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Ian Bell National Instruments

One Controller - Any Bus Connecting Programmable Automation Controllers ,Measurements, Sensors, Networks and PLCs. Ian Bell National Instruments. Agenda. Industrial Communications Overview Why Connect a PAC to Industrial Networks and PLCs? 3 Methods to Connect to Any PLC or Device

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Ian Bell National Instruments

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  1. One Controller - Any Bus Connecting Programmable Automation Controllers ,Measurements, Sensors, Networks and PLCs Ian Bell National Instruments

  2. Agenda • Industrial Communications Overview • Why Connect a PAC to Industrial Networks and PLCs? • 3 Methods to Connect to Any PLC or Device • Basic Analogue and Digital I/O • Industrial Network Communication • OPC

  3. Industrial Communications Overview • Common Industrial Networks • DeviceNet • PROFIBUS • Modbus TCP • Modbus Serial • CANopen • FOUNDATION fieldbus • Interbus • CC-Link • LonWorks • HART • PROFINET • Ethernet/IP Industrial communications connect industrial devices such as PLCs, sensors and actuators

  4. Software Capabilities PC PLC Ruggedness and Reliability PAC Architecture • Ruggedness and reliability of PLC • Software capabilities of PC • Modular and diverse I/O PAC

  5. Why Connect PACs to Industrial Networks and PLCs? • High-speed analogue measurements • High-resolution analogue measurements • Advanced analysis (digital filtering, frequency analysis) • Custom hardware performance with FPGA technology • High-speed closed-loop control • FPGA-based processing and analysis • Custom Sensors/Measurements

  6. Industrial Communications Basic I/O Analogue/Digital OPC 3 Methods to Connect to Any PLC PACs PLCs

  7. Basic I/OCheap, Easy, Fast and Effective • Available on every platform • Analog and digital I/O options • PLC users can easily integrate analogue and digital I/O into their code • Allows PACs to act as intelligent devices

  8. Basic I/O • Advantages • Fast, deterministic, little or no software overhead • Considerations • Doesn’t scale well • Point-to-point wiring (parallel) • Can’t communicate lots of data

  9. ExampleAutomated Filling of Aerosol Cans • Existing PLC system was being used to automate the filling of aerosol cans • PLC did not have the capability to do high-speed analogue for pressure measurements • NI CompactRIO PAC was used for high-speed pressure measurements on 8 channels (2 k per channel) • CompactRIO and PLC were integrated using digital I/O

  10. Industrial Communications Basic I/O Analogue/Digital OPC 3 Methods to Connect to Any PLC PACs PLCs

  11. Methods for Industrial Communications Plug-In Interfaces Gateways over Ethernet, Serial Ethernet/Serial Performance/Determinism Versatility

  12. Plug-In Interfaces Plug-In Communication Boards • CAN and CANopen • DeviceNet • FOUNDATION fieldbus • Serial (RS232, RS422, RS485) • Third-party PROFIBUS (Comsoft) • Support for PXI, PCI, PCMCIA, and CompactRIO

  13. Plug-In Interfaces Plug-In Communication Boards • Advantages • Direct, deterministic communication with the processor • Timing and synchronisation with other I/O (DAQ) • High-level API support for LabVIEW and other programming languages • Considerations • Many smaller buses and protocols are not supported • Many only available on PC and PXI (real-time supported)

  14. Example : PROFIBUS • PROFIBUS master/slave for PXI and PCI • More than 2 million nodes • Popular in Europe and Asia • Recommended: Comsoft DF PROFI II interfaces

  15. cRIO-PBMaster/Slave and cRIO-PBSlave • cRIO PB Master/Slave module • Supports operation as DP Master or DP Slave • Ships with configuration tool configurator II for DP Master configuration • Ships with GSD file to configure any DP Master system • cRIO PB Slave module • Supports operation as DP Slave • Ships with GSD file to configure any DP Master system

  16. Ethernet-based Industrial Protocols • Modbus TCP/IP • Ethernet/IP • EtherCAT • Profinet

  17. Why Ethernet: Protocols • Modbus TCP/IP • Modbus • EtherNet/IP • DeviceNet • CanOPEN • EtherCAT • PROFIBUS • PROFInet Traditional Industrial Protocols Ethernet Physical Layer

  18. Modbus TCP/IP Overview • First industrial protocol on Ethernet (introduced 1999) • Based on Modbus developed by Modicon in 1979 • Widely adopted and open Ethernet standard • Advantages • Uses standard Ethernet (hardware and TCP/IP transport layer) • Open and relatively simple • Disadvantages • Not a hard real-time protocol • Does not deliver determinism

  19. Ethernet-based Industrial Protocols • Modbus TCP/IP • Ethernet/IP • EtherCAT • Profinet

  20. EtherNet/IP Overview • Dominant bus for Rockwell Automation • Managed by Open Device Vendors Association (ODVA) • Extends DeviceNET concepts to Ethernet • Advantages • Uses Ethernet transport layer (TCP and UDP) • Disadvantages • Can overload networks with UDP messages if not correctly configured, recommend managed switches with IGMP snooping

  21. Ethernet/IP Terminology

  22. Communication from NI PAC to ControlLogix and ComapctLogix PLCs Ethernet/IP Uses explicit messaging Available for download from NI Labs

  23. Gateways over Ethernet, Serial Third-Party Gateways • Wide variety of communication buses and protocols supported • Ethernet or serial-based • Perfect for non-PXI, PCI, and PCMCIA systems • PROFIBUS • DeviceNet • EthernetIP Ethernet • ControlNet

  24. ExampleAdding Vision for Food Processing Optimisation • Needed NI Compact Vision System to calculate the mass/volume of the food item coming through on the conveyor belt • Ethernet/IP connectivity was a requirement EthernetIP Modbus TCP

  25. Industrial Communications Basic I/O Analogue/Digital OPC 3 Methods to Connect LabVIEW to Any PLC NI PACs PLCs

  26. What Is OPC? Windows PC • Universal language for reading and writing data • OPC Client: Read and write to OPC • OPC Server: Translates between OPC and device-specific protocols English

  27. OPC Client Windows PC Allen-Bradley OPC Server Ethernet/IP OPC Client Siemens OPC Server PROFINET Mitsubishi OPC Server CCLink OPC Driver Device-Specific OPC Server PLCs OPC Client

  28. NI OPC Servers for Third-Party PLCs • OPC support for more than 100 PLCs • Connects with LabVIEW DSC OPC client • Evaluation version included with DSC • Servers included for: • Allen-Bradley • AutomationDirect • Cutler-Hammer • GE • Hilscher • Modbus • Omron • Philips • Siemens • Toshiba • WAGO • Yaskawa • Yokogawa • …and more! • ni.com/opc

  29. OPC • Advantages • Most universal • Least device-dependent • Ideal for HMI and SCADA applications • Considerations • Slower, not deterministic, single-point only • Can require PC-based OPC servers • Not for safety or critical communications

  30. ABCO Adds LabVIEW to PLC System “The ease by which NI can speak to the Allen-Bradley hardware saved me valuable time on this delivery-critical job.” -Arif Bustani, electrical engineer ABCO • ABS brake testing system • PXI for high-speed encoder measurements • Added to existing Allen-Bradley PLC assembly line • OPC used for communication between PXI and Allen-Bradley PLCs

  31. Summary • PACs add flexibility to connect to anything • Use PACs to add any measurements to existing system • 3 Methods to Connect PAC to Any PLC: • Basic Analogue and Digital I/O • Native Industrial Communications • OPC

  32. Online Resources ni.com/comm ni.com/pac ni.com/labs www.modbus.org – Modbus TCP/IP www.odva.org – Ethernet/IP www.ethercat.org – EtherCAT www.profibus.com/pn - PROFINET

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