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Wireless ad-hoc sensor networks in the process industry: challenges and opportunities

Wireless ad-hoc sensor networks in the process industry: challenges and opportunities. October 2004 ABB Corporate Research. Outline. Brief introduction to ABB and CRC Radio wave propagation in industry Example projects Standards Now what?. ABB’s Research & Development (R&D).

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Wireless ad-hoc sensor networks in the process industry: challenges and opportunities

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  1. Wireless ad-hoc sensor networks in the process industry:challenges and opportunities October 2004 ABB Corporate Research

  2. Outline • Brief introduction to ABB and CRC • Radio wave propagation in industry • Example projects • Standards • Now what?

  3. ABB’s Research & Development (R&D) ABB Group Chief Technology Officer R&D in 2 Divisions R&D in 2 Divisions 2 Global Research Labs Global Research Labs R&D Investments 2003: 930 MUSD, of which 10% in global research.

  4. ABB annually invests US$ 930 million in R&D Order-related development 317 Product development 518 Research 95

  5. Beijing/Shanghai 2 Sitesin Asia Automation Technologies CH, SE, US W, DE, NO, IN Power Technologies CH, SE, US R, PL, FI, (CN) Global Labs and Locations 6 Sites in Europe Vaasa Oslo Västerås Ladenburg Krakow Baden-Dättwil Wickliffe Bangalore 2 Sites in USA Raleigh

  6. NO/SE: • Wireless communication • Mobile Internet & appl./HMI • Embedded systems development • NO: • Safety • NO/SE/DE/CH: • Comms & networking theory • Automation networks • DE: • Alternative powersupplies • Micro energy generation • CH: • IT Security Program competencies - Communication • Fieldbus technologies • Industrial Ethernet • Vertical integration • Wireless communication • Internet technologies • Mobile applications • Wireless power • Safety • Security

  7. Radio wave propagation industry

  8. Wireless communications in industrial env • Industrial plants, power plants, productions facilities • Harsh environments • Extreme temperature • Vibration • Steel constructions • Obstructions • Possible EMC • Results • Heavy multipath fading • Fast/slow fading • Good coverage • Local variations in received power

  9. Wireless communications in industrial env • Received power versus logarithmic distance between Tx and Rx

  10. Wireless communications in industrial env Simulations of radiowave propagation in a nuclear power plant

  11. Noise in 2.4GHz range, NEFI high voltage lab Measure spectrum in vicinity of arc: • arc length 10cm • arc current 16kA • antenna distance 2m • duration 1.0 sec • 3dBi omnidirectional whip antenna

  12. Noise in the 2.4GHz ISM band 2.4 - 2.5GHz, max hold No measurable effect in this band! Baseline plot Arc plot

  13. Bluetooth test at Sauda smelting plant • Strong electromagnetic fields, 25MW at 110V three phase • Typical industrial environment (heat, dust, metal obj.,) • No deterioration in the measured BER

  14. Outline • Brief introduction to ABB and CRC • Radio wave propagation in industry • Example projects • Standards • Now what?

  15. Example: Wireless Proximity Sensor • Pioneering technology for wireless automation • ABB has developed first solution for remotely powered, real-time wireless communication • WISA (Wireless Interface for Sensors and Actuators) – an ABB platform for wireless in manufacturing automation • WPS product launched in Nov. 03

  16. Wall Street Journal Innovation Award 2002 Innovation Gold Award Wall Street Journal 2002

  17. Technology evaluation Demonstrate wireless access to field device over ZigBee/802.15.4 Cable replacement Example: ZigBee for field instruments

  18. Outline • Brief introduction to ABB and CRC • Radio wave propagation in industry • Example projects • Standards • Now what?

  19. Available standards for WSN • Bluetooth (802.15.1) • Overkill (IP stack, voice channel) • Power consumption too high for battery powered devices • ZigBee (802.15.4) • Low complexity, low power, low bandwidth • Supports star, tree, and mesh topologies • 802.11s • New standard in the making for mesh networking using standard WLAN technology • Comming down in both cost and power consumption

  20. Bluetooth • Piconets master/slave structure • seven active slaves per master • 255 sleeping nodes • Supports scatternets with nodes being members of more than one piconet • 1Mbps in original version • Supports voice • Major obstacles: • Small size of piconet!!!! • Slow wakeup of sleeping nodes (excess of two seconds) • Complex stack (expensive equipment) • Expensive qualification programme

  21. ZigBee • Aims at industrial, PC peripherals, toys, home automation • Low power, low price, low complexity radio specification • Approximately 20mA ON, deep sleep modes available • Minimum 30ms latency • 250 kbps in 2.4GHz ISM band • 16 independent channels

  22. ZigBee • Based on IEEE 805.15.4 PHY/MAC • New low freq. PHY under development • NTW specified by ZigBee Alliance Ratified Oct-04 • Stack requirements: • 4-8 kBytes (including MAC) • 50 kBytes (including NTW)

  23. 802.11s • Standardisation work in progress • Expected date of submission 01.01.2006 • Proposal so far: • APs form wireless backbone supporting multihop • Leaf nodes do NOT route! • Automatic configuration and route repair • Use existing frame structure to allow multihop between access points • Targets up to 32 APs participating in the network

  24. WSN: so what is new? • Multihop. All nodes act as routers • Do away with fixed infrastructure all together • Extend coverage beyond single radio hop • No network planning • Faster deployment • Lower maintenance cost and effort • Self healing • Robust to the demise of single network elements

  25. A A) Tracking mobile production units B C B) Connectivity in inaccessible locations C) Mesh networks in open and closed loop control WSN: possibilities in industry

  26. WSN: opportunities in open loop • Application areas in industrial automation: • Condition monitoring. Detecting equipment wear-and-tear. • Asset management. Keeping track of inventory, • Energy management • Service application • General requirements: • Short packets • Low average date rate • Low power • Other areas: • Environmental monitoring • Defence • Building automation

  27. WSN: challenges in open loop • Can be done! • Use timestamping and store-and-forward • Will be the first to see real products • Honeywell • Emerson • ABB?

  28. WSN : opportunities in closed loop • Application areas: • Metals and mining • Pulp and paper • Oil and gas • Chemical • (temp, pressure, level,…) • General requirements • Short packets • Low average date rate • Low power • Short latency • Guaranteed packet delivery

  29. WSN : challenges in closed loop • A lot more complex on several levels • Energy sensitivity • Adaptive power control (Stanford) • Cluster head management • Hot-spots and aggregation node depletion • Latency “guarantees” over multihop networks • Interesting new work has been done on MAC level, e.g. non-uniform back-off, time-slicing, … • QoS in routing algorithms • Robust control algorithms • Kalman filtering with intermittent sampling • …

  30. Major players • Networking • Ember • Millennial • Dust • CrossBow • Building blocks • Chipcon • Figure8Wireless • Freescale • OKI • Atmel • Applications in control • Honeywell • Phillips • Emerson • ABB

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