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1 ARC Advisory Group
Wireless in Process AutomationTrends and Outlook
ETSI Board #67
13 June 2008
Wireless in Process AutomationTrends and Outlook
ETSI Board #67
13 June 2008
Harry ForbesSenior Analyst, North America
ARC Advisory [email protected]
David HumphreySenior Analyst, EuropeARC Advisory [email protected]
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ARC Advisory Group
Who Is ARC Advisory Group?Who Is ARC Advisory Group?
Strategic Advisory and Management Consulting Firm: The leader in manufacturing and logistics
Supply Chain: Sourcing to Fulfillment
Plant Systems: Production Management to Controls
Product Lifecycle Management: Design to Service
First-hand industry and application experience
Technology trends and business forecasts
Formed in 1986 22 years of growing knowledge
Enterprise to Plant Floor
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ARC Advisory Group
Industrial Wireless Segmentation
Which are the critical parameters?
Process Industries Wireless Market Forecast
Wireless Applications in Manufacturing
Wireless Standards organizations and efforts
AgendaAgenda
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ARC Advisory Group
Device Power Model
Replaceable battery (low-power)
Rechargeable battery
Mains power
Manufacturing Process Type
Continuous Process Manufacturing
Discrete Manufacturing
Wireless Network levelSensor level network
WLAN level network
Industrial Wireless SegmentationIndustrial Wireless Segmentation
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ARC Advisory Group
Manufacturing Process TypeManufacturing Process Type
Process AttributeContinuous Process
Manufacturing UnitDiscrete
Manufacturing Unit
Sensor types Predominately Analog Predominantly Discrete
Sensor count per unit 1000 100
Unit Physical Size 1000 Meter 10 Meter
Units per Plant 10s 100sProduction Cycle Length 100 Days 1 Day
Unit Startup Time Hours Minutes
Control Loop Time .1-1000 Sec .001-.5 Sec
Field Device Cost $1000 $100
Installation Cost/device cost 10 X 4 X
Automation Technology DCS PAC/PLC
Commonly Used DeviceNetworks
HART,Foundation Fieldbus,Profibus-PA,Ethernet
Profibus-DP,DeviceNet,Interbus,AS-i,Ethernet
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Process ManufacturingWireless Market ForecastProcess ManufacturingWireless Market Forecast
Size and Growth
Wireless penetration into Process Field DeviceMarket
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ARC Advisory Group
Wireless Market Growth in Process IndustriesWireless Market Growth in Process Industries
0
2 0 0
4 0 0
6 0 0
8 0 0
1,000
1,200
2 0 0 7 2 0 0 8 2009 2 0 1 0 2 0 1 1 2 0 1 2Worldwide Market for Wireless Devices in Process Manufacturing
($Millions) 2008 ARC Advisory Group
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ARC Advisory Group
Wireless Impact on Field Device Markets?Wireless Impact on Field Device Markets?
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Wireless Field Device PenetrationWireless Field Device Penetration
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11 ARC Advisory Group
Current and EmergingProcess Wireless ApplicationsCurrent and EmergingProcess Wireless Applications
Bridging
Field Process Sensing
Equipment Condition Monitoring
Advanced Metering Infrastructure (AMI)
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12 ARC Advisory Group
Wireless Cable Replacement (Bridging)Wireless Cable Replacement (Bridging)
Many commercial products
E.g. Cooper (MTL/Elpro),Phoenix Contact, ProSoft, others
Proprietary and Wi-Fi radio Optimized for longer range
Not glamorous, but veryuseful and economical
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Wireless Process SensingWireless Process Sensing
Commercial productssince 2003
Longer life now possible
More reliablecommunication
Better security
Becoming standards-based
IEEE8
02
.15
.4
HART V.7 (WirelessHART)
ISA 100
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Equipment Condition Monitoring - PresentEquipment Condition Monitoring - Present
These address assets that are NOT beingmonitored now, whichis most plant assets
ECM Application Components
Specialized Mobile Computers
Vibration Sensors
Analytical Software
Historical Data Repository
Current suppliers include:
ABB
Emerson GE/Bentley
Honeywell
SKF
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PowerGeneration
GenerationSwitchyard
TransmissionSubstation
DistributionSubstation
EndUser
Common Information Infrastructure
Advanced Metering +Demand Response
Advanced Metering:Integrates Devices at the Edge of the GridAdvanced Metering:Integrates Devices at the Edge of the Grid
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16 ARC Advisory Group
WLAN ApplicationsWLAN Applications
Mobile Operator Support
Process Operations
Maintenance, Safety, Environmental operations
Visibility During Planned Shutdowns
(turnarounds)
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Mobile Operator SupportMobile Operator Support
Initially networked via cradles
Applications
Rounds and readings
Data CaptureWork Order Generation
Condition Monitoring
Process Operations
Turnaround visibility Combines with AutoID,
and sensing
Converged with voice
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18 ARC Advisory Group
WLAN Infrastructure Trend:Discrete ManufacturingWLAN Infrastructure Trend:Discrete Manufacturing
Wi-Fi coverage becomes dense Multiple Wireless Applications
Automation
Data
Voice
Location services
Manufacturers are moving to aunified WLAN network model
Common services
Wider coverage
RF Spectrum management willbecome a part of networkmanagement practices
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19 ARC Advisory Group
WLAN Infrastructure Trend:Process ManufacturingWLAN Infrastructure Trend:Process Manufacturing
Layer 2
WLAN
Segment
Layer 2
WLAN
Segment
Bridge
or Router
.11s Mesh #1 .11s Mesh #2
Mesh
Portal
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Discrete Manufacturing Sensor Applications:ABB WISADiscrete Manufacturing Sensor Applications:ABB WISA
Commercial Product
Uses Bluetooth radio Radio only, not stack
Unique sensor power solution No batteries
Rotating magnetic field induced around machine
Well thought-out requirements for discrete manufacturingsensor use-cases Number of sensors, range, latency, reliability, etc.
FESTO has done related work using IEEE 802.15.4
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Location TrackingLocation Tracking
Technology Decision Variables
Technology
Radio type
RSSI vs. TDOA
Required Precision ofLocation
Cost ( installed cost, Total Cost of Ownership)
Possible Radios for Location Technologies
Wi-Fi (Aeroscout, Ekahau, Cisco, others)
802.15.4 (Innerwireless, others)
UWB (Zebra/Multispectral Solutions, Nanotron)
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ARC Advisory Group
Location System ArchitectureLocation System Architecture
Passive RFID Tags
Passive
Readers
Enterprise
Applications
Location Engine Appliance
Wi-Fi Tags, clients,
integrated sensors
Dual-mode
Wi-Fi /UWB Tags
UWB
Readers
ExcitersWi-Fi
Network
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ARC Advisory Group
Wireless Standards Organizationsand InitiativesWireless Standards Organizationsand Initiatives
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ARC Advisory Group
WSN Standards and TechnologiesWSN Standards and Technologies
IEEE 802
ZigBee Alliance
HART Communication Foundation
IETF
ISA
TinyOS Alliance
Bluetooth SIG
Proprietary technologies (ANT, Z-Wave, others)
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ARC Advisory Group
IEEE 802IEEE 802
802.15.4e MAC amendment to the existing standard 802.15.4-2006
to
better support the industrial markets
permit compatibility with Chinese WPAN
Suppliers do not use standard 1
5.4
MACs 15.4 TDMA (called GTS) network operation
not completely specified
802.11n
Next enhancement to Wi-Fi
802.11s
Multi-vendor Wi-Fi mesh networking
Ballots have failed so far
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ARC Advisory Group
ZigBee AllianceZigBee Alliance
Built over IEEE 802.15.4 standard ZigBee Scope
Network layer, Security, Mgmt, Profiles
Network formation
RF Channel choice
Scope equivalent to TCP/IP Suite
Too broad
Largely unsuccessful Solved the low-power
problem with:
Reduced function devices, RFDs
Mains-powered routers
Not a good fitfor manufacturingapplications
ZigBee Application focus Began with building lighting (2003)
Challenging performance requirements
Few commercial products
Now has shifted to Advanced Metering/Home Automation Networks
AMI needs wireless access to home energy controls
Utilities will want secure end-end IP connections
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ARC Advisory Group
HART Communication FoundationHART Communication Foundation
WirelessHART Part of HART Field Communication Specification, Revision
7.0
Ratified September 2007
Allows for wireless transmission of HART protocol
Based on IEEE 802.15.4 PHY with modified MAC Layer
Full mesh network topology
Adaptive frequency hopping
Time-division multiple access (TDMA)
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ARC Advisory Group
HART Communication FoundationHART Communication Foundation
Network Manager
Critical Makes all decisions
Devices can be dumb
Presently a sole-sourced technology
Dust Networks SoC and module products
2nd source of WirelessHART technology is possible
Client Device portion only, not network manager
Talk but no investment yet
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ARC Advisory Group
ISA 100ISA 100
Instrumentation, Systems, and AutomationSociety (ISA)
ISA develops standards for ANSI
ISA 100 scope includes all types of manufacturing
ISA 100.11a is first standard. Due 2009 ISA Compliance Institute
ISA began compliance function only in 2007
Compliance work for 3 important ISA standards
Wireless (ISA 100) Cyber-security (ISA 99)
Enterprise Interoperability (ISA 95)
ISA ability to execute is unproven
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IETFIETF
RFC 4944 (6LowPAN)
IPV6 over 802.15.4
ROLL Working Group
Began May 2007
Routing over low-power lossy nets
Application areas:
Industrial
Home
Buildings
Sensor Network
(Mesh, Star, or Tree)
Sensor Network Data Link Layer
IPV6 Services Layer
IPV4-IPV6 Routing
Sensor Network Gateway
IP V4
Network
IPV6
Network
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TinyOS AllianceTinyOS Alliance
TinyOS is an open-source OS for WSNs
Used for most academic WSN research
Global collaboration among academics
Not used in commercial WSN applications
RFM
Radio byte SensorSensor
MessagingLayer
clocksbit
byte
packet Radio Packet
RoutingLayer
sensing applicationapplication
HW
SW
ADC
messaging
routing
UART Packet
UART ADC
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ARC Advisory Group
Bluetooth SIGBluetooth SIG
Low Power Bluetooth (formerly Wibree)
Compatible with Bluetooth7-device PANs
ANT (Garmin) for non-Bluetooth applications
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ARC Advisory Group
Summary: Things To RememberSummary: Things To Remember
Critical Industrial Wireless Segmentations
Power use model (replaceable, rechargeable, mains)
Process vs. discrete applications
Wireless Sensor Networks vs. WLAN
Industrial Wireless Market Will Grow Rapidly
But adoption cycles and service lives are long Current wireless applications in process manufacturing:
Cable replacement
Process Sensing
Equipment condition monitoring
Mobile operator support Location tracking attractive, but far less mature
Industrial Wireless Standards
Many, many organizations are participating now
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ARC Advisory Group
Thank You.Thank You.For more information, contact the authors at
[email protected]@ARCweb.com
or visit www.arcweb.com
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