Wireless industrial monitoring and control networks: the journey so far and the road ahead

While traditional wired communication technologies have played a crucial role in industrial monitoring and control networks over the past few decades, they are increasingly proving to be inadequate to meet the highly dynamic and stringent demands of today’s industrial applications, primarily due to the very rigid nature of wired infrastructures. Wireless technology, however, through its increased pervasiveness, has the potential to revolutionize the industry, not only by mitigating the problems faced by wired solutions, but also by introducing a completely new class of applications. While present day wireless technologies made some preliminary inroads in the monitoring domain, they still have severe limitations especially when real-time, reliable distributed control operations are concerned. This article provides the reader with an overview of existing wireless technologies commonly used in the monitoring and control industry. It highlights the pros and cons of each technology and assesses the degree to which each technology is able to meet the stringent demands of industrial monitoring and control networks. Additionally, it summarizes mechanisms proposed by academia, especially serving critical applications by addressing the real-time and reliability requirements of industrial process automation. The article also describes certain key research problems from the physical layer communication for sensor networks and the wireless networking perspective that have yet to be addressed to allow the successful use of wireless technologies in industrial monitoring and control networks

Real-Time Wireless Sensor-Actuator Networks for Cyber-Physical Systems

A cyber-physical system (CPS) employs tight integration of, and coordination between computational, networking, and physical elements. Wireless sensor-actuator networks provide a new communication technology for a broad range of CPS applications such as process control, smart manufacturing, and data center management. Sensing and control in these systems need to meet stringent real-time performance requirements on communication latency in challenging environments. There have been limited results on real-time scheduling theory for wireless sensor-actuator networks. Real-time transmission scheduling and analysis for wireless sensor-actuator networks requires new methodologies to deal with unique characteristics of wireless communication. Furthermore, the performance of a wireless control involves intricate interactions between real-time communication and control. This thesis research tackles these challenges and make a series of contributions to the theory and system for wireless CPS. (1) We establish a new real-time scheduling theory for wireless sensor-actuator networks. (2) We develop a scheduling-control co-design approach for holistic optimization of control performance in a wireless control system. (3) We design and implement a wireless sensor-actuator network for CPS in data center power management. (4) We expand our research to develop scheduling algorithms and analyses for real-time parallel computing to support computation-intensive CPS

End-to-End Delay Analysis for Fixed Priority Scheduling in WirelessHART Networks

The WirelessHART standard has been specifically designed for real-time communication between sensor and actuator devices for industrial process monitoring and control. End-to-end communication delay analysis for WirelessHART networks is required for acceptance test of real-time data flows from sensors to actuators and for workload adjustment in response to network dynamics. In this paper, we map the scheduling of real-time periodic data flows in a WirelessHART network to real-time multiprocessor scheduling. We, then, exploit the response time analysis for multiprocessor scheduling and propose a novel method for the end-to-end delay analysis of the real-time flows that are scheduled using a fixed priority scheduling policy in a WirelessHART network. Simulations based on both random topologies and real network topologies of a physical testbed demonstrate the efficacy of our end-to-end delay analysis in terms of acceptance ratio under various fixed priority scheduling policies

Optimisation- based time slot assignment and synchronisation for TDMA MAC in industrial wireless sensor network

Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/166209/1/cmu2bf02232.pd

End-to-End Communication Delay Analysis in WirelessHART Networks

WirelessHART is a new standard specifically designed for real-time and reliable communication between sensor and actuator devices for industrial process monitoring and control applications. End-to-end communication delay analysis for WirelessHART networks is required to determine the schedulability of real-time data flows from sensors to actuators for the purpose of acceptance test or workload adjustment in response to network dynamics. In this paper, we map the scheduling of real-time periodic data flows in a WirelessHART network to real-time multiprocessor scheduling. We then exploit the response time analysis for multiprocessor scheduling and propose a novel method for the delay analysis that establishes an upper bound of the end-to-end communication delay of each real-time flow in a WirelessHART network. Simulation studies based on both random topologies and real network topologies of a 74-node physical wireless sensor network testbed demonstrate that our analysis provides safe and reasonably tight upper bounds of the end-to-end delays of real-time flows, and hence enables effective schedulability tests for WirelessHART networks

High Performance Wireless Sensor-Actuator Networks for Industrial Internet of Things

Wireless Sensor-Actuator Networks (WSANs) enable cost-effective communication for Industrial Internet of Things (IIoT). To achieve predictability and reliability demanded by industrial applications, industrial wireless standards (e.g., WirelessHART) incorporate a set of unique features such as a centralized management architecture, Time Slotted Channel Hopping (TSCH), and conservative channel selection. However, those features also incur significant degradation in performance, efficiency, and agility. To overcome these key limitations of existing industrial wireless technologies, this thesis work develops and empirically evaluates a suite of novel network protocols and algorithms. The primary contributions of this thesis are four-fold. (1) We first build an experimental testbed realizing key features of the WirelessHART protocol stack, and perform a series of empirical studies to uncover the limitations and potential improvements of existing network features. (2) We then investigate the impacts of the industrial WSAN protocol’s channel selection mechanism on routing and real-time performance, and present new channel and link selection strategies that improve route diversity and real-time performance. (3) To further enhance performance, we propose and design conservative channel reuse, a novel approach to support concurrent transmissions in a same wireless channel while maintaining a high degree of reliability. (4) Lastly, to address the limitation of the centralized architecture in handling network dynamics, we develop REACT, a Reliable, Efficient, and Adaptive Control Plane for centralized network management. REACT is designed to reduce the latency and energy cost of network reconfiguration by incorporating a reconfiguration planner to reduce a rescheduling cost, and an update engine providing efficient and reliable mechanisms to support schedule reconfiguration. All the network protocols and algorithms developed in this thesis have been empirically evaluated on the wireless testbed. This thesis represents a step toward next-generation IIoT for industrial automation that demands high-performance and agile wireless communication

Real-Time Sensor Networks and Systems for the Industrial IoT

The Industrial Internet of Things (Industrial IoT—IIoT) has emerged as the core construct behind the various cyber-physical systems constituting a principal dimension of the fourth Industrial Revolution. While initially born as the concept behind specific industrial applications of generic IoT technologies, for the optimization of operational efficiency in automation and control, it quickly enabled the achievement of the total convergence of Operational (OT) and Information Technologies (IT). The IIoT has now surpassed the traditional borders of automation and control functions in the process and manufacturing industry, shifting towards a wider domain of functions and industries, embraced under the dominant global initiatives and architectural frameworks of Industry 4.0 (or Industrie 4.0) in Germany, Industrial Internet in the US, Society 5.0 in Japan, and Made-in-China 2025 in China. As real-time embedded systems are quickly achieving ubiquity in everyday life and in industrial environments, and many processes already depend on real-time cyber-physical systems and embedded sensors, the integration of IoT with cognitive computing and real-time data exchange is essential for real-time analytics and realization of digital twins in smart environments and services under the various frameworks’ provisions. In this context, real-time sensor networks and systems for the Industrial IoT encompass multiple technologies and raise significant design, optimization, integration and exploitation challenges. The ten articles in this Special Issue describe advances in real-time sensor networks and systems that are significant enablers of the Industrial IoT paradigm. In the relevant landscape, the domain of wireless networking technologies is centrally positioned, as expected

Real-Time and Energy-Efficient Routing for Industrial Wireless Sensor-Actuator Networks

With the emergence of industrial standards such as WirelessHART, process industries are adopting Wireless Sensor-Actuator Networks (WSANs) that enable sensors and actuators to communicate through low-power wireless mesh networks. Industrial monitoring and control applications require real-time communication among sensors, controllers and actuators within end-to-end deadlines. Deadline misses may lead to production inefficiency, equipment destruction to irreparable financial and environmental impacts. Moreover, due to the large geographic area and harsh conditions of many industrial plants, it is labor-intensive or dan- gerous to change batteries of field devices. It is therefore important to achieve long network lifetime with battery-powered devices. This dissertation tackles these challenges and make a series of contributions. (1) We present a new end-to-end delay analysis for feedback control loops whose transmissions are scheduled based on the Earliest Deadline First policy. (2) We propose a new real-time routing algorithm that increases the real-time capacity of WSANs by exploiting the insights of the delay analysis. (3) We develop an energy-efficient routing algorithm to improve the network lifetime while maintaining path diversity for reliable communication. (4) Finally, we design a distributed game-theoretic algorithm to allocate sensing applications with near-optimal quality of sensing