Automation and Drives trends in distributed control systems

Automation and Drives trends in distributed control systems SIMATIC PCS 7 Introduction Dr. G. U. Spohr Asset Management Profibus PA redundancy Siemens A&D ST 2 1 GB Ethernet Wireless LAN Web - Technology MES Automation & Drives April 2005 A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 1

Automation and Drives Introduction SIMATIC PCS 7 Introduction Asset Management Some major technological trends which will influence the design of current and future decentralized control systems : Profibus PA redundancy 1 GB Ethernet n Intelligent Field-Devices and Asset Management Wireless LAN Web - Technology MES n Communication Technology n n n Redundant Profibus PA Fieldbus Gigabit Ethernet Wireless LAN n Web – Technology n Management Execution Systems MES A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 2

Automation and Drives Intelligent sensor- and actor-systems SIMATIC PCS 7 Introduction n intelligent sensor- and actor-systems often provide additional information Asset Management Profibus PA redundancy n acoustic pump monitoring n valve diagnostics n internal self diagnosis n . . . . 1 GB Ethernet Wireless LAN Web - Technology MES n these informations are transferred to the control system using HART or a fieldbus communication n. . but where do I evaluate these informations ? A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 3

Automation and Drives Integrated Plant Asset Management SIMATIC PCS 7 Introduction Asset Management Profibus PA redundancy 1 GB Ethernet Plant Asset Management Systems integrated in SIMATIC PCS 7 provides online, real time functions : n Monitoring of the components n Message at status change Diagnostics Maintenance Request Maintenance n Display of diagnostic information n Creation of maintenance request Wireless LAN Monitoring SIMATIC PCS 7 Plant Asset Management n Tracking of the maintenance activities Web - Technology MES Main benefits of the implementation : n Homogenous integration into the SIMATIC PCS 7 environment n Maintenance Station integrated into OS or as a dedicated station n Common visualization (symbols, faceplates) of all assets (unified assets) n Automatic generation of all Asset Management diagnostic pictures n Consequent implementation of NAMUR recommendations NA 64 & NE 91 A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 4

Automation and Drives Asset Management – Operating & Monitoring SIMATIC PCS 7 OS MS Introduction OS C 1 Asset Management Profibus PA redundancy AS 1 AS 2. . . AS n Web - Technology MES S 1 AS 1 1 GB Ethernet Wireless LAN OS MS Cn . . . AS 2 . . . n Maintenance Station integrated in Operator Station Maintenance Pictures . . . n OS Clients with access to maintenance area (pictures, messages, faceplates) n Maintenance Station has Sn AS n additionally direct online access to PDM and hardware engineering AS C MS OS S – – – Automation System Client Maintenance Station Operator Station Server n All SIMATIC PCS 7 components with diagnostic functions included n Common and unified symbols for representing the status of all assets Good Announcement of request for maintenance (low) Request for maintenance unknown/not activated Simulation Request for maintenance (medium) Request for maintenance activated Function control/ local Maintenance alert (high) Request for maintenance in process A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 5

Automation and Drives Integrated „Plant Asset Management“ Hierarchical Structure SIMATIC PCS 7 Fast and easy-to-use operator guidance through complete hierarchy by unified symbols Introduction Asset Management SIMATIC S 7 -400 and PROFIBUS Network Profibus PA redundancy 1 GB Ethernet status and selection of underlying hierarchy Wireless LAN Web - Technology MES ET 200 M Station diagnosis symbol of the component Clear hierarchical structure PROFIBUS Assets n Plant overview n Overview all controllers n Controller (with sub-hierarchy) n PROFIBUS Assets n DP station (e. g. ET 200 M) n Intelligent field device A&D AS SM MP Faceplates for intelligent device PCS 7_Overview_V 6 -1_E 200502. ppt 6

Automation and Drives Integrated „Plant Asset Management“ Automatic generation of hierarchical diagnostic pictures SIMATIC PCS 7 Introduction Asset Management Profibus PA redundancy 1 GB Ethernet OS OS C 1 S 1 AS 1 MS Cn . . . AS 2 . . . Sn AS n Wireless LAN Web - Technology MES Automatic generation of diagnostic area n Operating and monitoring n hierarchical pictures n asset symbols with faceplates n alarm linking n Engineering CFC charts with diagnostic blocks Plant view in SIMATIC PCS 7 engineering Unit 1 Unit 2 Boiler 21 Diagnosis AS - Station CP 1 - Field bus CP 2 - Field bus No engineering overhead !!! All Asset Management related information is generated automatically !!! A&D AS SM MP Remote I/O DP/PA - Link Picture CFC PCS 7_Overview_V 6 -1_E 200502. ppt 7

Automation and Drives PROFIBUS PA- Redundancy SIMATIC PCS 7 Possible Failures in a PA- Segment Introduction Asset Management Profibus PA Redundancy redundancy 1 GB Ethernet Wireless LAN Web - Technology MES A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 8

Automation and Drives PROFIBUS PA- Redundancy SIMATIC PCS 7 Basic Concept Introduction Asset Management Profibus PA Redundancy redundancy 1 GB Ethernet Wireless LAN Web - Technology MES A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 9

Automation and Drives SIMATIC PCS 7 system bus: flexibility in communication SIMATIC PCS 7 Introduction n 1 Gbps, ring topology: Double ring topology for Plant bus (double redundant) Fiber optic or twisted pair Switching technology n High performance variant: Industrial Fast Ethernet (100 Mbit/s, redundant) n Normal requirement: Industrial Ethernet (10 Mbits/s, redundant) n Introductory solution: Basic Communication Ethernet via normal LAN connection Asset Management Profibus PA redundancy 1 GB Ethernet Wireless LAN Web - Technology MES High communication capacity even for "XXL applications“ providing total system stability and high availability ! Gigabit Plant Backbone SCALANCE X 208 SCALANCE Serie X 400 A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 10

Automation and Drives Wireless LAN – These are the most important requirements SIMATIC PCS 7 Introduction Asset Management Profibus PA redundancy 1 GB Ethernet Wireless LAN Web - Technology MES Metal housing with high degree of protection Robust Protection against vibration and shock Extended temperature range Cyclic data traffic (deterministics) Redundancy Reliable Monitoring of the radio connection Stable radio connection Easy configuration Secure Access control (authentication) Encoding of the data WIRELESS – AS RELIABLE AS WIRE! A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 11

Automation and Drives Cyclic data traffic Reliable SIMATIC PCS 7 Data rates reserv. Introduction Asset Management Profibus PA redundancy 1 GB Ethernet Wireless LAN Web - Technology MES 802. 11 Data rates reserv. 802. 11 T 2 T 3 T 4 T 5 T 6 Time 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 3 rd 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 A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 12

Automation and Drives Redundancy Mode Reliable SIMATIC PCS 7 Introduction Asset Management Profibus PA redundancy 1 GB Ethernet Wireless LAN Web - Technology MES § Transmission of the data via two different radio channels e. g. by disturbance switching from 2, 4 GHz at 5 GHz or vice versa. Redundancy increases the availability and reduces the sensitivity to interference A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 13

Automation and Drives Security settings Secure SIMATIC PCS 7 Introduction Security levels: Asset Management Profibus PA redundancy 1 GB Ethernet Wireless LAN When choosing ‘none‘ no security level is activated! Web - Technology MES The required security level is achieved by one software setting A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 14

Automation and Drives Comparison of SCALANCE W / SCALANCE S Secure SIMATIC PCS 7 Introduction SCALANCE W-700 with WPA, TKIP, MIC and AES Authentication (Who am I? ) Coding Secure Asset Management Profibus PA redundancy 1 GB Ethernet SCALANCE S-600 with IPsec VPN tunneling and Firewall Authentication (Who am I? ) Authorisation (What may I? ) Coding SCALANCE W-700 Secure Wireless LAN Web - Technology SCALANCE S-600 MES Multiple protection against unauthorised access and bugging on automation components or cells. A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 15

Automation and Drives SCALANCE W or SCALANCE S EITHER. . . SIMATIC PCS 7 . . . OR SCALANCE W-700 Introduction SCALANCE W-700 SCALANCE S Asset Management Profibus PA redundancy Secure Ethernet 1 GB Ethernet Wireless LAN Web - Technology WPA/AES (Software included in AP) User- defined Firewall setting MES SCALANCE W-700 Ethernet Security mechanism deactivated VPN Tunnel SCALANCE S SCALANCE W-700 Ethernet A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 16

Automation and Drives IWLAN and mobile diagnosis SIMATIC PCS 7 Introduction IE Access Point SCALANCE W 788 -2 PRO Access Point SCALANCE W 788 -1 PRO Access Point SCALANCE W 788 -2 PRO IE Asset Management Profibus PA redundancy 1 GB Ethernet Wireless LAN IE Client Module SCALANCE W 744 -1 PRO S 7 -200 S 7 -400 Web - Technology Field PG with CP 7515 PROFIBUS MES ET 200 S S 7 -300 Automated guided vehicle systems IE Client Module SCALANCE W 744 -1 PRO ET 200 S Mobile diagnosis and service Wireless PLC Separate radio network Components for IWLAN for mobile data access. A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 17

Automation and Drives Monitoring and Control via SIMATIC PCS 7 Web Client SIMATIC PCS 7 Introduction Asset Management Profibus PA redundancy 1 GB Ethernet Wireless LAN Web - Technology MES n Monitoring and Control via the Internet / Intranet n Web Client as thin client n Complete plant overview n Remote diagnostics and asset management n Advanced security is ensured by n User-specific password n Firewall technology n Individual application concepts SIMATIC PCS 7 Web-Client Modem LAN Intranet n Minimal installation at the Web Client n “OCX” file via net download or CD Internet Explorer n Direct conversion of process screens for the web n Superior performance by n Compressed process pictures for the Web n Report by exception based runtime communication Worldwide and safe access to the plant based on stateof-the-art web technology ! A&D AS SM MP SIMATIC PCS 7 Web-Client LAN Intranet Terminal Bus Web-Server within a SIMATIC PCS 7 Client Plant Bus PCS 7_Overview_V 6 -1_E 200502. ppt 18

Automation and Drives PCS 7 OS Web Client SIMATIC PCS 7 Introduction Asset Management Profibus PA redundancy 1 GB Ethernet Wireless LAN Web - Technology MES Monitoring and Control via the Inter- / Intranet n n n Web Client as Thin Client Manager node Remote diagnostics and asset management Advanced security is ensured by n n n 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 n n A&D AS SM MP Compressed PCS 7 screens Report by exception based runtime communication PCS 7_Overview_V 6 -1_E 200502. ppt 19

Automation and Drives MES interface to the IT world with SIMATIC IT SIMATIC PCS 7 Introduction Asset Management Profibus PA redundancy Information technology (IT), process data management and production planning systems n Connects the control level with the MIS/MES level n Comprehensive basic packages available n Integration of vendor-neutral IT products 1 GB Ethernet Wireless LAN Web - Technology MES play an increasingly important role in production optimization and cost reduction To the ISA S 95 standard; integration of heterogeneous (as well as host) applications Short response times, more transparency, more reliable decision-making Integration & synchronization of all business processes with the SIMATIC IT technology platform A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 20

Automation and Drives SIMATIC IT Integration SIMATIC PCS 7 Introduction Asset Management Profibus PA redundancy Browsing of MES- relevant Objects 1 GB Ethernet Wireless LAN Web - Technology MES A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 21

Automation and Drives SIMATIC PCS 7 Introduction SIMATIC PCS 7 Asset Management Profibus PA redundancy 1 GB Ethernet Wireless LAN Web - Technology MES A&D AS SM MP PCS 7_Overview_V 6 -1_E 200502. ppt 22