Manufacturing Automation for Assembly and Inspection MM453

Manufacturing Automation for Assembly and

Inspection
MM453

Dr. Nigel Kent

Rm S366
[email protected]

Dublin City University

Sem 1 2022

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 10

Lecture 10

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 10
Fieldbus and Ethernet

Each network technology has a specific purpose. These can generally be

distinguished according to communication networks based on fieldbus or
Ethernet.
• Fieldbus A fieldbus establishes the connection between sensors,
actuators and control computer. Several devices can be connected
to a fieldbus and send their messages via the same line. In this case,
it must be specified who is allowed to exchange information and
when. Virtually every PLC manufacturer has designed their own
fieldbus. For this reason, there are numerous technologies that are
different from each other. For example, the maximum cable length,
the data rate or in the range of functions.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 10
Fieldbus and Ethernet

Each network technology has a specific purpose. These can generally be

distinguished according to communication networks based on fieldbus or
Ethernet.
• Ethernet. Ethernet is a technology originally developed for office
communication, i.e. for the exchange of data in PC-based local data
networks (LANs); it consists of a number of software and hardware
components. Ethernet allows much higher transfer rates of up to
400 Gigabit/ s. A number of PLC manufacturers have extended
basic Ethernet technology in order to meet various industrial
requirements. This has resulted in the existence of a number of
manufacturer-specific Ethernet systems.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 10
Fieldbus and Ethernet

Functioning of a fieldbus
The fieldbus operatea on a master slave principle. The master first
interrogates the sensor by requesting the sensor via message (1). The
sensor then sends the current temperature value as a message (2) to the
master, which is then processed in the controller. The master then sends
another message (3) to the actuator containing the fan speed value.
Since a fieldbus is operated cyclically like a PLC, the master then starts
to query the sensor again.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 10
Fieldbus and Ethernet

Advantages of fieldbus compared to conventional wiring

• Easy to install: less wiring and smaller, simpler switch cabinets
• Reduced error search in the event of failure
• One cable for digital/binary and analog signals
• Protection from faults with analog values
• Automated system is capable of self-diagnosis – e.g. when
faults occur in the sensors/actuators
• Simpler expansion or simple addition of sensors/actuators

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 10
Fieldbus and Ethernet

Disadvantages of fieldbus compared to conventional wiring

• Complexity requires qualified personnel for operation and
maintenance
• More elaborate in terms of measuring technology
• Longer response times due to sequential accessing of slaves
(depending on the fieldbus in question)
• Failure of the bus system causes failure of communication
between all components

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Lecture 10
Fieldbus and Ethernet

Different commercial vendors have thier own proprietry implementation

of fieldbus based on some of the following:
• Transmission medium: What type of cable (shielded/unshielded, no.
of wires) has to be used?
• Connectors: Which type of connector can be used (depending on
requirements with regard to degree of protection, EMC)?
• Topology: What is the structure of the fieldbus or how are the
individual components connected to one another?
• Maximum no. of components: How many components can the bus
system address?
• Energy supply via the bus: Does the fieldbus allow the cable to be
used for power supply and data transmission at the same time?
• Advantages and disadvantages: What are the strengths and
weaknesses of the bus system in question?

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Lecture 10
Profibus

Profibus
• The name Profibus stands for PROcess FIeld BUS.
• The name Profibus stands for PROcess FIeld BUS.
Development of the Profibus was started in 1987 and there is
currently a family of several fieldbus variants.
• Since Siemens uses Profibus as the central bus for its
controllers and these have a very large market share in Ireland
and Europe.
• Two variants of Profibus have been developed for
manufacturing and process automation: Profibus DP
(Decentralized Periphery) and Profibus PA (Process
Automation). The two variants differ in terms of cable, plug
configuration and interface.

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Lecture 10
Profibus

Profibus DP Profibus PA
Transmission Cable: 2-wire, shielded, twisted, Cable: 2-wire, shielded, twisted
Conductor cross-section: >0.34 pair Conductor cross-section:
mm2 , Characteristic impedance: >0.8 mm2 Characteristic
150 ohm Use of fiber optic cables impedance: 100 ohm Power
(FO) possible (multi-mode, single- supply optionally possible in cable
mode fiber-glass and plastic fiber),
maximum extension 90 km
Connector

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Lecture 10
Profibus

Profibus DP Profibus PA
Topology Line (copper, with active bus ter- Line, star,combination of the two
mination), line, star and ring.

Maximum cable length: 100 m to Max. 1900 m extension

1200 m depending on data rate

Data transmission rate at 100 m Data transmission rate for

cable length (electrical transmis- Profibus PA is 31.25 kBit/s
sion) is maximum 12.0 bit/s, at
1200 m max. 9.6 kbit/s

Maximum 90 km extension in the Components per bus segment

case of an optical network (de- max. 32, total 126
pending on the fiber optic system
used!)
Total no. components 126 Converter between Profibus DP /
PA
Max com- 126 126
ponents
Energy sup- No Optional 9 – 32 V
ply on bus

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 10
Profibus

Profibus DP Profibus PA
Features High transmission speed as com- Simple to combine with Profibus
pared to other fieldbuses DP via converter.

Suitable for more complex compo- Designed for use with simple
nents, extensive configuration op- analog sensors and actuators,
tions such as variable data rate fixed/low transmission speed, Lim-
ited extension
Systems Siemens / PNO / PI Siemens / PNO / PI
Developer

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Lecture 10
Profibus

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Lecture 10
Profibus

Other popular fieldbus types include:

• CANOpen
• CC-Link
• AS-Interface
• IO-Link
• MODBUS∗
∗ MODBUS TCP is among the more popular versions of
MODBUS. Since MODBUS TCP is compatible with Ethernet it is
technically not a fieldbus. As Industry 4.0 technologies become
more main stream the lines between these groupings become more
blurred.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 10
Ethernet in Industrial use

Operating principle
Unlike the master-slave method used in fielbuses, all Ethernet components are
equal. This is why collisions can occur in the network when messages are
exchanged. A ”listening mechanism” in each device detects whether another
device is sending a message and waits accordingly.

According to the IEEE standard, Ethernet communication is random and

therefore not deterministic. This has an impact on its use in industry.

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Lecture 10
Ethernet in Industrial use

Distinction between Industrial Ethernet and standard / office

Ethernet
In contrast to use in the office environment, the following
requirements apply to Industrial Ethernet:
• Environment requirement: The network components (cable, plug,
switches) must have a higher protection class so as to be resilient to dust,
splash water, lubricants and acid. Increased electromagnetic interference
resistance and an extended temperature range are also key aspects
• Network requirements: While star topology has mainly become
established in the office environment, line topology (daisy-chaining of
devices) tends to be used in industry. In order to ensure a high level of fail
safety, the network components have to be very reliable and precautions
also have to be taken in the network itself (ring closures, redundancy
concepts). Since the network has to be deterministic and as fail-safe as
possible, ”controlled” communication is required in the network

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Lecture 10
Ethernet in Industrial use

Categories of Industrial Ethernet technologies

The various Industrial Ethernet systems can be subdivided into categories
based on their technology type.
• Standard IP communication In this case, IP-based communication takes
place as in regular office communication. The drawback is that it is not
possible to achieve the classic real-time properties familiar from the
fieldbus area.
• Standard Ethernet communication In this category, communication
takes place directly using standard Ethernet messages. Components are
addressed by means of their MAC address
• Proprietary Ethernet communication This category does use parts of
the Ethernet standard but with the addition of manufacturer-specific
software and hardware extensions so as to achieve a deterministic
response. For example, an Ethernet message contains special information
that can be processed by a proprietary hardware/network component (e.g.
a slave component). The speed which can be achieved in this way is less
than 1ms and the response is deterministic

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Lecture 10
Ethernet in Industrial use

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Ethernet in Industrial use

Advantage of Fieldbus Networks Over Ethernet

• Deterministic
• More economical
• Straightforward installation requiring less wiring
• Ease of calibration of instruments
• Access to more data – measurement as well as diagnostic
• Easier troubleshooting
• Less sensitive to electrical noise
• More physically robust connectors and components
• Easier to transmit power over network
• Spans longer distances without repeaters or switches

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Ethernet in Industrial use

Advantage of Ethernet based networks

• Faster
• Same network for IT automation
• More topology options
• Large variety of network analysis tools
• Easier to expand
• Readily available technical support
• Universal connectivity to controllers, I/O and other components
• Ability to transmit multiple protocols simultaneously
• Superior and rapidly improving price/performance ratio
• Easier integration with multiple wireless networks

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