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

A critical analysis of research potential, challenges and future directives in industrial wireless sensor networks

In recent years, Industrial Wireless Sensor Networks (IWSNs) have emerged as an important research theme with applications spanning a wide range of industries including automation, monitoring, process control, feedback systems and automotive. Wide scope of IWSNs applications ranging from small production units, large oil and gas industries to nuclear fission control, enables a fast-paced research in this field. Though IWSNs offer advantages of low cost, flexibility, scalability, self-healing, easy deployment and reformation, yet they pose certain limitations on available potential and introduce challenges on multiple fronts due to their susceptibility to highly complex and uncertain industrial environments. In this paper a detailed discussion on design objectives, challenges and solutions, for IWSNs, are presented. A careful evaluation of industrial systems, deadlines and possible hazards in industrial atmosphere are discussed. The paper also presents a thorough review of the existing standards and industrial protocols and gives a critical evaluation of potential of these standards and protocols along with a detailed discussion on available hardware platforms, specific industrial energy harvesting techniques and their capabilities. The paper lists main service providers for IWSNs solutions and gives insight of future trends and research gaps in the field of IWSNs

Wireless Sensor Technology Selection for I4.0 Manufacturing Systems

The term smart manufacturing has surfaced as an industrial revolution in Germany known as Industry 4.0 (I4.0); this revolution aims to help the manufacturers adapt to turbulent market trends. Its main scope is implementing machine communication, both vertically and horizontally across the manufacturing hierarchy through Internet of things (IoT), technologies and servitization concepts. The main objective of this research is to help manufacturers manage the high levels of variety and the extreme turbulence of market trends through developing a selection tool that utilizes Analytic Hierarchy Process (AHP) techniques to recommend a suitable industrial wireless sensor network (IWSN) technology that fits their manufacturing requirements.In this thesis, IWSN technologies and their properties were identified, analyzed and compared to identify their potential suitability for different industrial manufacturing system application areas. The study included the identification and analysis of different industrial system types, their application areas, scenarios and respective communication requirements. The developed tool’s sensitivity is also tested to recommend different IWSN technology options with changing influential factors. Also, a prioritizing protocol is introduced in the case where more than one IWSN technology options are recommended by the AHP tool.A real industrial case study with the collaboration of SPM Automation Inc. is presented, where the industrial systems’ class, communication traffic types, and communication requirements were analyzed to recommend a suitable IWSN technology that fits their requirements and assists their shift towards I4.0 through utilizing AHP techniques. The results of this research will serve as a step forward, in the transformation process of manufacturing towards a more digitalized and better connected cyber-physical systems; thus, enhancing manufacturing attributes such as flexibility, reconfigurability, scalability and easing the shift towards implementing I4.0

Statistical Delay Bound for WirelessHART Networks

In this paper we provide a performance analysis framework for wireless industrial networks by deriving a service curve and a bound on the delay violation probability. For this purpose we use the (min,x) stochastic network calculus as well as a recently presented recursive formula for an end-to-end delay bound of wireless heterogeneous networks. The derived results are mapped to WirelessHART networks used in process automation and were validated via simulations. In addition to WirelessHART, our results can be applied to any wireless network whose physical layer conforms the IEEE 802.15.4 standard, while its MAC protocol incorporates TDMA and channel hopping, like e.g. ISA100.11a or TSCH-based networks. The provided delay analysis is especially useful during the network design phase, offering further research potential towards optimal routing and power management in QoS-constrained wireless industrial networks.Comment: Accepted at PE-WASUN 201

Spectrum handoff strategy for cognitive radio-based Mac in industrial wirless sensor and actuator networks

In this thesis, a Cognitive Radio(CR)-based MAC for Industrial Wireless Sensor and Actuator Network (IWSAN) applications is proposed. IWSANs are typically used for closed-loop control applications, and they demand strict requirements in terms of time and robustness. Low latency and low error rates are required in order not to endanger persons or machinery. Moreover, these applications operate in industrial environments such as factories or transport scenarios (as aeronautics or railway) where multipath fading and shadowing are present due to metal surfaces. Furthermore, interference from other communication systems or industrial machinery is also common in these environments. The proposed MAC, based on the CR paradigm, is capable of ensuring time and robustness requirements in industrial channels. In the process of designing the CR-based MAC for IWSAN applications, a comparison between several non-CR-based MACs and CR-based MACs has been carried out. This comparison, which allows stating the benefits of CR for these applications, is presented in this thesis. The performance of every MAC is determined theoretically using Network Calculus, and it is validated through OPNET simulations. CR solutions, due to their adaptability characteristics, are capable of avoiding interference and ensuring robustness in industrial environments. However, none of the selected MACs are capable of ensuring robustness without comprising time requirements, since interference is avoided but not in a bounded time. On the other hand, the MAC proposed in this thesis is capable of avoiding interference ensuring time and robustness requirements at the same time. This MAC is therefore suitable for IWSAN applications. To ensure a deterministic behavior against interference, a novel handoff algorithm, which detects interference and hops to another channel, has been proposed. This algorithm has been designed to be used jointly with one of the evaluated MACs. The detection of the interference and the hop to another channel is done in a bounded time, because the proposed algorithm detects interference while the system is transmitting. The performance of this proposal is evaluated using Network Calculus and OPNET simulations, and the results are compared with the system without the proposed handoff algorithm. The comparison of the results shows how the evaluated MAC is only capable of ensuring both time and robustness requirements when the proposed handoff strategy is used. Moreover, the spectrum sensing algorithm used to obtain information about the environment is delved and its performance is measured through MATLAB simulations. An energy detector has been chosen due to its simplicity. Also, a cyclostationary Modulation Classifier is presented and a simplification has been carried out allowing its implementation on real hardware. The Modulation Classifier is capable of distinguishing between OFDM, QPSK and GFSK signals. The performance of the algorithm is presented in this thesis for different signals and for different receiver impairments such as frequency offset, DC offset and I/Q imbalance. Finally, a cognitive platform to validate the spectrum sensing algorithms is presented. This platform has been designed using a Xilinx Virtex 6 FPGA by a working group composed of researchers from IK4-Ikerlan and Mondragon Unibertsitatea. The platform, which uses both spectrum sensing algorithms, is an Ethernet-to-RF bridge. It has been designed to replace an Ethernet wired link by a wireless one for IWSAN applications. The proposed platform ensures a reliable communication link against interference. In the proposed implementation, the energy detector is used by the transmitter in order to find a free channel to transmit data, whereas the modulation classifier is used by the receiver in order to distinguish between the signal transmitted by the RF-Ethernet bridge and other signals. In this way the receiver can find the channel where the transmitter is carrying out the communication.En esta tesis se propone una MAC basada en el paradigma de la Radio Cognitiva (RC) para redes de sensores y actuadores inalámbricos industriales. Estas redes se suelen utilizar para aplicaciones de control en lazo cerrado, que exigen requisitos estrictos de tiempo y robustez. Para no poner en peligro la salud de las personas o la maquinaria es necesario que la red asegure una baja latencia y una tasa baja de errores. Además, al trabajar en ambientes industriales como fábricas o transportes (trenes, aviones, etc.), estas redes tienen que hacer frente a canales con mucho desvanecimiento por multitrayecto y efecto sombra debido a las superficies metálicas. También es común en estos entornos que haya interferencias de otros sistemas de comunicaciones o de la propia maquinaria industrial. La MAC propuesta en esta tesis es capaz de asegurar los requisitos temporales y de robustez demandados trabajando en este tipo de entornos. En el proceso de diseño de la MAC basada en RC para redes de sensores y actuadores inalámbricos industriales, se ha llevado a cabo una comparación de diferentes MACs diseñadas para estas redes. Se han evaluado tanto MACs basadas en RC como no basadas en ella, estableciendo las ventajas de la RC para estas aplicaciones. La evaluación se ha llevado a cabo haciendo un estudio teórico mediante Network Calculus, cuyos resultados se han validado mediante simulaciones en OPNET. Los resultados muestran como la RC es capaz de evitar interferencias y asegurar robustez en ambientes industriales. Sin embargo, ninguna de las MACs seleccionadas ha conseguido asegurar ambos requisitos, temporales y de robustez, al mismo tiempo; se puede evitar las interferencias pero no sin comprometer los requisitos temporales de la aplicación. Sin embargo, la MAC propuesta es capaz de evitar interferencias asegurando al mismo tiempo los requisitos temporales y de robustez. Por lo tanto, la MAC propuesta es apropiada para este tipo de redes. Para asegurar el comportamiento determinista del sistema, se ha propuesto un novedoso algoritmo de handoff que es capaz de detectar una interferencia y saltar a otro canal. Este algoritmo se ha diseñado para ser utilizado conjuntamente con una de las MACs previamente evaluadas. La detección de la interferencia y el salto a otro canal se hace en un tiempo determinado de tiempo, ya que es posible detectar interferencias mientras el sistema está transmitiendo. Su rendimiento se ha evaluado mediante Network Calculus y simulaciones en OPNET, y se ha comparado con los resultados obtenidos con la MAC cuando no se utiliza el esquema propuesto. De la comparación se deduce que el esquema de handoff añade a la MAC la capacidad de asegurar a la vez los requisitos temporales y de robustez. Además, en la tesis se explica el algoritmo de spectrum sensing que la MAC utiliza para obtener información del entorno, y su rendimiento se ha estudiado mediante simulaciones en MATLAB. Debido a su simplicidad, se ha optado por un detector de energía para este propósito. También se presenta un clasificador de modulaciones cicloestacionario. Este clasificador ha sido simplificado todo lo posible para posibilitar su implementación en hardware real. El clasificador de modulaciones es capaz de distinguir entre señales OFDM, QPSK y GFSK. Su rendimiento se detalla para diferentes señales y para diferentes deficiencias presentes en el receptor, como son offset de frecuencia, offset de continua o desequilibrios I/Q. Por último, se presenta una plataforma cognitiva que se ha utilizado para validar los algoritmos de spectrum sensing. Un grupo de trabajo compuesto por investigadores de IK4-Ikerlan y Mondragon Unibertsitatea ha diseñado esta plataforma sobre una FPGA Virtex 6 de Xilinx. La plataforma, que utiliza los dos algoritmos de spectrum sensing, es un puente Ethernet-RF. Su objetivo es reemplazar un enlace cableado de Ethernet por uno inalámbrico para aplicaciones de redes de sensores y actuadores industriales. Gracias a los algoritmos de spectrum sensing, la plataforma es capaz de asegurar un enlace robusto ante interferencias. El detector de energía se utiliza en el transmisor para encontrar los posibles canales libres donde transmitir la información. Mientras que el clasificador de modulaciones se utiliza en el receptor para distinguir entre la señal del transmisor y otras posibles señales. Esto permite al receptor saber en qué canal de todos los posibles está el transmisor.Tesi honetan proposatzen da Irrati Kognitiboaren (IK) paradigman oinarritutako MAC bat industriako haririk gabeko sentsore eta eragingailuen sareetarako. Sare horiek begizta itxiko kontrol aplikazioetarako erabili ohi dira, denbora eta sendotasunaren aldetik baldintza ugari eskatzen dute eta. Pertsonen osasuna eta makinak arriskuan ez jartzeko, beharrezkoa da sareak latentzia eta hutsegite tasa txikiak bermatzea. Gainera, industri giroetan lan egiteko direnez, esaterako, lantegietan edo garraioetan (trenak, hegazkinak, etab.), sare horiek gai izan behar dira gainazal metalikoek eragiten dituzten ibilbide aniztunaren eta itzal efektuaren ondorioz asko barreiatzen diren kanalei aurre egiteko. Ingurune horien ohiko ezaugarria da, baita ere, beste komunikazio sistema batzuen edo industriako makinen beraien interferentziak egotea. Tesi honetan proposatzen den MACa gai da honelako inguruetan lan egiteko denborari eta sendotasunari dagokienez eskatzen dituen baldintzak ziurtatzeko. IKan oinarrituta haririk gabeko sentsore eta eragingailu industrialen sareetarako MACa diseinatzeko prozesuan, horrelako sareetarako aurkeztu diren hainbat MAC alderatu dira. IKan oinarritutako MACak zein bestelakoak ebaluatu dira, eta IKak aplikazio hauetarako dituen abantailak ezarri dira. Ebaluaziorako Network Calculus erabili da, zeinaren bidez azterketa teoriko bat egin baita, eta azterketaren emaitzak OPNETen simulazioak eginda baliozkotu dira. Emaitzek erakusten dutenez, IKa gai da industriako inguruneetan interferentziak ekidin eta sendotasuna ziurtatzeko. Halere, aukeratu diren MACetatik batek ere ez du lortu baldintza biak, denborari buruzkoa zein sendotasunari buruzkoa, aldi berean ziurtatzea; interferentziak ekidin daitezke, baina ez aplikazioaren denborari buruzko baldintzak arriskuan jarri gabe. Dena dela, proposatu den MACak portaera determinista bat ziurtatzen du interferentziekiko, eta aldi berean denborari eta sendotasunari buruzko baldintzak ere ziurtatzen ditu. Hortaz, MAC hau egokia da sare mota honetarako. Sistemaren portaera determinista ziurtatzeko, handoff algoritmo berritzailea proposatu da, zeina interferentzia bat antzeman eta beste kanal bat igarotzeko gai den. Algoritmo hori aurretik ebaluatutakoa MACetako batekin batera erabiltzeko diseinatu da. Interferentzia antzeman eta beste kanal batera salto egitea denbora jakin batean egiten da, izan ere, sistema transmititzen ari dela antzeman baitaitezke interferentziak. Network Calculusen bitartez eta OPNETeko simulazioen bitartez ebaluatu da sistemaren errendimendua, eta proposatutako eskema erabiltzen ez denean MACak ematen dituen emaitzekin alderatu da. Alderaketa horretatik ondorioztatzen denez, handoff eskemak denborari eta sendotasunari buruzko baldintzak batera ziurtatzeko ahalmena ematen dio MACari. Gainera, tesiak azaltzen du inguruneari buruzko informazioa eskuratzeko MACak erabiltzen duen spectrum sensing algoritmoa, eta bere errendimendua MATLABen simulazioak eginez aztertu da. Bere sinpletasuna dela eta, energia detektore bat aukeratu da asmo honetarako. Modulazio sailkatzaile zikloegonkor bat ere aurkezten da. Sailkapen hori ahalik eta gehien sinplifikatu da benetako hardwarean inplementatu ahal izateko. Modulazioen sailkatzaileak OFDM, QPSK eta GFSK seinaleak bereizi ditzake. Bere errendimendua hargailuan dauden seinale eta akats desberdinetarako zehazten da, esaterako maiztasunaren offset-a,zuzenaren offset-a edo I/Q desorekak. Bukatzeko, spectrum sensing-eko algoritmoak baliozkotzeko erabili den plataforma kognitibo bat aurkezten da. IK4-Ikerlaneko eta Mondragon Unibertsitateko ikertzailez osatutako lantalde batek diseinatu du plataforma hori Xilinxen Virtex 6 FPGA baten oinarrutz. Plataformak spectrum sensing-eko bi algoritmo erabiltzen ditu eta Ethernet-RF zubi bat da. Bere helburua da Etherneteko kable bidezko lotura bat haririk gabeko batekin ordeztea industriako sentsore eta eragingailuen sareetan aplikatzeko. Spectrum sensing-eko algoritmoei esker, plataformak lotura sendoa bermatu dezake interferentziak gertatzen direnean. Energia detektorea transmisorean erabiltzen da informazioa transmititzeko erabilgarri egon daitezkeen kanalak aurkitzeko. Modulazioen sailkatzailea, berriz, hargailuan erabiltzen da transmisorearen seinalea eta egon daitezkeen beste seinale batzuk bereizteko. Horri esker, hargailuak badaki posible diren kanal guztietatik non dagoen transmisorea

A novel MAC proposal for critical and emergency communications in industrial wireless sensor networks

In this paper, three MAC protocols, EE-MAC, CF-MAC and OD-MAC, are proposed. EE-MAC incorporates emergency communication and allows immediate channel access for emergency traffic. CF-MAC compensates regulatory and open-loop control traffic and introduces a prioritized access for high priority nodes. It also allows nodes with critical data to reserve communication slots using control channel. Whereas OD-MAC presents a deadline based dynamic scheduler which ensures timely delivery of time-critical information. The paper presents mathematical modelling of the proposed protocols. For evaluation purposes, the performance of the proposed protocols is compared to IEEE 802.15.4e LLDN. The results show that the proposed protocols offer up to 92% reduction in delay in emergency communications at the cost of 5% to 15% increase in delay of time-insensitive data. A 60% and 85% reduction was observed in the channel access delay for regulatory and open-loop control traffic respectively along with notable improvements in communications reliability

Dynamic priority based reliable real-time communications for infrastructure-less networks

This paper proposes a dynamic priority system at medium access control (MAC) layer to schedule time sensitive and critical communications in infrastructure-less wireless networks. Two schemes, priority enabled MAC (PE-MAC) and optimized PE-MAC are proposed to ensure real-time and reliable data delivery in emergency and feedback systems. These schemes use a dynamic priority mechanism to offer improved network reliability and timely communication for critical nodes. Both schemes offer a notable improvement in comparison to the IEEE 802.15.4e low-latency deterministic networks. To ensure more predictable communication reliability, two reliability centric schemes, quality-ensured scheme (QES) and priority integrated QES, are also proposed. These schemes maintain a pre-specified successful packet delivery rate, hence improving the overall network reliability and guaranteed channel access