/ContentManagement/ContentDisplay.cfm&ContentID=60680http://www.isa.org/InTechTemplate.cfm?Section=Article_Index1&template=/ContentManagement/ContentDisplay.cfm&ContentID=60680http://www.us.profibus.com/http://www.easydeltav.com/video/product/foundation_fieldbus.asphttp://www.easydeltav.com/video/product/foundation_fieldbus.asphttp://www.fieldbus.org/images/stories/newsroom/newsletter/200702/http://www.fieldbus.org/images/stories/newsroom/newsletter/200702/http://www.beckhoff.com/english.asp?embedded_pc/cx1000_2.htmhttp://www.beckhoff.com/english.asp?embedded_pc/cx1000_2.htmhttp://ethernet.industrial-networking.com/articles/%0Barticledisplay.asp?id=79http://ethernet.industrial-networking.com/articles/%0Barticledisplay.asp?id=79http://ethernet.industrial-networking.com/articles/%0Barticledisplay.asp?id=79http://ethernet.industrial-networking.com/articles/%0Barticledisplay.asp?id=79http://ethernet.industrial-networking.com/articles/%0Barticledisplay.asp?id=79http://ethernet.industrial-networking.com/articles/%0Barticledisplay.asp?id=79http://ethernet.industrial-networking.com/articles/%0Barticledisplay.asp?id=79http://www.beckhoff.com/english.asp?embedded_pc/cx1000_2.htmhttp://www.beckhoff.com/english.asp?embedded_pc/cx1000_2.htmhttp://www.fieldbus.org/images/stories/newsroom/newsletter/200702/http://www.fieldbus.org/images/stories/newsroom/newsletter/200702/http://www.easydeltav.com/video/product/foundation_fieldbus.asphttp://www.easydeltav.com/video/product/foundation_fieldbus.asphttp://www.us.profibus.com/http://www.isa.org/InTechTemplate.cfm?Section=Article_Index1&template=/ContentManagement/ContentDisplay.cfm&ContentID=60680http://www.isa.org/InTechTemplate.cfm?Section=Article_Index1&template=/ContentManagement/ContentDisplay.cfm&ContentID=60680http://www.isa.org/InTechTemplate.cfm?Section=Article_Index1&template=/ContentManagement/ContentDisplay.cfm&ContentID=60680http://en.wikipedia.org/wiki/Fieldbus


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Use in Industry

Fieldbus continues to be an important elementof the automation industry. InTechmagazine

conducted a Market Study 80% of manufacturing facilities use fieldbus

Manufacturers use more than one fieldbusprotocol in their process

Fieldbus connected to the Internet?No - 82%, Yes - 18%


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Primary Vendors of Technology

Acromag, Inc.

RTD Embedded Technologies, Inc.

Contemporary Controls

RM Michaelides Software & Elektronik GmbH

Interface Concept

Steinhoff Automation & Fieldbus-Systems

Hilscher Gesellschaft fr Systemautomation mbH

PTO

Beckhoff

http://www.eg3.com/search411.cgi?query=fieldbus&case=on&engine=VENDORS
http://www.eg3.com/search411.cgi?query=fieldbus&case=on&engine=VENDORShttp://www.eg3.com/search411.cgi?query=fieldbus&case=on&engine=VENDORShttp://www.eg3.com/search411.cgi?query=fieldbus&case=on&engine=VENDORShttp://www.eg3.com/search411.cgi?query=fieldbus&case=on&engine=VENDORShttp://www.eg3.com/search411.cgi?query=fieldbus&case=on&engine=VENDORS


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Existing or Evolving Standards?

Ethernet-based industrial communication systems recentlyestablished, and have extensions for real-time communication.

Will potentially replace traditional fieldbuses in the long run. Currently the issue stopping most Ethernet fieldbus implementations

is the availability of device power. Measurement & control devices

need power from the bus and Power-Over-Ethernet (PoE) does notdeliver enough.

Here is a partial list of the new Ethernet-based industrialcommunication systems: EtherCAT Ethernet Powerlink

SERCOS III PROFINET IO ETHERNET/IP VARAN SafetyNET Industrial Ethernet

IEC 61158 is an evolving standard with a 5-year maintenance cycle.


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Application Example

Quest Separation Technologies | Food & Beverage Needed new facility The typical timeline for design, construction, and

startup of a facility of this scale is 9 to 12 months. Wanted plant to start production in less than five months. Emerson Process Management's PlantWeb digital plant architecture, based on the

FOUNDATION fieldbus communications protocol, intelligent field devices, and theDeltaV digital automation system met this project's daunting challenge.

Reduced capital and engineering expenditures Reduced operations and maintenance effort Reduced regulatory compliance effort Reduced variability of plant and processes Designed plant to be scaleable in future Fieldbus technology, the DeltaV system, and PlantWeb architecture saved Quest

many man-hours in installation time. The breakthrough automation solution alsosaved Quest 10 percentin installed material costs, and it reduced both space andprocess control equipment by up to 43 percent. As a team, Quest and Emerson metthe deadline in record time.


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Application Example

Valley Record Distributors - Woodland, CA

Automated conveyor system installed

By Dorner Manufacturing Corporation

Thousands of dollars were eliminated by not having tohard wire the I/O devices back to the main computers.The PLCs and PROFIBUS made that benefit possible.The line operates very efficiently, increasing production

substantially. Less warehouse space is consumed by themachine layout. If the machinery has to be moved toanother location, its modular design makes this mucheasier than previous designs. Speed and efficiency ofthe new sortation line exceeded that of the first-installed

system.


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Summarize Technical Paper

Title: With 20 million nodes,Profibus says it's mainstream.Source: Control Engineering, 54 (9): 31,September 01, 2007. ISSN: 0010-8049Publisher: Reed Business InformationDocument Type: JournalPublication Country: United States,

Language: English


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Summarize Technical Paper

The Profibus Trade Organization (PTO) commemorated20 million installed nodes world-wide (as of April 2007).

Profibus digital industrial network and fieldbustechnology are mainstream for general applications.

Examining fieldbus platforms at the end of 2006,Profibus claims a 46% market share by node count.

The organization projects the 30 million node milestonecould be passed as early as March, 2009.

PTO estimates that when all the instrumentation andperipheral equipment to support those networks areincluded, the total market value for those 20 millionnodes exceeds $50 billion.

These numbers should tell an end user that fieldbustechnology is mainstream. It is operating today in alltypes of plant environments.


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Profibus

Profibus is a vendor-independent, open fieldbusstandard for a wide range of applications inmanufacturing, and process automation. Devicesconfigured by different manufacturers can communicatewithout special interface adjustments. Profibus can beused for both high-speed, time-critical data transmissionand extensive complex communication tasks.

Profibus family consists of three compatible versions: Profibus-FMS (Fieldbus Message Specification) Profibus-DP (Decentralized Peripherals) Profibus-PA (Process Automation)

PROFIBUS (Process Field Bus) is the most popular fieldbus today


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How integrates?

Factory

Level

Cell

Level

Field

Level

Bus CycleTime

< 1000 ms

Bus CycleTime

< 100 ms

Bus CycleTime

< 10 ms

MMS, TCP/IP Backbone

Profibus-FMS

Profibus-DP Profibus-PA

I/ODrive ValvesField

Device

Trans-

mitterField

Device

AreaController


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Video

http://www.easydeltav.com/video/product/foundation_fieldbus.asp

http://www.easydeltav.com/video/product/index.asp
http://www.easydeltav.com/video/product/foundation_fieldbus.asphttp://www.easydeltav.com/video/product/foundation_fieldbus.asphttp://www.easydeltav.com/video/product/index.asphttp://www.easydeltav.com/video/product/index.asphttp://www.easydeltav.com/video/product/foundation_fieldbus.asphttp://www.easydeltav.com/video/product/index.asphttp://www.easydeltav.com/video/product/index.asphttp://www.easydeltav.com/video/product/foundation_fieldbus.asphttp://www.easydeltav.com/video/product/foundation_fieldbus.asp

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FIELDBUS Engineering Technology