Evaluating XMPP Communication in IEC 61499-based Distributed Energy Applications

The IEC 61499 reference model provides an international standard developed specifically for supporting the creation of distributed event-based automation systems. Functionality is abstracted into function blocks which can be coded graphically as well as via a text-based method. As one of the design goals was the ability to support distributed control applications, communication plays a central role in the IEC 61499 specification. In order to enable the deployment of functionality to distributed platforms, these platforms need to exchange data in a variety of protocols. IEC 61499 realizes the support of these protocols via "Service Interface Function Blocks" (SIFBs). In the context of smart grids and energy applications, IEC 61499 could play an important role, as these applications require coordinating several distributed control logics. Yet, the support of grid-related protocols is a pre-condition for a wide-spread utilization of IEC 61499. The eXtensible Messaging and Presence Protocol (XMPP) on the other hand is a well-established protocol for messaging, which has recently been adopted for smart grid communication. Thus, SIFBs for XMPP facilitate distributed control applications, which use XMPP for exchanging all control relevant data, being realized with the help of IEC 61499. This paper introduces the idea of integrating XMPP into SIFBs, demonstrates the prototypical implementation in an open source IEC 61499 platform and provides an evaluation of the feasibility of the result.Comment: 2016 IEEE 21st International Conference on Emerging Technologies and Factory Automation (ETFA

A Diagnostics Model for Industrial Communications Networks

Over the past twenty years industrial communications networks have become common place in most industrial plants. The high availability of these networks is crucial in smooth plant operations. Therefore local and remote diagnostics of these networks is of primary importance in solving any existing or emerging network problems. Users for most part consider the “plant networks” as black boxes, and often not sure of the actual health of the networks. The major part of the work outlined in this research concentrates on the proposed “Network Diagnostics Model” for local and remote monitoring. The main objective of the research is to aid the establishment of tools and techniques for diagnosis of the industrial networks, with particular emphasis on PROFIBUS and PROFINET. Additionally this research has resulted in development of a number of devices to aid in network diagnostics. The work outlined in this submission contributes to the developments in the area of online diagnostics systems. The development work was conducted in the following phases: 1. Development of Function Block (FB) for diagnosing PROFIBUS network for implementation on PLC. 2. Development of OPC server for diagnosing PROFIBUS network for implementation on PC. 3. Development of a web based diagnostic software for multiple fieldbuses for implementation on imbedded XP platform. 4. Development of OPC server for diagnosing PROFINET network for implementation on PC 5. Conformance testing of masters (PLC) in PROFIBUS network to increase the health of the network. 6. Use of diagnostics tools for performance analysis of fieldbuses networks for high performance applications. The research work outlined in this submission has made a significant and coherent contribution to online diagnostics of fieldbus communications networks, and has paved the way for the introduction of the online diagnostics devices to the market place. It has shown that the proposed model provides a uniform framework for research and development of diagnostics tools and techniques for fieldbus networks. Organizations that use fieldbus should consider installing advanced online diagnostic systems to boost maintenance efficiency and reduce operating costs, and maintain the availability of plant resources. Based on the experience gained over a number of years a multilayer model is proposed for future development of diagnostics tools

Web service control of component-based agile manufacturing systems

Current global business competition has resulted in significant challenges for manufacturing and production sectors focused on shorter product lifecyc1es, more diverse and customized products as well as cost pressures from competitors and customers. To remain competitive, manufacturers, particularly in automotive industry, require the next generation of manufacturing paradigms supporting flexible and reconfigurable production systems that allow quick system changeovers for various types of products. In addition, closer integration of shop floor and business systems is required as indicated by the research efforts in investigating "Agile and Collaborative Manufacturing Systems" in supporting the production unit throughout the manufacturing lifecycles. The integration of a business enterprise with its shop-floor and lifecycle supply partners is currently only achieved through complex proprietary solutions due to differences in technology, particularly between automation and business systems. The situation is further complicated by the diverse types of automation control devices employed. Recently, the emerging technology of Service Oriented Architecture's (SOA's) and Web Services (WS) has been demonstrated and proved successful in linking business applications. The adoption of this Web Services approach at the automation level, that would enable a seamless integration of business enterprise and a shop-floor system, is an active research topic within the automotive domain. If successful, reconfigurable automation systems formed by a network of collaborative autonomous and open control platform in distributed, loosely coupled manufacturing environment can be realized through a unifying platform of WS interfaces for devices communication. The adoption of SOA- Web Services on embedded automation devices can be achieved employing Device Profile for Web Services (DPWS) protocols which encapsulate device control functionality as provided services (e.g. device I/O operation, device state notification, device discovery) and business application interfaces into physical control components of machining automation. This novel approach supports the possibility of integrating pervasive enterprise applications through unifying Web Services interfaces and neutral Simple Object Access Protocol (SOAP) message communication between control systems and business applications over standard Ethernet-Local Area Networks (LAN's). In addition, the re-configurability of the automation system is enhanced via the utilisation of Web Services throughout an automated control, build, installation, test, maintenance and reuse system lifecycle via device self-discovery provided by the DPWS protocol...cont'd

Layer 2 Ethernet Communication Tunneling Possibilities in Automation Systems

Future trends in energy generation are renewable energy sources and distributed energy generation. In control systems, these changes require higher automatization, more intelligent devices and secure and reliable communication. Another requirement is faster communication. Building a system that is able to fulfill real-time communication requirements over network layer is a hindrance to automation systems. There are multiple protocols that can manage the requirements, but many of them have limitations and requirements of their own. The limitations can be related to packet sizes, used devices or they may require a license. Tunneling protocols can bring a more general solution for the real-time problem. Tunneling Ethernet communication over network layer and letting the tunneling protocol to handle the network layer packaging instead of the communication protocol removes the need of a layer 3 protocol. Layer 2 tunneling provides a direct connection between separate local area networks. It enables a way for devices to communicate with each other over network layer using layer 2 communication protocols. Tunnel uses a pre-configured route to the destination gateway device making the routing of messages simpler and faster than with traditional IP routing. Layer 2 tunneling can be used in any communication system that utilizes layer 2 and layer 3 communication. This thesis focuses on use of tunneling in automation systems. The purpose of this thesis is to provide information and possible solutions for layer 2 Ethernet tunneling. The main focus is in suitable tunneling protocols and communication protocols, but also security and resilience solutions are studied. This thesis is composed of published studies, researches, articles and books that address the topic

Introduction to industrial control networks

An industrial control network is a system of interconnected equipment used to monitor and control physical equipment in industrial environments. These networks differ quite significantly from traditional enterprise networks due to the specific requirements of their operation. Despite the functional differences between industrial and enterprise networks, a growing integration between the two has been observed. The technology in use in industrial networks is also beginning to display a greater reliance on Ethernet and web standards, especially at higher levels of the network architecture. This has resulted in a situation where engineers involved in the design and maintenance of control networks must be familiar with both traditional enterprise concerns, such as network security, as well as traditional industrial concerns such as determinism and response time. This paper highlights some of the differences between enterprise and industrial networks, presents a brief history of industrial networking, gives a high level explanation of some operations specific to industrial networks, provides an overview of the popular protocols in use and describes current research topics. The purpose of this paper is to serve as an introduction to industrial control networks, aimed specifically at those who have had minimal exposure to the field, but have some familiarity with conventional computer networks.http://ieeexplore.ieee.org/xpl/RecentIssue.jsp?punumber=9739hb2016Electrical, Electronic and Computer Engineerin

Modelos y plataforma IEC 61499 adaptados al control distribuido de máquinas herramienta en sistemas de fabricación ágil

Los sistemas de fabricación han ido evolucionando para adaptarse a las cada vez más cambiantes demandas del mercado, pasando de los sistemas de fabricación en masa a los sistemas flexibles y, finalmente, a los sistemas ágiles. Estos últimos están soportados por sistemas reconfigurables, capaces de ser modificados sin parar su funcionamiento, así como por tecnologías de la información y la comunicación, por lo que pueden adaptarse muy rápidamente a cambios en la producción. Para denominar estos nuevos sistemas han surgido también términos como e-manufacturing, cloud-manufacturing, industrie 4.0. El estándar actual de referencia para el desarrollo de software de control en los sistemas de fabricación es IEC 61131, del que algunos trabajos han indicado su poca adecuación frente a los requisitos de los nuevos sistemas. Por este motivo ha surgido el más complejo IEC 61499, que define arquitecturas y modelos para un software de control distribuido y reconfigurable. La industria demanda a este estándar la capacidad para desarrollar software de control: predecible, escalable, mantenible y extensible. A este respecto, aunque ha sido objeto de múltiples trabajos por parte de la comunidad académica, a día de hoy IEC 61499 no ha adquirido esa capacidad, por lo que no es aceptado todavía por la industria. El objeto de la presente tesis es aportar propuestas que contribuyan a que el estándar alcance dicha capacidad. Con este fin, se propone el uso de metodologías y modelos de componentes software adaptados al dominio de aplicación, en particular, al control de máquinas herramienta en sistemas de fabricación ágil. Este dominio ha sido elegido por su complejidad, frente a los sencillos tipos de aplicación y casos de uso considerados en anteriores propuestas relacionadas con IEC 61499. Para establecer dichas metodologías y modelos adaptados se estudia en primer lugar el dominio indicado, determinando los principios de diseño de su software de control. Estos principios sirven de base para efectuar una revisión del estado actual del estándar. Seguidamente, se propone y modela el control distribuido de una máquina herramienta genérica, a partir del cual se establecen los modelos de bloque función y de ejecución IEC 61499 adaptados a ese dominio. Dichos modelos facilitan el establecimiento de una metodología de diseño, a la vez que permiten una implementación del estándar determinista, eficiente, escalable y que cumple restricciones de tiempo real. A la hora de verificar experimentalmente la metodología y los modelos adaptados es necesaria una plataforma de ejecución. Debido a que las plataformas IEC 61499 existentes no soportan dichos modelos se ha especificado, diseñado e implementado la plataforma COSME. A diferencia de anteriores plataformas, ésta incorpora características que hacen posible su empleo en entornos industriales. En este sentido, la plataforma COSME ha sido desarrollada dentro de un proyecto de investigación, transferencia y colaboración tecnológica entre la universidad y un grupo industrial fabricante de máquinas herramienta. Dicho proyecto ha permitido que esta plataforma, la metodología y los modelos adaptados hayan sido validados en casos de uso reales

A system development methodology for embedded applications

In recent years, Singapore’s manufacturing sector has contributed more than a quarter of the total Gross Domestic Product (GDP) and has established global leadership positions in several manufacturing areas such as electronics, Information Technology (IT) and industrial automation. The Singapore Economic Review Committee (ERC) recommendation states that “software and embedded systems that drive products are one of the most important technologies for the manufacturing sector. “ With the increasing adoption of automated and intelligent products, embedded systems have emerged as a crucial technology for Singapore. However, the development of embedded applications is not a trivial undertaking as it can usually involve multi-discipline parties and different application platforms. Most embedded application developments use either vendor specific or desktop based methodologies. Vendor specific methodologies constrain the company to rely on the specific vendor's solutions, whereas desktop-based methodologies are not well suited to embedded application development. Therefore, this research aims to develop a standard-based system development methodology for embedded applications. The research programme comprises 5 stages. The first stage reviews the existing system development methodologies for embedded applications. The next stage formulates the proposed conceptual methodology followed by the development of the proof-of-concept tool to demonstrate the merits of the proposed approach. The methodology is then tested and evaluated respectively by using industrial experiments and feedback from a workshop. The final stage refines the methodology based on the feedback and presents the final system development methodology. The research has provided a sound foundation which future research in methodology for embedded applications to develop further.Eng

Modellgestützter Entwurf von Feldgeräteapplikationen

Die Entwicklung von Feldgeräten ist ein äußerst komplexer Vorgang, welcher auf vielen Vorrausetzungen aufsetzt, diverse Anforderungen und Randbedingungen mitbringt und bisher wenig beachtet und veröffentlicht wurde. Angesichts der fortschreitenden Digitalisierung drängen immer mehr Anbieter auf den Automatisierungsmarkt. So sind aktuell zunehmend Technologien und Ansätze aus dem Umfeld des Internet of Things im Automatisierungsbereich zu finden. Diese Ansätze reichen von Sensoren ohne die in der Industrie üblichen Beschreibungen bis hin zu Marktplätzen, auf denen Integratoren und Anwender Softwareteile für Anlagen kaufen können. Für die neuen Anbieter, die häufig nicht aus dem klassischen Automatisierungsgeschäft kommen, sind die bisher bestehenden Modelle, Funktionalitäten, Profile und Beschreibungsmittel nicht immer leicht zu verwenden. So entstehen disruptive Lösungen auf Basis neu definierter Spezifikationen und Modelle. Trotz dieser Disruptivität sollte es das Ziel sein, die bewährten Automatisierungsfunktionen nicht neu zu erfinden, sondern diese effektiv und effizient in Abhängigkeit der Anforderungen auf unterschiedlichen Plattformen zu verwenden. Dies schließt ihre flexible Verteilung auf heterogene vernetzte Ressourcen explizit ein. Dabei können die Plattformen sowohl klassische Feldgeräte und Steuerungen sein, als auch normale Desktop-PCs und IoT-Knoten. Ziel dieser Arbeit ist es, eine Werkzeugkette für den modellbasierten Entwurf von Feldgeräteapplikationen auf Basis von Profilen und damit für den erweiterten Entwurf von verteilten Anlagenapplikationen zu entwickeln. Dabei müssen die verschiedenen Beschreibungsmöglichkeiten evaluiert werden, um diese mit detaillierten Parameter- und Prozessdatenbeschreibungen zu erweitern. Außerdem sollen modulare Konzepte genutzt und Vorbereitungen für die Verwendung von Semantik im Entwurfsprozess getroffen werden. In Bezug auf den Geräteengineeringprozess soll der Anteil des automatisierten Geräteengineerings erweitert werden. Dies soll zu einer Flexibilisierung der Geräteentwicklung führen, in der die Verschaltung der funktionalen Elemente beim Endkunden erfolgt. Auch das Deployment von eigenen funktionalen Elementen auf die Geräte der Hersteller soll durch den Endkunden möglich werden. Dabei wird auch eine automatisierte Erstellung von Gerätebeschreibungen benötigt. Alle diese Erweiterungen ermöglichen dann den letzten großen Schritt zu einer verteilten Applikation über heterogene Infrastrukturen. Dabei sind die funktionalen Elemente nicht nur durch die Gerätehersteller verteilbar, sondern diese können auch auf verschiedenen Plattformen unterschiedlicher Gerätehersteller verwendet werden. Damit einher geht die für aktuelle Entwicklungen wie Industrie 4.0 benötigte geräteunabhängige Definition von Funktionalität. Alle im Engineering entstandenen Informationen können dabei auf den unterschiedlichen Ebenen der Automatisierungspyramide und während des Lebenszyklus weiterverwendet werden. Eine Integration diverser Gerätefamilien außerhalb der Automatisierungstechnik wie z. B. IoT-Geräte und IT-Geräte ist damit vorstellbar. Nach einer Analyse der relevanten Techniken, Technologien, Konzepte, Methoden und Spezifikationen wurde eine Werkzeugkette für den modellgestützten Entwurf von Feldgeräten entwickelt und die benötigten Werkzeugteile und Erweiterungen an bestehenden Beschreibungen diskutiert. Dies Konzept wurde dann auf den verteilten Entwurf auf heterogener Hardware und heterogenen Plattformen erweitert, bevor beide Konzepte prototypisch umgesetzt und evaluiert wurden. Die Evaluation erfolgt an einem zweigeteilten Szenario aus der Sicht eines Geräteherstellers und eines Integrators. Die entwickelte Lösung integriert Ansätze aus dem Kontext von Industrie 4.0 und IoT. Sie trägt zu einer vereinfachten und effizienteren Automatisierung des Engineerings bei. Dabei können Profile als Baukasten für die Funktionalität der Feldgeräte und Anlagenapplikationen verwendet werden. Bestehende Beschränkungen im Engineering werden somit abgeschwächt, so dass eine Verteilung der Funktionalität auf heterogene Hardware und heterogene Plattformen möglich wird und damit zur Flexibilisierung der Automatisierungssysteme beiträgt.The development of field devices is a very complex procedure. Many preconditions need to be met. Various requirements and constrains need to be addressed. Beside this, there are only a few publications on this topic. Due to the ongoing digitalization, more and more solution providers are entering the market of the industrial automation. Technologies and approaches from the context of the Internet of Things are being used more and more in the automation domain. These approaches range from sensors without the typical descriptions from industry up to marketplaces where integrators and users can buy software components for plants. For new suppliers, who often do not come from the classical automation business, the already existing models, functionalities, profiles, and descriptions are not always easy to use. This results in disruptive solutions based on newly defined specifications and models. Despite this disruptiveness, the aim should be to prevent reinventing the proven automation functions, and to use them effectively, and efficiently on different platforms depending on the requirements. This explicitly includes the flexible distribution of the automation functions to heterogeneous networked resources. The platforms can be classical field devices and controllers, as well as normal desktop PCs and IoT nodes. The aim of this thesis is to develop a toolchain for the model-based design of field device applications based on profiles, and thus also suitable for the extended design of distributed plant applications. Therefore, different description methods are evaluated in order to enrich them with detailed descriptions of parameters and process data. Furthermore, c oncepts of modularity will also be used and preparations will be made for the use of semantics in the design process. With regard to the device engineering process, the share of automated device engineering will be increased. This leads to a flexibilisation of the device development, allowing the customer to perform the networking of the functional elements by himself. The customer should also be able to deploy his own functional elements to the manufacturers' devices. This requires an automated creation of device descriptions. Finally, all these extensions will enable a major step towards using a distributed application over heterogeneous infrastructures. Thus, the functional elements can not only be distributed by equipment manufacturers, but also be distributed on different platforms of different equipment manufacturers. This is accompanied by the device-independent definition of functionality required for current developments such as Industry 4.0. All information created during engineering can be used at different levels of the automation pyramid and throughout the life cycle. An integration of various device families from outside of Automation Technology, such as IoT devices and IT devices, is thus conceivable. After an analysis of the relevant techniques, technologies, concepts, methods, and specifications a toolchain for the model-based design of field devices was developed and the required tool parts, and extensions to existing descriptions were discussed. This concept was then extended to the distributed design on heterogeneous hardware and heterogeneous platforms. Finally, both concepts were prototypically implemented and evaluated. The evaluation is based on a two-part scenario from both the perspective of a device manufacturer, and the one of an integrator. The developed solution integrates approaches from the context of Industry 4.0 and IoT. It contributes to a simplified, and more efficient automation of engineering. Within this context, profiles can be used as building blocks for the functionality of field devices, and plant applications. Existing limitations in engineering are thus reduced, so that a distribution of functionality across heterogeneous hardware and heterogeneous platforms becomes possible and contributing to the flexibility of automation systems

A system development methodology for embedded applications

In recent years, Singapore’s manufacturing sector has contributed more than a quarter of the total Gross Domestic Product (GDP) and has established global leadership positions in several manufacturing areas such as electronics, Information Technology (IT) and industrial automation. The Singapore Economic Review Committee (ERC) recommendation states that “software and embedded systems that drive products are one of the most important technologies for the manufacturing sector. “ With the increasing adoption of automated and intelligent products, embedded systems have emerged as a crucial technology for Singapore. However, the development of embedded applications is not a trivial undertaking as it can usually involve multi-discipline parties and different application platforms. Most embedded application developments use either vendor specific or desktop based methodologies. Vendor specific methodologies constrain the company to rely on the specific vendor's solutions, whereas desktop-based methodologies are not well suited to embedded application development. Therefore, this research aims to develop a standard-based system development methodology for embedded applications. The research programme comprises 5 stages. The first stage reviews the existing system development methodologies for embedded applications. The next stage formulates the proposed conceptual methodology followed by the development of the proof-of-concept tool to demonstrate the merits of the proposed approach. The methodology is then tested and evaluated respectively by using industrial experiments and feedback from a workshop. The final stage refines the methodology based on the feedback and presents the final system development methodology. The research has provided a sound foundation which future research in methodology for embedded applications to develop further.Eng

Fieldbus technology in industrial automation

http://ieeexplore.ieee.org/Fieldbus technology in industrial automation is not only relatively complex because of the number of solutions possible, but also, and above all, because of the variety of applications. Ironically, these in turn are responsible for the multitude of solutions available. If the analysis of the basic needs is relatively standard, as they will always involve connecting sensors, actuators, and field controllers with each other, the options in architecture are numerous and can impose the need for certain services. The required performances themselves and the quality of service expected fundamentally depend on the applications. This article traces this technology from its beginnings, which go back to the first industrial networks in the 1970's. The principal stages of development are recounted, from the initial requirement specifications to the current state of international standardization. The diverse technical solutions are then analyzed and classified. In particular, we study the temporal aspects, the medium access control protocols and application relationships