trends in distributed control systems

Automation and Drives

SIMATIC PCS 7

1

Introduction

Asset Management

Profibus PA redundancy

1 GB Ethernet

Wireless LAN

Web - Technology

MES

A&D AS SM MP PCS7_Overview_V6-1_E200502.ppt

trends in distributed

control systems

Dr. G.U. Spohr

Siemens A&D ST2

Automation & DrivesApril 2005

Automation & DrivesApril 2005


SIMATIC PCS 7

2

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Introduction

Some major technological trends which will influence the design of current and future decentralized control systems :

Intelligent Field-Devices and Asset Management

Communication Technology Redundant Profibus PA Fieldbus Gigabit Ethernet Wireless LAN

Web – Technology

Management Execution Systems MES


SIMATIC PCS 7

3

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Intelligent sensor- and actor-systems

intelligent sensor- and actor-systems often provide additional information

acoustic pump monitoring

valve diagnostics

internal self diagnosis

........

these informations are transferred to the control system using HART or a fieldbus communication

.... but where do I evaluate these informations ?

Asset Management


SIMATIC PCS 7

4

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Integrated Plant Asset Management

Plant Asset Management Systems integrated in SIMATIC PCS 7provides online, real time functions :

Monitoring of the components

Message at status change

Display of diagnostic information

Creation of maintenance request

Tracking of the maintenance activities

Main benefits of the implementation : Homogenous integration into the SIMATIC PCS 7 environment

Maintenance Station integrated into OS or as a dedicated station

Common visualization (symbols, faceplates) of all assets (unified assets)

Automatic generation of all Asset Management diagnostic pictures

Consequent implementation of NAMUR recommendations NA 64 & NE 91

Monitoring

SIMATIC PCS 7 Plant Asset Management

DiagnosticsMaintenance

RequestMaintenance

Asset Management


SIMATIC PCS 7

5

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Asset Management – Operating & Monitoring

Maintenance Stationintegrated inOperator Station

OS Clients with accessto maintenance area (pictures, messages, faceplates)

Maintenance Station hasadditionally direct onlineaccess to PDM andhardware engineering

...AS 1 AS 2 AS n

AS 1 AS 2 AS n

S n

OSMS

AS – Automation SystemC – ClientMS – Maintenance StationOS – Operator StationS – Server

Asset Management

OS MS

C 1 C n...

OS

Maintenance Pictures

S 1

Common and unified symbols for representing the status of all assets

Good

Simulation

Functioncontrol/ local

Request for maintenance(medium)

Announcement of request for maintenance (low)

Maintenance alert (high)

Request for maintenance unknown/not activated

Request for maintenance activated

Request for maintenancein process

All SIMATIC PCS 7 components with diagnostic functions included

...

...


SIMATIC PCS 7

6

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Integrated „Plant Asset Management“Hierarchical Structure

Asset ManagementSIMATIC S7-400 and PROFIBUS Network

ET 200M Station

PROFIBUS Assets

Faceplatesfor intelligent device

status and selection of underlying hierarchy

diagnosis symbolof the component

Clear hierarchical structure Plant overview

Overview all controllers Controller (with sub-hierarchy)

PROFIBUS Assets DP station (e.g. ET 200M)

Intelligent field device

Fast and easy-to-use operator guidance through complete hierarchyby unified symbols


SIMATIC PCS 7

7

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Integrated „Plant Asset Management“Automatic generation of hierarchical diagnostic pictures

Automatic generation of diagnostic area Operating and monitoring

hierarchical pictures asset symbols with faceplates alarm linking

Engineering

CFC charts with diagnostic blocks

Asset Management

AS 1 AS 2 AS n

S n

OS MS

C 1 C n...

OS

S 1...

...

AS - Station

CP1 - Field bus

CP2 - Field bus

Remote I/O

DP/PA - LinkLink Picture

CFC

Diagnosis

Diagnosis

Unit 2

Unit 1

Boiler 21

Plant

Technologische Sicht PCS 7Technologische Sicht PCS 7Technologische Sicht PCS 7

No engineering overhead !!!All Asset Management related infor-mation is generated automatically !!!

Plant view inSIMATIC PCS 7

engineering


SIMATIC PCS 7

8

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


PROFIBUS PA- Redundancy

Possible Failures in a PA- Segment

Profibus PARedundancy


SIMATIC PCS 7

9

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


PROFIBUS PA- Redundancy

Basic Concept

Profibus PARedundancy


SIMATIC PCS 7

10

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


SIMATIC PCS 7 system bus: flexibility in communication

1 Gbps, ring topology:Double ring topology for Plant bus (double redundant)Fiber optic or twisted pairSwitching technology

High performance variant: Industrial Fast Ethernet (100 Mbit/s, redundant)

Normal requirement: Industrial Ethernet (10Mbits/s, redundant)

Introductory solution:Basic Communication Ethernetvia normal LAN connection

Gigabit Plant Backbone

1 GB Ethernet

SCALANCE X208

High communication capacity even for "XXL applications“ providing total system stability and high availability !

SCALANCE Serie X400


SIMATIC PCS 7

11

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Wireless LAN –These are the most important requirements

WIRELESS – AS RELIABLE AS WIRE!

Cyclic data traffic (deterministics)Redundancy

ReliableMonitoring of the radio connectionStable radio connection

Easy configuration

SecureAccess control (authentication)Encoding of the data

Metal housing with high degree of protection

RobustProtection against vibration and shockExtended temperature range

Wireless LAN


SIMATIC PCS 7

12

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Cyclic data traffic

Time

Datarates

reserv. 802.11 802.11 802.11

Datarates

reserv.

Datarates

reserv.T1

T2

T3

T4

T5

T6

Nodes 1, 2 and 3 may access predictably the radio channel, controlled through Robust Access Point

Node 4 is allowed access to the radio channel „only“ in the 3rd cycle

Conform with 802.11, SCALANCE W guaranteed data reservation Any client devices applicable (non-SIMATIC as well)

Cyclic data traffic, well known from fieldbusses

Reliable

Wireless LAN


SIMATIC PCS 7

13

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Redundancy Mode

Transmission of the data via two different radio channels e.g. by disturbance switching from 2,4 GHz at 5 GHz or vice versa.

Reliable

Redundancy increases the availability and reduces the sensitivity to interference

Wireless LAN


SIMATIC PCS 7

14

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Security settings

When choosing‘none‘ no security level is activated!

Security levels:

Secure

The required security level is achieved by one software setting

Wireless LAN


SIMATIC PCS 7

15

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


SCALANCE W-700 withWPA, TKIP, MIC and AES

Authentication (Who am I?) Coding

SCALANCE S-600 with IPsec VPN tunneling and Firewall

Authentication (Who am I?) Authorisation (What may I?) Coding

Comparison of SCALANCE W / SCALANCE S

SCALANCE W-700

SecureSecure

Multiple protection against unauthorised access and bugging on automation components or cells.

Secure

SCALANCE S-600

Wireless LAN


SIMATIC PCS 7

16

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


SCALANCE W or SCALANCE S

VPNTunnel

User- definedFirewall setting

SCALANCE S

Securitymechanismdeactivated

Ethernet

Ethernet

WPA/AES(Software included in AP)

SCALANCEW-700

Ethernet

Ethernet

Ethernet

SCALANCEW-700

SCALANCEW-700

EITHER ...

SCALANCE S

Secure

SCALANCEW-700

... OR

Wireless LAN


SIMATIC PCS 7

17

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


IWLAN and mobile diagnosis

Field PG withCP 7515

IE ClientModuleSCALANCEW744-1PRO

ET 200S

S7-400

IE ClientModuleSCALANCEW744-1PRO

S7-200

Access PointSCALANCEW788-1PRO

PROFIBUS

S7-300 ET 200S



IEIE

Automated guidedvehicle systems

Mobile diagnosis and serviceWireless PLCSeparate radio network

Components for IWLAN for mobile data access.

Wireless LAN


SIMATIC PCS 7

18

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Monitoring and Control via the Internet / Intranet Web Client as thin client Complete plant overview Remote diagnostics and asset management

Advanced security is ensured by User-specific password Firewall technology Individual application concepts

Minimal installation at the Web Client “OCX” file via net download or CD

Direct conversion of process screens for the web

Superior performance by Compressed process

pictures for the Web Report by exception based

runtime communicationWeb-Server within a

SIMATIC PCS 7 Client

SIMATIC PCS 7Web-Client

Monitoring and Controlvia SIMATIC PCS 7 Web Client

Web - Technology

LAN Intranet

Terminal Bus

Plant Bus

SIMATIC PCS 7Web-Client

Modem

InternetExplorer

LAN Intranet

Worldwide and safe access to the plant based on state-of-the-art web technology !


SIMATIC PCS 7

19

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Monitoring and Control via the Inter- / Intranet Web Client as Thin Client Manager node Remote diagnostics and asset management

Advanced security is ensured by user-specific password Firewall technology Individual applications concepts

Minimal installation at the client (OCX via net)

Direct conversion of process screens for the web

Superior performance by Compressed PCS 7 screens Report by exception based runtime communication

PCS 7 OS Web Client

Web - Technology


SIMATIC PCS 7

20

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Integration & synchronization of all business processes with the SIMATIC IT technology platform

MES -interface to the IT world with SIMATIC IT

Connects the control level with the MIS/MES level

Comprehensive basic packages available

Integration of vendor-neutral IT products

To the ISA S95 standard; integrationof heterogeneous (as well as host) applications

Short response times, more transparency,more reliable decision-making

play an increasingly important role in production optimization and cost reduction

Information technology (IT), process data management and production planning systems

MES


SIMATIC PCS 7

21

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


Browsing of MES- relevant Objects

SIMATIC IT Integration

MES


SIMATIC PCS 7

22

Introduction

Asset Management


1 GB Ethernet

Wireless LAN

Web - Technology

MES


SIMATIC PCS 7

Documents

trends in distributed control systems