Fieldbus - Motion Control Tips

CC-Link IE and CC-Link installed base on target to reach 24 million during 2018

December 14, 2018 By Miles Budimir Leave a Comment

The number of devices communicating via the open CC-Link IE Ethernet and CC-Link Fieldbus networks passed the 22 million mark in 2017, confirming their position as one of the fastest rising industrial network technologies globally. Having posted an increasing annual growth figure of over 2 million every year for the past four years, the governing body – the CC-Link Partner Association (CLPA) – is predicting that number will comfortably exceed 24 million sometime during 2018.

The number of devices installed annually, equipped with CC-Link fieldbus or more recently the increasingly popular CC-Link IE gigabit Ethernet, has been constantly expanding since the foundation of the CLPA, back in 2000. By 2017 the annual growth rate had reached over 15% adding nearly 3 million nodes when compared to the previous year’s figures.

A key feature that has made CC-Link IE and CC-Link industrial automation network technologies so popular is their open status. Users are not limited to one single automation hardware vendor or a small number of control and automation equipment suppliers. Instead, machine and system builders can select components from an ever-expanding pool of CLPA partner companies and be sure that these products are compatible and easy to integrate.

John Wozniak, P.E., Manager of CLPA-Americas, explains: “The increase in the number of CC-Link IE and CC-Link devices is a result of the growing number of CLPA partners.” Currently, there are over 3,400-partner companies worldwide and more than 1,800 certified products available from over 300 manufacturers.

The CLPA’s solutions are a de facto standard in Japan and other parts of Asia which helps boost the total figures. However, usage is not limited to this market and adoption is growing here in the Americas as well as Europe. Acceptance has been helped recently by an interoperability specification developed between the CLPA and PROFINET & PROFIBUS International (PI).

By 2017 the annual growth rate had reached over 15% adding nearly 3 million nodes when compared to the previous year’s figures.

An additional development that has benefited CC-Link IE end users is a collaboration between the CLPA and the OPC Foundation (OPCF), which resulted in the development of an OPC UA companion specification for the CLPA’s CSP+ for Machine technology. This increases process transparency and simplifies the configuration and maintenance of plant systems by treating complete machines as single devices.

John Wozniak adds: “The Partner Association is committed to providing its users with access to solutions that help with achieving the goals and objectives required by Industry 4.0. The CLPA has been leading the way in industrial networking cooperation, which has allowed our users to benefit from a wide range of open and flexible solutions from many manufacturers, developers and integrators. We firmly believe this is one of the main reasons why we are continuing to attract more and more support for our technologies from industry.”

How to select a network for a motion controller?

March 16, 2018 By Miles Budimir Leave a Comment

Over a range of motion control applications, there is no one-size-fits-all approach for selecting a network. However, there are several key factors to consider when deciding on the best networking option for your particular application.

For starters (and perhaps most importantly), consider timing; that is, how quickly the system reacts to inputs or changes in the system as well as the network scan rate. Be sure that the rates are fast enough to accommodate the application. Otherwise, sluggish performance may be the end result. For instance, multi-axis motion control requires high levels of synchronization, so low levels of jitter or signal variability are essential. On the other hand, a relatively slow conveyor system may not require fast speeds at all and so jitter may not be an important parameter in that case.

Another factor is the existing control system. Selecting a network may depend on what network(s) the motion controller supports, or whether or not there is already a protocol in place used by other equipment, something like a legacy network. And it’s possible that using a network that one is familiar with and has experience working with can eliminate the need for a learning curve, saving development time.

Diagnostic capability may also be a key consideration. Older networking protocols had minimal diagnostic capabilities, but contemporary motion control networks generally have a range of diagnostic functions. These can include diagnosing communication issues, device errors and faults, as well as pinpointing the source of issues so they can be quickly identified and corrected.

Other points to consider may be the level of enterprise connectivity needed or required, third-party device support, and as always, cost.

FAQ: What’s the favored network for PLCs, Ethernet or fieldbus options?

December 8, 2016 By Miles Budimir Leave a Comment

The obvious or trite answer is; it depends. It depends on the needs of the application such as speed, timing, number of I/O, etc.

But there’s also the notion that what PLC you happen to be using will dictate the choice of network. So, a Rockwell PLC would be Ethernet/IP or DeviceNET, Siemens would be Profibus, and so on.

Not to be overlooked is the power of the installed base. The numbers indicate that fieldbuses are still the dominant networking choice for most PLC applications. In fact, they are substantially more than 50% of all PLC networks. However, Ethernet and Ethernet-based networks have been steadily gaining ground over the last few decades and will only continue to do so in the near future.

So why are fieldbus networks still so common? One simple answer may just be their legacy, the existing installed base, which provides little incentive to go with a completely new network setup. Switching to a new industrial network is a major undertaking in terms of engineering costs, time and effort. And if there isn’t a significant advantage or payoff from switching networks, it likely won’t be done.

A key differentiator is determinism, with fieldbus networks claiming guaranteed response times that Ethernet can’t deliver. Distance is another factor. Generally speaking, fieldbuses can handle longer distances than Ethernet.

MicroSmart PLCs from IDEC feature an Ethernet port that supports the Modbus TCP protocol, and a serial port supporting the Modbus RTU protocol. Custom web pages provide IoT capability that can be configured for remote monitoring and control.

Another advantage of fieldbus networks is their simplicity. Connecting typical control components such as encoders, motors, or prox switches to control systems is easier and less expensive using fieldbuses. In other words, in some cases Ethernet may be overkill.

Of course, Ethernet offers advantages as well, particularly the ease with which it allows factory floor systems to be connected to larger enterprise-wide networks. It also offers advanced I/O capabilities and can readily handle large amount of data, an important feature given the interest and potential in the Industrial Internet of Things (IIoT).

Sercos III Specification Update V1.3 Now Available

March 27, 2012 By Miles Budimir Leave a Comment

Santa Rosa Beach, Fl. – The Sercos vendor organizations have released an update to the specification for Sercos III Real-time Ethernet. The V1.3 specification broadens the functionality and range of applications of the international Sercos real-time standard, while considering new trends in machine and plant construction. The extensions are fully compatible with the existing specification, ensuring a high level of standardization and the best possible interoperability of devices from different manufacturers.

Following the lead of electronic drives, hydraulics and pneumatics are turning more and more towards digitally controlled modules. This increases flexibility and shifts tasks previously solved by mechanical means to software solutions. The Sercos organization recognizes the importance of this trend and has extended the existing Sercos drive profile such that electric, hydraulic and pneumatic drives now are supported across different technologies.

Two new profiles have been added to the Sercos specification. The energy profile defines parameters and commands for the reduction of the energy consumption in a uniform and vendor-independent manner. An encoder profile makes the interface of absolute and incremental encoders available to all devices on a Sercos network.

New services specified at the protocol level include oversampling and time-stamping. The oversampling procedure allows the acquisition and transmission of equidistant values faster than the configured bus or connection cycle. This increases the process control intricacy in extremely time-critical applications, such as laser applications, because it allows more data to be collected and command values to be communicated at a faster speed. Measurement methods are integrated directly into the protocol, thereby making it possible to access these mechanisms across different manufacturers and independently of the product.

In addition, the specification defines a time-stamping procedure for the event-triggered acquisition of values with corresponding time stamps, as well as the time-triggered activation of command values. This function is event-controlled, promptly transmitting defined events such as certain measurement values to the controller and switching outputs independently from the clock cycle. This increases process stability in complex solutions such as those needed in semiconductor or solar manufacturing.

The specification update is completed by an installation guide that specifies cabling with copper wire and optical fiber, each in consideration of IP20 and IP65/67 protection classes.

For additional information, visit www.sercos.com or www.sercos.de/en.

Compact Power Hub delivers outstanding power in space-restricted Fieldbus systems

May 20, 2011 By Motion Control Tips Editor Leave a Comment

Pepperl+Fuchs (www.pepperl-fuchs.com), one of the largest manufacturers of industrial sensors and sensor system for factory automation applications in the world, has announced the release of a high performance, versatile power supply built for larger process automation projects, the FieldConnex Compact Power Hub.

Unlike other comparable power supply offered in the market, the new FieldConnex Compact Power Hub consumes less cabinet space with its 150 mm x 268 mm footprint, as it provides eight segments of redundant power. The advanced passive impedance design and especially selected components allows the FieldConnex Compact Power Hub to deliver outstanding power and performance in less space without compromise. It also supports safe fieldbus segments according to High Power Trunk concept and the Entity Ex nL or Ex ic classification.

“The power supply modules that mount on the motherboard are just 12.5 mm,” said Brian Traczyk, Product Manager at Pepperl+Fuchs. “Depending on the module the typical power loss is only 1.3 or 1.6 watts, which promises a long service life with the most efficient control room cabinet-packing density available today.”

“And because the FieldConnex Compact Power Hub is designed with built-in redundancy, two power modules are assigned to each segment. This means that exchanging a failed power module does not require any interruption of the power supply, and will not affect plan operation.”

The compact motherboard of FieldConnex Compact Power Hub comes in various versions that suit numerous application needs. It also provides all necessary interfaces and wiring connections and can support up to 16 plug-in power modules, which are safely secured and plugged in without the need for other tools.

MooreHawke’s TRUNKSAFE Fault-Tolerant Fieldbus system approved by FF

April 12, 2011 By Motion Control Tips Editor Leave a Comment

MooreHawke, a division of Moore International’s (www.miinet.com), proudly announced that its TRUNKSAFE TS Series power conditioner has been certified by the Fieldbus Foundation and is now included in the foundation’s list of registered product.

“Because of the revolutionary nature of TRUNKSAFE, obtaining approval and registration is a significant step,” said Leonard Moore, President of Moore Industries.

“TRUNKSAFE is the only fault-tolerant fieldbus system of its type in the world, and now end users and systems integrators can have complete confidence that it is suitable for use on both critical and non-critical process segments.”

TRUNKSAFE provides a real measure of fault-tolerance without duplicating/triplicating each component and installing special software at the DCS. The TRUNKSAFE Fault-Tolerant segment’s design only requires two TRUNKSAFE power conditioners, two H1 cards, one TRUNKSAFE device coupler and two cables. Users do not need to install special software at the DCS nor to duplicate the field instrument. If one of the field cables fails, the system still continues to operate via the alternative cable while the system notifies the DCS.

The TRUNKSAFE device coupler has been especially hardened to eliminate common-mode failures that might affect the whole segment.

Aside from saving money, TRUNKSAFE also prevents a hardware fault from affecting the entire segment.

TRUNKSAFE can be used on both Profibus and FOUNDATION fieldbus segments and on both non-critical and critical processes. It can be also used together with MooreHawke’s standard fieldbus power conditioner system.

Texas Instruments introduces new AM1810 Sitara ARM MPU

December 28, 2010 By Motion Control Tips Editor Leave a Comment

Texas Instruments Incorporated (www.ti.com) is proud to announce the launch of its all-new AM1810 Sitara ARM microprocessor (MPU) – a new single-chip ARM9 solution with an embedded PROFIBUS interface – the most popular fieldbus used for communications among factory automation equipment.

This embedded, low-power tool removes the need for an external ASIC, FPGA or PROFIBUS, which saves development cost and time while enhancing system performance. The AM1810 Sitara ARM MPU offers ample performance to support industrial applications implementation, whether or not these applications require a PROFIBUS. Industrial applications best suited for the AM1810 Sitara ARM MPU include a human machine interface (HMI) or programmable logic controller (PLC).

Texas Instruments also announced that it joined the PROFIBUS International, affirming its commitment to the industrial market by delivering an integrated and certified solution to improve costs and help make development easier for industrial designers.

Compared to other multi-chip solutions on the market, the AM1810 Sitara ARM MPU directly connects the PROFIBUS interface to the RS-485 transceiver, doing away with the need for a FPGA or ASIC.

“In the industrial space, the PROFIBUS standard is synonymous with reliable networking, and with this certification, TI is giving a higher assurance that our product is a quality alternative to existing solutions,” said Ram Sathappan, industrial end equipments manager of Texas Instruments Inc. “We are very excited to be a member of PI and introduce our certified AM1810 Sitara ARM MPU PROFIBUS solution to the industrial market. Our aim is to help our customers reduce BOM costs, PCB space and design time. We are confident that TI’s one chip solution, the AM1810 Sitara ARM MPU with PROFIBUS, will do just that.”

WAGO’s new Ethernet fieldbus controller platform

November 29, 2010 By Motion Control Tips Editor Leave a Comment

WAGO Corporation (www.wago.us) is now offering a new Ethernet fieldbus controller that can process 1,000 instructions in just 235 μS. Using the company’s second generation Ethernet platform, it also offers upgraded memory capacity for web applications and PLC programs, along with an embedded dual-port Ethernet switch.

“We are both upgrading the processor and offering enhanced features in our new Ethernet products,” said Charlie Norz, WAGO’s I/O System Product Manager. “Ethernet 2.0 is compatible with our existing platform and still uses a rackless design, which means the I/O modules fit together on a DIN rail and the user can easily add or subtract modules as needed.”

“We have upgraded our processor, so that it is 100 percent faster than our existing products, and a new file system on the controller enables the user to log more data or store web pages. The new controller doubles the amount of available memory, offering 1 Mbyte of program memory and a 2 Mbyte file system,” Norz added.

The keys to the fast processing capabilities of the 750-881 are the upgrade in program memory and a new 32-bit CPU. The Fast File System supervises substantial data logging and a web-based management system, while an e-mail capability is also offered for authorized personnel. The standard CoDeSys V2 programming environment for the 750-881 is IEC 61131 compatible and offers all five programming languages. Up to 250 I/O modules can be supported by the PFC that allows machine users to tailor solutions from among 400+ digital, analog and specialty modules.

The additional processing power in WAGO’s new second generation Ethernet platform also allows the programmable fieldbus controller to process 1,000 instructions in just 235 μS.

Belden’s robust data communications technology with Ethernet and fieldbus solutions

November 15, 2010 By Motion Control Tips Editor Leave a Comment

Modern data communications technology, an indispensible requirement for implementing smart grids, is also now being increasingly utilized in the distribution and generation of wind energy. Compared with other industrial environments, the conditions in wind energy plants are also rugged and harsh. Infrastructure systems and components should also cope with extreme stresses. That is why the connection, cabling and network technology from Belden (www.belden.com), along with its Lumberg and Hirschmann Automation brands, which have already successfully demonstrated their reliability and effectiveness in the field of industrial automation, are also the selected components for data communications in wind energy plants.

The comprehensive product portfolio is composed of embedded Ethernet solutions, fieldbus distributors and repeaters plus Industrial fieldbus and Ethernet cable, industrial plug-in connection systems and patch panels.

“Power stations’ data links to the power grid are progressing well, and Ethernet is increasingly being used in place of existing disparate and, in some cases, proprietary solutions. This means, for instance, that inverters are also being equipped with appropriate interfaces,” said Ute Decker, Belden’s Vertical Marketing Manager for Alternative Power Generation. She observed other trend, namely, increasing data is being recorded, transmission is increasingly in real time, and networks are acquiring ever more subscribers. “In this context we find that security, i.e., protecting the transmitted data against unauthorized access, is becoming more and more important,” she added.

In the distribution and generation of wind energy, data is exchanged not only in wind energy plants, but also between the plants and substations. There are separate networks for different tasks. “Besides Ethernet, certain applications also use fieldbuses such as CAN and wireless solutions for condition monitoring, and some remote monitoring facilities make use of existing interfaces such as GSM or DSL,” said Ms. Decker. To ensure the reliability of data communications, the systems and components must be particularly robust and must be able to withstand both high levels of humidity and extreme temperatures.

“The modular and compact Industrial Ethernet switches in our MICE, RS, RSB and MACH series have been successfully used in countless wind energy plants for many years, as have the WLAN access points in our BAT series, the industrial security solutions of our EAGLE line, and network management tools such as Industrial HiVision,” Ute Decker added.

HMS unveils new CANopen X-gateway Family

November 2, 2010 By Motion Control Tips Editor Leave a Comment

HMS Industrial Networks, Inc. (www.hms.se) has announced that it will release an all-new Anybus X-gateway series that connects CANopen networks with 10 other industrial Ethernet and fieldbus networks.

At the SPS/IPC/Drives fair in Nuremberg, Germany, HMS will launch a major enhancement to the X-gateway family, unveiling 10 completely updated design of CANopen master (manager) gateways in small slim-line housing. Any CANopen enabled device with slave functionality can communicate with any other industrial Ethernet or fieldbus network through the new and powerful CANopen X-gateways. The CANopen gateway family includes versions for all well-known fieldbusses such as DeviceNet, Profibus, ControlNet, Modbus and for industrial Ethernet with EtherNet/IP, Profinet, Modbus-TCP and EtherCAT protocol. CANopen-based networks are typical applications that need to be incorporated into higher functional industrial Ethernet or fieldbus networks. Target markets include transportation, machine building, medical, infrastructure and other types of energy distribution, as well as control applications such as renewable energies.

The CANopen X-gateways, which are embedded into a small plastic housing, are slim-lined devices for 24 Volt power supply and standard DIN rail mounting. These are based on the Anybus communication modules and act as intelligent link between two industrial networks. They always function as a master (manager) on the CANopen side and work as slaves (servers) on the uplink network side. Based on HMS NP30 microprocessor, the implementation is certified by CIA (CAN in Automation) for conformance to the CANopen DS 301 v4.0.2 standard.

For the CANopen master interface’s configuration, any standard CANopen configuration tool can be utilized. The Ethernet slave or uplink fieldbus interface is configured with the standard engineering tool of the programmable logic controller (PLC) and a standard device description file (GSD/EDS). The Anybus X-gateway series transmits I/O data completely transparent into the two networks – I/O data from the uplink fieldbus/Ethernet network is mapped into the CANopen PDOs and vice versa.