Supervisory Control and Data Acquisition
One Controller - Any Bus
Connecting Programmable Automation
Controllers ,Measurements, Sensors, Networks
and PLCs
Ian Bell - National Instruments
Ir. Jos Pramudijanto, M.Eng.
Jurusan Teknik Elektro FTI ITS
Telp. 5947302 Fax.5931237
Email: [email protected]
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Objektif:
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
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Industrial Communications
Overview
Industrial communications connect
industrial devices such as PLCs,
sensors and actuators
Common Industrial
Networks
•DeviceNet
•PROFIBUS
•Modbus TCP
•Modbus Serial
•CANopen
•FOUNDATION fieldbus
•Interbus
•CC-Link
•LonWorks
•HART
•PROFINET
•Ethernet/IP
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PAC Architecture
Software Capabilities
Ruggedness and reliability of PLC
Software capabilities of PC
Modular and diverse I/O
PAC
PC
PLC
Ruggedness and Reliability
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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
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3 Methods to Connect to Any PLC
Basic I/O
Analogue/Digital
Industrial
Communications
OPC
PACs
PLCs
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Basic I/O
Cheap, 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
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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
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Example
Automated 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 highspeed pressure measurements on 8
channels (2 k per channel)
CompactRIO and PLC were integrated
using digital I/O
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3 Methods to Connect to Any PLC
Basic I/O
Analogue/Digital
Industrial
Communications
OPC
PACs
PLCs
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Methods for Industrial
Communications
Plug-In
Interface
s
Ethernet/Serial
Performance/Determinism
Versatility
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Gateways
over
Ethernet,
Serial
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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
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Plug-In
Interfaces
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Plug-In Communication Boards
Plug-In
Interfaces
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)
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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
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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
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Ethernet-based Industrial Protocols
Modbus TCP/IP
Ethernet/IP
EtherCAT
Profinet
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Why Ethernet: Protocols
Modbus
Modbus TCP/IP
DeviceNet
EtherNet/IP
CanOPEN
EtherCAT
PROFIBUS
PROFInet
Traditional Industrial
Protocols
Ethernet Physical
Layer
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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
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Ethernet-based Industrial Protocols
Modbus TCP/IP
Ethernet/IP
EtherCAT
Profinet
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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
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Ethernet/IP Terminology
Explicit Messages
• TCP/IP
• Used to set parameters and initiate
implicit communication
Implicit Messages
• UDP/IP multicast
• Used to communicate I/O data
• Normally set-up for cyclical updates
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Communication from NI PAC to
ControlLogix and ComapctLogix PLCs
Ethernet/IP
Uses explicit messaging
Available for download from NI Labs
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Third-Party Gateways
Wide variety of communication buses and
protocols supported
Gateways
over
Ethernet or serial-based
Ethernet,
Perfect for non-PXI, PCI, and PCMCIA Serial
systems
PROFIBUS
DeviceNet
EthernetIP
ControlNet
Ethernet
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Example
Adding 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
Modbus TCP
EthernetIP
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3 Methods to Connect LabVIEW to
Any PLC
Basic I/O
Analogue/Digital
Industrial
Communications
OPC
NI PACs
PLCs
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What Is OPC?
Universal language
for reading and
writing data
OPC Client: Read
and write to OPC
OPC Server:
Translates between
OPC and devicespecific protocols
Windows PC
English
English
Speaker:
Speaker:
“Hello!”
“Hello!”
English
Spanish
Translator
Spanish
Speaker
German
Translator
German
Speaker
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French
Translator
French
Speaker
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OPC Client
Windows PC
Allen-Bradley
OPC Server
Ethernet/IP
PLCs
PROFINET
Siemens
OPC Server
CCLink
Mitsubishi
OPC Server
OPC
Driver
Device-Specific
OPC Server
OPC
Client
OPC Client
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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
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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
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ABCO Adds LabVIEW to PLC
System
“The ease by which NI can speak to
ABS brake testing system the Allen-Bradley hardware saved
me valuable time on this deliveryPXI for high-speed encodercritical job.”
-Arif Bustani, electrical engineer
measurements
ABCO
Added to existing Allen-Bradley
PLC assembly line
OPC used for communication
between PXI and Allen-Bradley
PLCs
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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
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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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