Development of a Universal EtherCAT-Based Fieldbus Module

Suomalaisessa yrityksessä SKS Control Oy:ssa aloitettiin tuotekehitysprojekti jonka tarkoitus oli uusia eräs vanha tuoteportfolio. Portfolio sisältää tuotteita jotka käytetään sähköiseen liikkeenohjauksen yhteydessä ja portfoliossa löytyy esimerkiksi erilaisia CPU-moduuleja, näyttöjä, HMI:ta ja I/O laitteita ym. Tämä kirjoitelma keskittyy yhteen uuteen tulevaan moduuliin, joka on EtherCAT pohjanen kenttäväylämoduuli. Tämän uuden tuotteen tarkoitus on korvata muutama vanha tuote ja samalla tuoda uusia ominaisuuksia jotka olisi ollut vaikeita tai mahdottomia toteuttaa vanhoilla tuotteilla. Sitä osaa tuotekehitysprojektia joka esitetään tässä työssä sisältää kolmea eri osaa. Ensimmäinen osa käsittelee olennaisimmat alueet tuotteen teoreettisesta taustasta ja samalla esittelee tuotteen halutut spesifikaatiot ja ominaisuudet. Tämän yhteydessä esitetään myös erilaiset keinot toteuttaa nämä halutut ominaisuudet. Työn toinen osa käsittelee tuotteen rautapuolen suunnittelua jakamalla kaikki toiminnalliset osat pienempiin osakokonaisuuksiin ja käsittelemällä niitä erikseen. Tässä osassa keskitytään enemmän elektroniikan suunnitteluun kun mekaaniseen. Lopuksi työ käsittelee tuotteeseen liittyvää ohjelmointiosuutta joka pääosin käsittelee rautapuolen ohjelmointia VHDL kielellä ja pienemmissä määrissä muita tuotteeseen liittyviä ohjelmointikieliä kuten C.A product development project was set up at the Finnish company SKS Control Oy in order to renew an older product portfolio consisting of a number of different devices used in electrically implemented motion control systems. These products include, for example, a range of programmable CPU units, display devices, HMIs, and I/O devices. This work focuses on the process of developing one of the new products, which is an EtherCAT-based fieldbus module. The purpose of this product is to replace a number of older products by integrating their functionality into one extensive modular-structured device. Along with this, the new module is intended to provide various new features that were hard or impossible to implement with the older products. The part of the product development work which is presented here consists of three main parts. The first one presents some of the most relevant theoretical background behind the field-bus module along with a list of wanted features and properties. Together with the theory, this part discusses a way of satisfying these design constraints while using a module structure similar to the other products in the portfolio. Second, the work covers the hardware design of the module by dividing it into smaller functional blocks and discussing them separately. Here the focus lies on the electronic design rather than the mechanical. Finally, the work includes a section about the software work included in the product development. This part mainly focuses on the hardware description language VHDL and, to a smaller extent, on additional software, such as C, used in the product or together with it

Towards an In-depth Understanding of Deep Packet Inspection Using a Suite of Industrial Control Systems Protocol Packets

Industrial control systems (ICS) are increasingly at risk and vulnerable to internal and external threats. These systems are integral part of our nation’s critical infrastructures. Consequently, a successful cyberattack on one of these could present disastrous consequences to human life and property as well. It is imperative that cybersecurity professionals gain a good understanding of these systems particularly in the area of communication protocols. Traditional Transmission Control Protocol (TCP) and User Datagram Protocol (UDP) are made to encapsulate some of these ICS protocols which may enable malicious payload to get through the network firewall and thus, gain entry into the network. This paper describes technical details on various ICS protocols and a suite of ICS protocol packets for the purpose of providing digital forensic materials for laboratory exercises toward a better understanding of the inner workings of ICS communications. Further, these artifacts can be useful in devising deep packet inspection (DPI) strategies that can be implemented in network firewalls, in expanding challenge materials for cyber competitions, and in attribution, vulnerability assessment, and penetration testing research in ICS security. We also present software tools that are available for free download on the Internet that could be used to generate simulated ICS and Supervisory Control and Data Acquisition (SCADA) communication packets for research and pedagogical purposes. Finally, we conclude the paper by presenting possible research avenues that can be pursued as extensions to this seminal work on ICS security. Prominent among these possible extensions is the expansion of the ICS packet suite to include those protocols in the wireless domain such as Wi-Fi (802.11), Bluetooth, Zigbee, and other protocols that utilizes proprietary Radio Frequency

Relatório de Estágio na Inficon AG e na PT Inovação & Sistemas

This document focuses the projects developed during two independent internships, which were carried out at Inficon AG and PT Inovação & Sistemas. Since the research areas of both internships are unrelated, individual abstracts are presented

Teollisen Internetin käyttöönotto automaatiolaitteissa

Industrial Internet is a term that is used to describe digitalization of industry. It is a research direction in Finland, where there are already various groups studying it. Despite this, the term Industrial Internet is still relatively vague and there is a lack of concreteness around the topic. The objective of this thesis is to explore the current status of Industrial Internet and study the capabilities of automation devices from an Industrial Internet point of view. I explore Industrial Internet through a literary review where I study various use cases. The use cases of Industrial Internet are divided into two main types: platform centric and machine to machine (M2M) communication centric. The use cases provide a list of characteristics and requirements for Industrial Internet from these two perspectives. General requirements are, for example scalability and flexibility, which are achieved through various IT technologies, such as Service-Oriented-Architecture. This thesis also consists of a practical part where I configured the control logic and data collection for a test bed that simulates drop tests of active magnetic bearings. The control logic consists of a programmable logic controller and corresponding software. The data collection consists of software for collecting and analyzing measurement data and the measuring equipment. After the literary review and practical part, I propose the creation of a cloud based Industrial Internet platform around the active magnetic test bed. The purpose of the platform is to provide a direction for further research. The creation of the platform consists of two phases: first phase includes the creation of the platform so that the test bed achieves current functionality but cloud based. The second phase consists of changing the platform to meet the requirements of the literature review. The end results will be an application independent system solution for Industrial Internet.Teollinen Internet on termi, jolla kuvataan teollisuuden digitalisaatiota. Aihe on kasvavan kiinnostuksen kohde ja esim. Suomessa on useita tahoja, jotka panostavat aiheen tutkimukseen. Siltikin Teollinen Internet on käsitteenä epäselvä ja sitä vaivaa konkretian puute. Tämän työn tarkoituksena on tutustua Teollisen Internetin nykytilaan ja automaatiolaitteiden ominaisuuksiin Teollisen Internetin näkökulmasta. Teollisen Internetin esimerkit jakautuvat pääasiassa kahteen luokkaan: alustalähtöisiin ja koneiden väliseen kommunikaatioon (M2M-kommunikaatio). Esimerkit tarjoavat listan ominaisuuksia ja vaatimuksia Teolliselle Internetille kummastakin näkökulmasta. Yleisiä ominaisuuksia ovat esimerkiksi skaalattavuus ja joustavuus, jotka saavutetaan erilaisilla tietoteknisillä vaatimuksilla, esim. palvelukeskeisellä arkkitehtuurilla. Lisäksi työhön kuuluu käytännön osuus, jossa kirjoitin ohjainlogiikan ja datankeräyksen testilaitteeseen, joka simuloi aktiivimagneettilaakerien pudotuskokeita. Ohjainlogiikka koostui PLC-laitteesta ja siihen liittyvistä ohjelmistoista. Datan keräys koostui mittausdatan keräykseen ja purkamiseen vaadittavista ohjelmistoista sekä laitteistosta. Kirjallisuudesta kerättyjen vaatimusten ja käytännön kokemuksien perusteella esitän pilvipohjaisen, Teolliseen Internetiin suunnatun ohjelmistoalustan kehittämistä testilaitteen ympärille. Ohjelmistoalusta voi toimia yliopistollisen jatkotutkimuksen pohjana. Ohjelmistoalustan toteuttaminen tapahtuu kahdessa vaiheessa: ensimmäisessä vaiheessa kehitetään pilvipohjainen alusta, joka saavuttaa testilaitteiston nykyisen toiminnallisuuden. Toisessa vaiheessa ohjelmistoalusta muutetaan vastaamaan Teollisen Internetin vaatimuksia, jolla saavutetaan sovellusriippumaton järjestelmäratkaisu

Development of functional safety applications for Autec products. Study of protocols: CANopen, CANopen Safety, FSOE and ProfiSafe

This thesis has the principal goal of developing intrinsic safety applications in distributed real-time industrial systems, mainly based on fieldbuses and RTE networks. To achieve this important objective the first part of this elaborate provides an introduction of the principal protocols, such as CANopen Safety, Fail safe Over Ethercat (FSOE) and Profisafe, used for the safety relevant applications in the automation environment,analysing properties,story and the use of them by industry

Intelligent Machining Systems

Machining is one of the most widespread manufacturing processes and plays a critical role in industries. As a matter of fact, machine tools are often called mother machines as they are used to produce other machines and production plants. The continuous development of innovative materials and the increasing competitiveness are two of the challenges that nowadays manufacturing industries have to cope with. The increasing attention to environmental issues and the rising costs of raw materials drive the development of machining systems able to continuously monitor the ongoing process, identify eventual arising problems and adopt appropriate countermeasures to resolve or prevent these issues, leading to an overall optimization of the process. This work presents the development of intelligent machining systems based on in-process monitoring which can be implemented on production machines in order to enhance their performances. Therefore, some cases of monitoring systems developed in different fields, and for different applications, are presented in order to demonstrate the functions which can be enabled by the adoption of these systems. Design and realization of an advanced experimental machining testbed is presented in order to give an example of a machine tool retrofit aimed to enable advanced monitoring and control solutions. Finally, the implementation of a data-driven simulation of the machining process is presented. The modelling and simulation phases are presented and discussed. So, the model is applied to data collected during an experimental campaign in order to tune it. The opportunities enabled by integrating monitoring systems with simulation are presented with preliminary studies on the development of two virtual sensors for the material conformance and cutting parameter estimation during machining processes

Industrial networks and IIoT: Now and future trends

Connectivity is the one word summary for Industry 4.0 revolution. The importance of Internet of Things (IoT) and Industrial IoT (IIoT) have been increased dramatically with the rise of industrialization and industry 4.0. As new opportunities bring their own challenges, with the massive interconnected devices of the IIoT, cyber security of those networks and privacy of their users have become an important aspect. Specifically, intrusion detection for industrial networks (IIoT) has great importance. For instance, it is a key factor in improving the safe operation of the smart grid systems yet protecting the privacy of the consumers at the same time. In the same manner, data streaming is a valid option when the analysis is to be pushed from the cloud to the fog for industrial networks to provide agile response, since it brings the advantage of fast action on intrusion detection and also can buy time for intrusion mitigation. In order to dive deep in industrial networks, basic ground needs to be settled. Hence, this chapter serves in this manner, by presenting basic and emerging technologies along with ideas and discussions: First, an introduction of semiconductor evolution is provided along with the up-to-date hi-tech wired/wireless communication solutions for industrial networks. This is followed by a thorough representation of future trends in industrial environments. More importantly, enabling technologies for industrial networks is also presented. Finally, the chapter is concluded with a summary of the presentations along with future projections of IIoT networks

Design of a New High Bandwidth Network for Agricultural Machines

Ethernet is by now the most adopted bus for fast digital communications in many environments, from household entertainment to PLC robotics in industrial assembly lines. Even in automotive industry, the interest in this technology is increasingly growing, pushed forward by research and by the need of high throughput that high dynamics distributed control demands. Although 100base-TX physical layer (PHY) does not seem to meet EMC requirements for vehicular and heavy-duty environments, OPEN Alliance BroadR Reach (soon becoming IEEE standard as IEEE 802.3bw) technology is the most promising and already adopted Ethernet-compatible PHY, reaching 100Mbps over an unshielded twisted pair. An agricultural machine is usually a system including tractor and one or more implements attached to it, to the back or to the front. Nowadays, a specific CAN-based distributed control network support treatments and applications, namely ISOBUS, defined by ISO 11783. This work deals with architectural and technological aspects of advanced Ethernet networks in order to provide a high-throughput deterministic network for in-vehicle distributed control for agricultural machinery. Two main paths of investigation will be presented: one concerning the prioritization of standard Ethernet taking advantage of standard ways of prioritization in well-established technologies; the other changing the channel access method of Ethernet using an industrial fieldbus, chosen after careful investigation. The prioritization of standard Ethernet is performed at two, non-mutual exclusive layers of the ISO OSI stack: one at L3, using the diffserv (former TOS) Ip field; one at L2, using the priorities defined in IEEE 802.1p, used in IEEE 802.1q (VLAN). These choices have several implications in the specific field of application of the agricultural machines. The change of the access method, instead, focused on the adoption of a specific fieldbus, in order to grant deterministic access to the medium and reliability of communications for safety-relevant applications. After a survey, that will be reported, the Powerlink fieldbus was chosen and some modifications will be discussed in order to suit the scope of the research