Phil Harris

December 3, 2008
ME EN 486

What is a fieldbus
History and Current State
Who, What, When
Application Example
Changing Standards
Technical Paper
Class Application -- Fun Quiz

Fieldbus is a general term that describes a digital communications
network that is being used in industry to replace the existing
standard (4-20 mA analog signal)
REVIEW -- Characteristics of Fieldbus networks
Bi-directional means it is a duplex port; the data can be
transmitted in two directions at the same time.
Multi-drop is also referred to as multi-access and it can be
interpreted as a single bus with many nodes connected to it.
Serial-bus means the data is transmitted serially according to
RS232 or RS485 protocol. Profibus uses RS485 protocol.
Fieldbus works on network structures such as daisy-chain, star,
branch, ring, and tree network

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

The Fieldbus links the PLCs to the components which actually do the
work

Human Machine Interface (HMI)




Programmable Logic Controllers (PLCs)




FIELDBUS



Components -- sensors, actuators, electric motors
console lights, switches, and valves
Fieldbus technology has been around since 1988
Completion of the ISA S50.02 standard which took
many years.
Previously computers were connected using RS-232
by which only two devices could communicate.
Now we can connect many nodes to a device.
In 1999, the IEC SC65C/WG6 standards committee met
to resolve difference in the draft IEC fieldbus standard.
Developed 8 protocol sets or requirements for IEC
61158 including Profibus, SwiftNet, Foundation Fieldbus
**More than 4,000 pages to IEC 61158**
Ideally One consistent standard would govern all fieldbus
applications
Reality Many standards that vary depending on the applications
IEC 61158 consists of 6 parts under general title Digital data
communications for measurement and control
Part 1: Overview and guidance for the IEC 61158 series
Part 2: Physical Layer specification and service definition
Part 3: Data Link Service definition
Part 4: Data Link Protocol specification
Part 5: Application Layer Service definition
Part 6: Application Layer Protocol specification
Currently Making changes and developments to make the
processing more reliable and faster.

In complex automated
systems where an
organized hierarchy of
controller systems is
needed.
In industrial and
manufacturing plants
where many
instruments need to be
connected.
Know the worst case
scenario and can adjust.

Used in Factories
To reduce installation
cost by moving the
I/O interface from the
programmable logic
controller (PLC) to a
remote I/O unit
mounted close to the
machine.
Eliminate wire lengths
and number of wires

A major advantage of fieldbus is the capital
expenditure (CAPEX) savings associated with
cable elimination
multiple devices share wire-pairs in order to
communicate over the bus network
faster testing and shorter time to operation
Ongoing maintenance and process control
system performance are significantly enhanced
through fieldbus systems, which results in
operations expense savings (OPEX).
THE GOOD
(CAP-EX) Savings
(OP-EX) Savings
THE BAD
Cost of Devices
Fieldbus components can be expensive
Fieldbus Cards = $50 up to $1,000s
EtherCAT = $100s
Risk of Evolution
Cost to Invest
Engineering costsMay need specific applications/components from
supplying company
Equipment costs
Installation costs
Maintenance costs Short Term INCREASED, Long Term DECREASED
Operating costsAdditional Training needed
Retooling costs
Profibus is a vendor-independent, open fieldbus
standard for a wide range of applications in
manufacturing, and process automation.

Devices made by multiple manufacturers can work
together and communicate. Few adjustments are
needed.

Profibus uses C/C++ Application Program Interface
(API) is a set of functions, procedures, methods, classes or
protocols that an operating system, library or service provides
to support requests made by computer programs

Profibus can be used for:
Complex tasks
High-speed, time-critical data transmission
Profibus family consists of three compatible versions:
Profibus-FMS (Fieldbus Message Specification)
For communication tasks at the cell level and can be used
for FMS services.
Profibus-DP (Decentralized Peripherals)
Designed for communication between automation control
systems and distributed I/O at the device level (only card
used in EAAL).
Profibus-PA (Process Automation)
Designed for process automation; permits sensors and
actuators to be connected on one common bus.

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

ABSOLUTELY
Fieldbus Components:
Bus Terminal
EtherCAT
Fieldbus Box
Lightbus
PC Fieldbus Cards
Switches
Factory
Level
Cell
Level
Field
Level
Bus Cycle
Time
< 1000 ms
Bus Cycle
Time
< 100 ms
Bus Cycle
Time
< 10 ms
MMS, TCP/IP Backbone
Profibus-FMS
Profibus-DP Profibus-PA
I/O Drive
Valves
Field
Device
Trans-
mitter
Field
Device
Area
Controller
www.relcominc.com/fieldbus/fblinks.html
www.us.profibus.com
www.eg3.com/WebID/indust/fieldbus
http://www.profibus.com/pall/applications/casestudie
s/article/02539/
http://www.beckhoff.com/english.asp?fieldbus_compo
nents/default.htm
http://www.fint.no/en/Products/Starter_Kits/PROFIb
us/ST41+Starterkit+for+T410.9SVTFlI56n_d2Z-
0ow_j1X9f3TP9D6CJ1MZI.ips
http://www.industrialethernet.com/clskecat.html
Professor Ed Red



Fieldbus continues to be an important element
of the automation industry.
Starter Kits Available
PC Program
Circuit Board
Surveys 70-80% of large manufacturing
facilities use fieldbus and most connected to
internet
Profibus Limitations from Application example
Cummins Engine
Assembly in UK
There are more than 2,000
possible engine variants
Engines were transported
through the
manufacturing process by
a combination of
overhead chain conveyor,
powered floor conveyor
and an AGV system.
All replaced by an EMS
(Electric Monorail System)
during a two week
shutdown in 2006.

The EMS comprises 600 meters
of overhead monorail, 50
carriers, 14 switch points, 3 lift
units, 1 rotate unit, 34 assembly
stations and 4 pressure test
stations
Status and Command words are
received and sent to each carrier
from the S7-317DP PLC again
via PROFIBUS DP
Since the system was installed,
production rates increased from
220 engines per day to 350
engines per day.
Limited to -40/0 to 85 Celsius
*** LIMITATIONS? ***
Ethernet-based industrial communication systems recently
established
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 does not deliver enough.
IEC 61158 is an evolving standard with a 5-year maintenance cycle.
Hybrid wired/wireless PROFIBUS networks supported by
bridges/routers
Ferreira, L. Alves, M. Tovar, E. Portugal; 2002
Recently there has been the desire to extend the capabilities of fieldbuses to
cover functionalities not previously considered in such networks, with
particular emphasis on industrial wireless communications.
Thinking about wireless means considering hybrid wired/wireless solutions
capable of interoperating with legacy (wired) systems. One possible solution is
to use intermediate systems (IS) acting as repeaters to interconnect the wired
and wireless parts

Real-time fieldbus communications using Profibus networks

Tovar, E. Vasques, F.
Dept. of Comput. Eng., Polytech. Inst. of Porto ;
This paper appears in: Industrial Electronics, IEEE Transactions
Volume: 46, Issue 6

Goal: Find different solutions of how to make Profibus systems to operate in
real-time and respond appropriately
Profibus is based on a simplified timed token (TT) protocol, solution for real-
time communication systems
Worst case is that only one real-time message is made per timed token visit
Come up with two different ideas that have different applications
More responsive systems (tighter time requirements/deadlines)
Increased non real-time traffic throughput
http://www.directindustry.com/prod/pepper
l-fuchs/fieldbus-diagnostic-module-7315-
364678.html
Follow signal from fieldbus to component and back
again
Diagnostic devices (green) that check the system
Buses and devices provide feedback about systems
SMAR Video
http://www.smar.com/products/dt302.asp
Shows Profibus Implementation
Names some advantages
THE FUN QUIZ
PROFIBUS is the most popular fieldbus today T / F
POE Stands for:
A Power On Ethernet
B - Power Over Ethernet
C - Power Onto Ethernet
Correct relation of Fieldbus to other components
A - Human Interface Fieldbus Components PLC
B - PLC Human Interface Components Fieldbus
C - Human Interface PLC Fieldbus Components
D - PLC Fieldbus Human Interface Components


Fieldbus used mostly by industrial applications
Costs Saves money through Capital and Operational
expenses
Requires supporting technology
Continuously evolving and upgrading
Profibus is the most widely used
Promoted in 1989
3 Different Types
Still making improvements and developments
Wireless Integration
Faster, Even more reliable
Ethernet