Using Ethernet & TSN for rail metro networks - The Industrial ...

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Using Ethernet & TSN for rail metro networks - The Industrial ...
7.2019 Issue   113
                                                                                           ISSN 1470-5745

                   The Journal of Industrial Networking and IoT

                                                       Using Ethernet & TSN for
                                                       rail metro networks                          7

Key considerations for    The end of the      Digital twin concept for   Is 5G robust enough
passenger Wi-Fi        22 Fieldbus Wars?   27 industrial automation 29   for industry?       37

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Using Ethernet & TSN for rail metro networks - The Industrial ...
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                                                                                                                                                                      Contents
Operational Effectiveness                                                                                   Contents
The conclusion of the biannual report on the
State of the Industrial Internet of Things                                 Industry news                                                                         4
produced by PTC (ptc.com) puts the spotlight
on the importance of operational effectiveness                             Simplified Ethernet for rail metro networks using TSN                                 7
as a measure of IIoT progress.
According to the report: "Based on findings                                Fast, reliable internet access for trains leverages technology                      14
from recent quarters, there are a noteworthy
number of enterprises pursuing initiatives                                 EtherCAT G offers I/O response for high-performance machines                        16
to build and enable IoT solutions to achieve
operational effectiveness. This report will                                Mobile automation solutions for intelligent machinery                               18
primarily focus on obtaining operational
effectiveness through industrial IoT,                                      Palm oil tank farms ready for digitalization                                        20
supporting use cases and technologies
apparent across different forms of                                         Five key considerations for passenger Wi-Fi networks                                22
manufacturing and operations environments."
Looking in more detail, the report identified                              Parameterization & monitoring of Ethernet Hart devices                              25
five applications that are the top Industrial
IoT use cases. The leading applications in                                 The end of the Fieldbus Wars?                                                       27
order are operational intellligence (31%),
asset monitoring and maintenance (19%),                                    Digital twin concept as applied to industrial automation                            29
predictive maintenance (12%), remote
monitoring (8%) and remote service (4%).                                   Development solution for next generation Ethernet using TSN                         34
The biggest beneficiaries in terms of company
departments was manufacturing (46%)
followed by service (22%) and operations                                   Is 5G already robust enough for industry?                                           37
(19%).
                                                                           Secure multicast & applications for securing multicast CIP traffic                  40
PTC has been engaging with its customers
since 2015 to reveal their current and planned
use of IIoT to drive digital transformation
                                                                           New Products                                                                        45
across their operations and products. The
sample for this data set includes enterprises                              Private Ethernet                                                                    50
across multiple verticals and geographies with
a focus on industrial settings.
The biggest impact of the IIoT seems to be a                       Industrial Ethernet Book
higher level operational view that is enabling                     The next issue of Industrial Ethernet Book will be published in September/October 2019
manufacturing management, in particular,                           Deadline for editorial: August 9, 2019 Deadline for artwork: August 30, 2019
to analyze and monitor metrics. Not too
surprisingly, engineers are more focused                           Product & Sources Listing
on planned maintenance and monitoring                              All Industrial Ethernet product manufacturers (not resellers) are entitled to free of charge
activities where network connectivity provides                     entries in the Product locator and Supplier directory sections of the Industrial Ethernet Book.
insight into the operation of machinery.                           If you are not currently listed in the directory, please complete the registration form at
Interestingly, data sourcing is most common                        www.iebmedia.com/buyersguide/ to submit your company details.
achieved using edge devices (68%) and IoT
gateways (37%) versus utilizing a cloud
                                                                   Update your own products
platform (34%) or more traditional enterprise
                                                                   If you wish to amend your existing information, login to the Editor section
systems (15%).
                                                                   www.iebmedia.com/buyersguide/register.htm and modify your entry.
There also continues to be an ongoing trend
where IIoT adopters are moving from test sites                     Do you want to receive issues of Industrial Ethernet Book? Call, mail or e-mail your details, or
to full scale production, as proof of concept                      subscribe at www.iebmedia.com/service/
becomes clearer.
At the end of the day, data seems to be "king"
                                                                  Editor: Al Presher, editor@iebmedia.com
and information analysis is still a work in
progress and situational based on the needs of                    Contributing Editor: Leopold Ploner, info@iebmedia.com
a particular business. Digital transformation                     Advertising: info@iebmedia.com
means different things in different industries                    Tel.: +49-8192-994-9928 · Fax: +49-8192-994-8876
but the common thread is manufacturing as                         Online Editor: Adela Ploner, info@iebmedia.com
the main focus.
                                                                  Circulation: subscriptions@iebmedia.com
"Business value is being achieved by
enterprise adopters seeking and obtaining                         Published by
outcomes including strategic differentiation                      IEB Media, Bahnhofstrasse 12, 86938 Schondorf am Ammersee, Germany
in products or services, increasing operational
                                                                  ISSN 1470-5745
effectiveness, and improving productivity."
                                      Al Presher

                    7. 2019   i n d u str i a l e th e r n e t b o o k                                                                                                3
Using Ethernet & TSN for rail metro networks - The Industrial ...
PROFIsafe and IO-Link
Industry news

                       pass the 10 million mark
                 More than 2.2 million PROFIsafe nodes were brought to market in 2018, growth of nearly 25% compared to
                the previous year. More than 3.3 million IO-Link nodes were brought to market, more than 40% growth rate.

                PROFIBUS & PROFINET INTERNATIONAL

                                                                                                                                                                                       SOURCE: PI
                (PI) has concluded its annual count of the
                installed base of devices with interfaces
                using communication technologies from PI.
                As in previous years, the numbers from 2018
                indicate a very positive trend.

                PROFINET Growth
                In the case of PROFINET, the 5.1 million
                devices brought to market in 2018 represent
                an increase of 0.6 million over the previous
                year’s record. By the end of 2018, a total of
                26 million PROFINET devices were working to
                automate production. The annual number of
                PROFIBUS devices installed – 2.4 million –
                even rose slightly as compared to the previous
                year. Reaching nearly 61 million, the overall
                number passed yet another threshold. The
                total of the two annual values of 7.5 million
                also represents an all-time high number.
                   PROFIBUS’s trend in process automation
                also remains stable. Though the annual value      3.3 million IO-Link nodes were brought to market in 2018. The overall count amounts to 11.4 million IO-Link nodes,
                reached in 2018 – 0.8 million – was slightly      and means that the 10-million hurdle was passed by a considerable margin as well.
                less than the previous year, a total of 12.3
                million PROFIBUS devices (i. e. 20% of the
                overall total of 61 million) are now being used
                in process systems.

                PROFIsafe
                With 2.2 million PROFIsafe nodes brought to
                market in 2018, which corresponds to growth
                of nearly 25% as compared to the previous
                year, PROFIsafe also saw its highest annual
                gain ever. In total, PROFIsafe passed the
                10-million hurdle by a considerable margin
                with its 11 million nodes.

                IO-Link
                As in the previous years, IO-Link likewise
                achieved a record in two regards in 2018. On
                the one hand, 3.3 million IO-Link nodes were
                brought to market, which amounts to growth
                of more than 40% compared to last year. An
                overall count of 11.4 million IO-Link nodes
                means that the 10-million hurdle was passed
                by a considerable margin here as well.            With its 11.2 million units, PROFIsafe passed the 10-million hurdle. With 2.2 million PROFIsafe nodes brought to
                                                                  market in 2018, this corresponds to growth of nearly 25% as compared to the previous year.
                Development direction
                For Karsten Schneider, Chairman of PROFIBUS       presented at the PI Konferenz in Frankfurt                      the future as well, which in turn will be a
                & PROFINET International (PI), these figures      (March 2019)," Schneider said in a press                        crucial element for the economic success of
                confirm the validity of decisions made over the   release.                                                        our member companies," he added.
                past few years with regard to the development        "Record-setting PI Konferenz attendance
                direction of PI technologies.                     also confirms the broad acceptance of our                       News by PROFIBUS & PROFINET International
                   “This motivates us to continue with resolve    technologies today and the trust in our                         (PI).
                and to implement step by step the strategy        organization to make the right decisions in

      4                                                                                                             in d u s t r ial et h er ne t b o o k   7.2019
Using Ethernet & TSN for rail metro networks - The Industrial ...
| EK11-16E |

                                  System-integrated overcurrent
                                  protection with EtherCAT interface
                                  Extremely space-saving and flexibly usable

                                  www.beckhoff.com/overcurrent-protection
                                  In the EtherCAT Terminals from the EL922x series Beckhoff integrates the overcurrent protection for the fusing
                                  of 24 V DC systems – including EtherCAT interface – in a compact 12 mm. Transparent plant monitoring via
                                  EtherCAT is thus also directly integrated. The EL922x can supply both consumers outside the terminal network
                                  and further terminals inside it with a fused voltage – simply and conveniently. Virtually all typical requirements
                                  can be met through the individual settings. The range consists of a total of 19 different standard and high-line
                                  terminals with a particularly high number of analysis options.

                                  Direct overcurrent protection integration
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               IEB113_p5.indd 5                                                                                                                        11.07.1928 16:27
Using Ethernet & TSN for rail metro networks - The Industrial ...
Cloud-based platforms to drive
Industry news

                        factory simulation software
                 The market for factory simulation software products will grow at a compound annual growth rate of 11% to
                reach US $4.1 billion for over 172,000 users in 2030.

                ACCORDING TO GLOBAL TECH MARKET ADVISORY           that engineers only see and modify the details           forecasted for 2030. In fact, automotive
                firm, ABI Research, sales for factory simulation   and information that they need for their job or          represents the largest opportunity in every
                software products include software that uses       level of expertise, and engineers in different           country except for South Korea, where
                computer modeling to analyze how production        locations can work on different parts of the             electronics manufacturing has a slight edge.
                might work in any given factory or situation       same model. This increases data security,                   “Automotive manufacturing leads the
                and implement virtual commissioning to test        speeds up the simulation process, and makes              way for many transformative technologies
                proposed changes and upgrades before they          the product easier to use.”                              and therefore has a higher demand to
                are put into effect.                                  Vendors that provide or partner with larger           simulate those technologies. It also has an
                   “Today, many manufacturing enterprises          smart manufacturing platforms control the                edge on most industries in sheer size and
                have started to use simulation software, but       largest chunks of the market share. In discrete          organizational transformation, with more
                most have not yet realized the added benefits      industries, this means Dassault Systèmes with            holistic solution deployments due to cross-
                of using simulation software as part of a larger   its 3DEXPERIENCE platform, Siemens with                  functional technology transformation teams.
                smart manufacturing platform or to virtually       its Digital Industries portfolio and Rockwell            Vendors of factory simulation software and
                test other new technologies,” said Nick Finill,    Automation with Arena and its partnership                larger platforms specifically target these teams
                Principal Analyst at ABI Research. “Cloud-         with PTC control most of the market. In                  for growth opportunities,” concludes Finill.
                based platforms can provide a similar interface    process industries, AVEVA, AspenTech, and                   These findings are from ABI Research’s
                for simulations from the different points of       Siemens control most of the market.                      Industrial Virtualization, Visualization, and
                view of process engineers, operations support         The automotive industry represents the                Simulation Market Tracker market data report.
                managers, plant engineers, and control             largest opportunity globally, with US$1.8
                engineers. Companies can assign user roles so      billion in factory simulation software revenues          News by ABI Research.

                Specification of PROFINET with TSN complete
                The goal set by PI (PROFIBUS & PROFINET International) to integrate TSN as additional Layer 2 technology in
                the PROFINET architecture has been reached with the current PROFINET specification V2.4.

                THE SPECIFICATION WORK FOR PROFINET WITH TSN                                                                                            need to understand
                has been completed and the three parts of                                                                                               the details or even
                the document are available for download on                                                                                              implement them
                the PI website. Manufacturers and users alike                                                                                           themselves. As
                can interoperably implement the advantages                                                                                              a result, device
                offered by TSN, such as future-proof IEEE                                                                                               manufacturers can
                Ethernet technology with higher bandwidth,                                                                                              simply expand their
                deterministics, flexible network configuration                                                                                          existing PROFINET
                and large range of chips.                                                                                                               portfolio with TSN.
                   The user interface remains unchanged,                                                                                                  Of course, the
                i.e., the use of IO data, diagnostics and                                                                                               specification will
                parameterization, since the new TSN                                                                                                     continue to be
                mechanisms act largely on the underlying                                                                                                maintained in the
                communication layers. This makes it easier for                                                                                          familiar annual
                users to get started with the new technology.                                                                                           maintenance
                   Through the dedicated work of the experts                                                                                            process so that
                from many companies, the specification was                                                                                              new customer
                prepared in just over a year in an intensive       and also demonstrated at trade fairs. For                requirements, experiences from the field or
                development and review process. The open           easy understanding of the functionality, a               technological developments can be integrated
                discussion and many years of experience            guideline is also available that clearly explains        in an open and easy-to-understand way.
                of the expert contributors in the respective       the fundamentals of TSN.                                 This process supports the “living” PROFINET
                working groups ensure an accurate and                The PROFINET specification 2.4 and IEEE                standard, which has proven itself a million
                complete technical description.                    specifications are necessary fundamentals                times over and is still developed continuously,
                   In addition, both the initial implementations   above all for the developers of the basic                according to user needs and compatibly.
                as well as concepts for the certification were     technology of hardware and firmware. The
                created early on in parallel. The stability of     device manufacturers then simply use the                 News report provided by PI (PROFIBUS &
                the specification could thereby be tested          corresponding stacks or modules and no longer            PROFINET International).

      6                                                                                                       in d u s t r ial et h er ne t b o o k   7.2019
Using Ethernet & TSN for rail metro networks - The Industrial ...
Simplified Ethernet for rail

                                                                                                                                                                         Applications
               metro networks using TSN
  Two networking technology trends are helping to shape multiple trackside Ethernet networks. IEEE Time
 Sensitive Networks (TSN) technology and proposed redundancy protocols will help enable radical reduction in
 the complexity of rail metro Ethernet networks, assisting in reductions of both CAPEX and OPEX costs.

                                                                                                                                                        SOURCE: BELDEN
                                    Local                         Local                                             Local           Local
                                                                                                                                      Local
                                   Switch                        Switch                                            Switch            Switch
                                                                                                                                   Switch
   Trackside

               CBTC AP           CBTC AP                        CBTC AP        CBTC/CCTV AP    CBTC/CCTV AP        CBTCAP
                                                                                                                       AP          CBTC AP    CBTC AP

                                                                                                                        Key
                                                                                     Station
                                                                                                                        CBTC Netw ork A
                                                                                                                        CBTC Netw ork B

                                                                                                                        Combined Ne twork

  Combined Communications Based Train Control (CBTC) and Application (CCTV) Networks provide powerful solutions.

 FOR PASSENGER ACCESS TO THE INTERNET and       concerns and increasing urban mobility mean costs that the operator can control. The use
 other wireless services onboard and to both    that the demands on urban railway system of a CBTC system allows energy savings to be
 manage and control increasingly sophisticated  capacity have never been greater.                 made through the application of different
 trains, the rail metro communications network     Traditionally, increasing the capacity on an   driving profiles (such as coasting and
 philosophy is changing. Operators are          urban rail network has involved large levels of   reduced acceleration curves) when passenger
 increasingly making Ethernet the bearer of     capital expenditure on the rail infrastructure. demand is less; at off-peak travelling times,
 choice. This move to Ethernet-based networks   Typical solutions to capacity challenges may      for example. When coupled with passenger
 comes at a time when capacity demands on       have involved laying additional running lines, counting technology, this management of
 rail metro systems are greatly increasing due  perhaps boring new tunnels and lengthening the rail vehicles can be made fully automatic.
 to global trends that are driving the public   platforms to enable longer trains. These large       CBTC systems run over a digital networked
 transportation market.                         civil projects are not only expensive, they       radio system by means of antennas or radiating
    These trends are:                           are also potentially disruptive to running an     cable for the bi-directional communication
    • Urbanization                              operational service.                              between the track equipment and the trains.
    • Concern over greenhouse gases and            Through the use of exact, real- time, train The 2.4GHz band is commonly used in these
       global warming                           positioning information, Communications systems (public WiFi band), though other
    • Reducing carbon resources                 Based Train Control (CBTC) provides a solution alternative frequencies such as 900 MHz (US),
    • De-regulation                             to the capacity challenges and avoids the         5.8 GHz or other licensed bands may be used
    • Increased Digitalization – The Rail IoT   need for many of these expensive and              as well (the use of licensed bands is becoming
    This article briefly describes two of these disruptive civil engineering capital projects. more common to ensure that interference is
 trends and the resulting multiple trackside    An increased utilization of the existing rail     less likely).
 Ethernet networks. IEEE Time Sensitive         infrastructure is realized through the removal       To comply with these requirements, the
 Networks (TSN) technology is introduced and    of traditional fixed signaling blocks and         communications network being deployed
 then its use (along with redundancy protocols) instead managing train headways as well as        must be designed for the exclusive use of the
 is proposed to enable radical reduction in the speed and acceleration profiles continuously      CBTC system. Typically the communications
 complexity of rail metro Ethernet networks,    in real time. A CBTC system managing shorter, network is made up of two interlaced trackside
 hence reducing both CAPEX and OPEX costs.      lighter, faster trains running more closely       Ethernet networks, with the rail vehicle being
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                                                            will result in greaterUScapacity
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                                                                                                  in constant   wireless connection with at least
  Trends: multiple trackside networks vs. longer trains running on a fixed block one of the two networks.
                                                signaling system.                                    Wireless access points for each network are
  Increasing Urbanization Driving Metro            A large proportion of the total cost of spaced and placed down the length of the
  Capacity Demands                              running rail passenger vehicles is fixed for rail infrastructure. This interlaced architecture
                                                long durations (such as vehicle leasing or helps overcome any wireless handover delays
    The trend of increasing urbanization finance costs). Fuel or energy usage very between access points and the moving vehicle.
  coupled with climate change, environmental often represents the largest proportion of In addition, the CBTC communications network

                         7. 2019    i n d u str i a l e th e r n e t b o o k                                                                                             7
Using Ethernet & TSN for rail metro networks - The Industrial ...
OCC                                                        BOCC

                                                                                                                                                                                                                                          SOURCE: BELDEN
Applications

                     WLC1000                     WLC1000                       WLC1000                         WLC1000

                  MACH 4002 (L3)                MACH 4002 (L3)             MACH 4002 (L3)                  MACH 4002 (L3)

                  MACH 104 (L3)                 MACH 104 (L3)                           MACH 104 (L3)                MACH 104 (L3)                    MACH 104 (L3)                       MACH 104 (L3)

                  MACH 104 (L3)
                                                                   Phase I                                                             Phase II                                                             Phase III

                  MACH 104 (L3)                 MACH 104 (L3)                           MACH 104 (L3)                MACH 104 (L3)                    MACH 104 (L3)                       MACH 104 (L3)

                  MACH 1040 (L2)                MACH 1040 (L2)                         MACH 1040 (L2)               MACH 1040 (L2)                    MACH 1040 (L2)                      MACH 1040 (L2)
                                                                                                                                                                                                                     Legend
                                                                                                                                                                                                                          1Gbit/s Fiber
                                                                                                                                                                                                                          1Gbit/s TX

                                                                                                                                                                                                                          MRP Ring

                                          BAT-F           BAT-F                     BAT-F        BAT-F                   BAT-F        BAT-F             BAT-F           BAT-F
                                                                                                                                                                                                           (L2) Redundancy MRP-Rings
                                                 Trackside                              Trackside                             Trackside                      Trackside
                                                                                                                                                                                                           (L3) Redundancy H-VRRP Pairs

               This diagram shows one-half of the CBTC Ethernet network. The full dual network system will contain twice the hardware and interconnectivity.

               is ‘ring fenced’ to guarantee the bandwidth and                                 • reduced headway between trains                                 our journey less stressful. The number of
               latency performance criteria. This means that                                   • fewer onboard staff (perhaps no driver)                        Ethernet based applications that need a train-
               CBTC Ethernet networks exclusively carry data                                   • improved security                                              to-ground connection to function is on the
               relating to the safety-critical CBTC application.                               To understand onboard equipment reliability                      increase.
                                                                                            and to ensure that the train performs as                               These applications require a trackside
               Increasing Digitization and Passenger                                        expected, the goal is to monitor and collect                        wireless infrastructure and the ability to
               Expectations Driving Ethernet Network                                        data on a whole range of onboard systems.                           transfer the data to the remote control room
               Deployment                                                                   Increasingly, the data flow does not stop at                        or monitoring workstation. As we noted
                                                                                            just being onboard; diagnostic systems now                          previously, this data cannot be carried on the
               As requirements for trains become more                                       report back to depots before the train arrives                      CBTC Ethernet Communications infrastructure
               demanding, the diagnostic and control                                        for maintenance so that spares and tools can                        as the signaling application will no longer
               systems supporting them also need to grow.                                   be organized.                                                       have the guaranteed network performance
               Some of the demands include:                                                   Passenger Information Systems provide us                          needed. This means that more Ethernet
                  • increased fuel efficiency                                               with real-time information while ticketing,                         network infrastructure is required, including
                  • increased reliability                                                   seat reservation systems and WiFi access to                         an example of a deployed network for a
                  • shorter dwell times at platforms                                        the internet or entertainment systems make                          real-time video surveillance system.

                                                                                                                                                                                                                                            SOURCE: BELDEN
                                      OCC                                                         BOCC

                     WLC1000                      WLC1000                      WLC1000                         WLC1000

                    MACH1040                       MACH1040                   MACH1040                          MACH1040

                                                                          L3
                                                                        BTN(3
                                                                               rd

                                                                         party

                               G        G                                                                  G        G                                              G           G

                                                                                                                                                         MACH104                   MACH104
                    MACH104                 MACH104               Station #1...33              MACH104                   MACH104                                                                             Depot1/2
                                                                                                                                                         MACH102                   MACH102

                        RS20                 RS20                                                 RS20                   RS20                              RS30                    RS30
                                                                                                                                                                                                                        1000mit/s Fiber
                                                                                                                                                                                                                        1000mit/s TX
                      RS20                     BAT450-F                                        BAT450-F                   BAT450-F                   BAT450-F                      BAT450-F
                                                                                                                                                                                                                        100mit/s Fiber
                                                                                                                                                                                                                        100mbit/s TX
                                                                BAT450-F        A                                         A        BAT450-F
                                   Trackside                                                                                                                                         Legend                             MRP Ring
                                                                    OCTOPUS             OCTOPUS           OCTOPUS          OCTOPUS
                                   Onboard                                                                                                                                                                              CCTV gateway
                                                                                                                                                                                                              G
                                                                                                                                                                                                              A         CCTV agent
                                                                                                                                                                                                                     100nbit/s TX PoE

               Real-Time Video Surveillance Ethernet Network.

       8                                                                                                                                          in d u s t r ial et h er ne t b o o k      7.2019
Using Ethernet & TSN for rail metro networks - The Industrial ...
240 power budgets on any assignable port

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IEB112_p11.indd 11                                                                                      26.04.1917 10:23
Using Ethernet & TSN for rail metro networks - The Industrial ...
SOURCE: BELDEN
Applications

               Overall Trackside Network Architecture.

               Multiple Trackside Ethernet Networks                   • Highly limited latency fluctuations                -- published as Standard IEEE 802.1Qbv-20162
               Conclusion                                               (jitter)                                           -- is to utilize TDMA (Time Division Multiple
                                                                      • Extremely low packet loss.                         Access) to divide time into discreet segments
                  The deployment of CBTC and other trackside                                                               of equal length, so-called cycles. This allows
               networks means that there is a large amount          TSN mechanisms/interdependencies                       dedicated time slots to be provided for the
               of Ethernet equipment installed trackside to         TSN adds a level of determinism to Ethernet-           transmission of data packets with real-time
               backhaul the associated data to the Control          based data communication that is able to               requirements within the cycles. With the aid
               or Operational centers. To put the amount of         meet even the highest demands placed on                of the Time-Aware Scheduler, the transmission
               hardware being installed in our two examples         an Ethernet network. TSN has been conceived            of conventional Best Effort Ethernet traffic
               into perspective, the typical spacing of CBTC        as a modular system by which the precise               can be temporarily interrupted in order to
               wireless APs is 200m to 300m (dependent              characteristics of the implementation (and             forward time-sensitive data traffic within the
               on tunnel topography). Within a city metro           the associated hardware and software                   reserved time slots for high-priority traffic.
               system, stations are, on average, 1km apart          requirements) can be tailored to fit the               The Time-Aware Scheduler thus permits the
               (often less).                                        individual network requirements.                       prioritization of periodic real-time data in
                  This means that for a 30 km stretch of metro         Appropriately so, TSN is not made up of a           relation to conventional Best Effort data
               railway, there could be 240 wireless APs alone,      single standard document, but it is a family           traffic.
               made up as follows:                                  of standards which have been in development               Similar to the strict prioritization scheme,
                  • 30 stations with 4 APs each (120 devices)       by the IEEE 802.1 TSN Task Group1 since                the Time-Aware Scheduler utilizes the CoS
                  • CBTC Network A (500m apart) (60                 2012. These activities have yielded their first        priorities (PCP - Priority Code Point) that
                     devices)                                       results: central mechanisms of the TSN family          are present in the VLAN tag of the Ethernet
                  • CBTC Network B (500m apart) (60                 are already available as standard documents.           header. In this case, all Ethernet frames are
                     devices)                                       In order to give an overview of these new              processed until they reach the Time-Aware
                  When the associated cabling (copper and           technologies, the following sections will              gate queues at the output port. At this
               fiber), trackside switches and backbone data         address the most important TSN mechanisms              point, the Time-Aware Scheduler intervenes
               backhaul equipment are also considered, it’s         and their interdependence.                             in the packet processing. More precisely,
               obvious that the current methodology for                                                                    with the use of the Time-Aware Scheduler,
               network deployment in metro systems could            Time-Aware Scheduler                                   the selection of the next Ethernet frame to
               be made more efficient. Considerable cost            Until now, it was not possible with the strict         be transmitted is no longer just determined
               savings could also be achieved (both during          priorities of Class of Service (CoS) mechanisms        strictly by a hierarchy at the queue, but rather
               deployment and through the life of the               such as the IEEE 802.1Q to guarantee bounded           the state of the respective gates is also taken
               systems). Now, let’s explore Time Sensitive          end-to-end latency of time-sensitive data              into consideration. This state may be either
               Networking (TSN) and its potential to achieve        traffic. Due to queueing effects, an Ethernet          open or closed, based on actual time. Ethernet
               these network deployment efficiencies.               frame with low priority that is already in             frames that are waiting for transmission in the
                                                                    transmission could delay Ethernet frames of            associated queues will be considered in the
               TSN – Time Sensitive Networking                      even the highest priority at every Ethernet            packet selection, depending on these states.
               Time-Sensitive Networking (TSN) is currently         switch along the transmission path. As one of          For example, only the queue with a priority
               being developed at the IEEE as a novel               the central components of TSN, the Time-Aware          of 7 can be processed at a particular point
               technology that offers an entirely new level         Scheduler (TAS) introduces the possibility to          in time.
               of determinism in standard IEEE 802.1 and            assign specific time slices for transmission              The Gate Control List determines which
               IEEE 802.3 Ethernet networks. This means             based on the CoS Ethernet frame priority.              traffic queue is permitted to transmit at a
               that future communications networks in the           Thus, traffic of a specific priority is granted        specific point in time within the cycle. Besides
               transportation industry will be able to provide:     exclusive access to the transmission medium.           the states of the Time-Aware Gates, the Gate
                  • Calculable, guaranteed end-to-end               Forwarding and delivery of the Ethernet frames         Control List indicates the length of time for
                    latencies for traffic of different priorities   is guaranteed at a defined point in time.              which a specific entry will be active. In the
                    on the same network                                The fundamental idea of this TSN mechanism          case of the Gate Control List, the list mirrors

    10                                                                                                       in d u s t r ial et h er ne t b o o k   7.2019
Traffic Queue 7             Traffic Queue 6                                   Traffic Queue 1        Traffic Queue 0

                                                                                                                                                                           SOURCE: BELDEN
                                                                                                                                                                                            Applications
                                                                                                                                                O = Gate open
                                                                                                                                                C = Gate closed

                                                                                                                                            Gate Control List:

                                                                                                                                              TO: o CCCCCC
                                                                                                                                              T1: Coooooo
                                                                                                                                                  Repeat

             OK                               X                                            X                      X
  Time-Aware Gate             Time-Aware Gate                                  Time-Aware Gate        Time-Aware Gate
      Queue 7                     Queue 6                                          Queue 1                Queue 0

                                       Transmission Selection

The Time-Aware Scheduler implements the time-based prioritization.

the cycle that consists of a Best Effort phase,                      phase. Frame pre-emption makes it possible to       in order to ensure that the frames match the
as well as a phase with prioritized data traffic.                    reduce the guard band to the maximum size           correct time slots in each switch. This enables
                                                                     of one Ethernet framelet plus the maximum           the transmission of communication streams
Necessity of Guard Bands and Interruption                            remaining transmission time (63 byte times)         that can be transmitted through end- to-end
of Ethernet Frames                                                   that cannot be pre-empted any more.                 connections, with guaranteed latencies and
                                                                        In the case of a fast Ethernet network,          without queuing times.
   Due to the very poor predictability of                            for example, the dead time from each guard             This means, in particular, that all network
Best Effort traffic patterns, it is generally                        band can be reduced to ~0.12 ms and thus,           participants must possess a common
not foreseeable when a specific Best Effort                          a significant improvement of the use of the         understanding of time. Specifically, all
data packet will need to be processed. For                           bandwidth available can be achieved.                participants must know when a cycle begins
example, the transmission of an Ethernet                                Due to the fact that frame pre-emption is a      and which time slot is active in the cycle. In
frame in time slot 2 could be initiated too                          significant intrusion into the normal process       order to enable this, the use of a protocol for
late. This Ethernet frame would then, despite                        of Ethernet frame forwarding and processing,        time synchronization, such as the Precision
the use of the Time-Aware Scheduler, extend                          it is necessary for both devices of an Ethernet     Time Protocol (PTP) in accordance with IEEE
into the time slot number 1 of the subsequent                        connection (e.g. two Ethernet switches) to          15886 or any available IEEE 1588 profile, such
cycle. This would therefore result in a delayed                      announce their support for this mechanism           as IEEE 802.1AS7 is mandatory.
processing of real- time data and a violation                        through the use of the Link Layer Discovery             Both IEEE 1588 as well as IEEE 802.1AS
of guaranteed end-to-end latencies.                                  Protocol (LLDP) identified in IEEE802.1 AB5).       permit the synchronization of distributed
   In order to maximize the usable bandwidth                         Only with frame pre-emption support on both         clocks within a network with an accuracy of
for Best Effort Ethernet frames, the IEEE                            ends of the link can the feature be activated       under 1 µs. Implemented in hardware, timing
802 working group developed a method for                             on the corresponding end devices or switch          precision in the range of a few nanoseconds
Ethernet frame pre-emption (IEEE 802.1Qbu3,                          ports. With this, backwards compatibility with      can be achieved (Hirschmann PTP white
IEEE 802.3br4), which was completed in June                          existing Ethernet devices is maintained.            paper8). In contrast to the protocols known
2016. With this method, conventional Ethernet                                                                            from IT environments, such as Network Time
frames can be divided into partial packets                           Synchronous transmission cycles                     Protocol (NTP), IEEE 1588 doesn’t necessarily
(“framelets”) of as small as 64 bytes and each                       The Time-Aware Scheduler utilizes only local        have to utilize a global synchronization with,
framelet may be transmitted separately. This                         configuration data− the data that is available      for example, an atomic clock. More commonly,
permits starting the transmission of a large                         in a particular network device (end device or       the network participant with the most precise,
Ethernet frame, despite insufficient remaining                       switch). This configuration data consists of        freely running clock is determined with the
time within the Best Effort phase. The frame                         information about the lengths of cycles and         aid of the Best Master Clock (BMC) algorithm.
can be interrupted at the last 64 byte                               time slots, for example. Therefore, besides            This device then serves as the reference
boundary before the current time slot ends                           the Time-Aware Scheduler, close coordination        clock (Grandmaster Clock) against which
and can then completed in the next Best Effort                       between the devices in the network is required      all remaining network participants are

                        7. 2019    i n d u str i a l e th e r n e t b o o k                                                                                                                 11
SOURCE: BELDEN
                                                                      Cycle n                                                               Cycle n+1
Applications

                                                                        2                                                    1                                                                2

                                                                                                        Frame

                                                     VLAN Priorities 7,6,5,4,2,1,0                          G          VLAN Priority 3                                    VLAN Priorities 7,6,5,4,2,1,0

                  Time t

                                                                   Large frame is transmitted
                                                                   and violates the following
                                                                            time slice

                  Without Guard Band
                  With Guard Band
                                                                      Cycle n                                                               Cycle n+1
                                                                        2                                                    1                                                                2

                                                                                                        Frame                                                       Frame

                                                     VLAN Priorities 7,6,5,4,2,1,0                G                    VLAN Priority 3                                    VLAN Priorities 7,6,5,4,2,1,0

                  Time t

                            Guard band prohibits the                                                                                                             The guard band in TSN prevents Best Effort
                             start of the frame and
                           protects the following time
                                                                                                                                                                 frames from extending into a time slot
                                       slice
                                                                     G      = Guard Band                                                                         that is reserved for real-time data, but it
                                                                                                                                                                 decreases the available bandwidth.

               synchronized. For TSN, it is of primary                               1588 provides an additional IP (Internet         reference. That offers the option to use the
               importance that the time is synchronized to                           Protocol) encapsulation scheme for use in        global synchronization for unambiguous event
               all clocks within a network. The actual time of                       wide area networks (WANs). As a result of        logging, while the network-wide synchronized
               day, on the other hand, plays only a secondary                        the TSN standardization process, the existing    clock can be used for the Time-Aware
               role.                                                                 IEEE 802.1AS profile has been expanded by the    Scheduler, since in this case, synchronization
                  The IEEE 1588 profile, IEEE 802.1AS, follows                       addition of parameters from IEEE 1588 that       according to global conventions such as the
               the same fundamental synchronization model                            are required for use in automation networks.     leap second is not required.
               as PTP. It was originally developed to limit the                        For example, IEEE 1588 offers support            Among other things, this capability will also
               large number of configuration options to those                        for multiple time domains that can be            be included in the next version of this profile
               parameters that are relevant in local networks                        synchronized in parallel. Accordingly, with      with IEEE 802.1AS-Rev9.
               (LANs). For example, in case of the transport                         IEEE 1588, network participants can be             Since the current version of IEEE 1588
               technology and encapsulation, IEEE 802.1AS                            synchronized with a global time reference (as    was specified back in 2008, this technology
               is confined to Ethernet transport, while IEEE                         with NTP), as well as a second network time      for time synchronization has already been
                                                                                                                                                            established in many
                                                                                                                                                            markets and application
                                                                                                                           Common Timebase
                                                                                                                                                            areas. In some cases,
                                                                                                                                                            profiles for special
                                                                                                                                                                             SOURCE: BELDEN

                                                                                                                                                            applications, such as
                                                                                                                                                            the energy market, have
                                                                                                                                                            been developed and are
                                                                                                                                                            in use today. In these
                                         Time slot 1                                                                                                        cases, there is no need
                                         Time slot 2                                                                                                        to specifically utilize
                                                                                                                                                            IEEE 802.1AS for time
                                                                                                                                             Listener       synchronization, the
                     Talker
                                                                                                                                                            TSN mechanisms permit
                                                                  Industrial                 Industrial            Industrial                               the use of any arbitrary
                                                               Ethernet Switch            Ethernet Switch       Ethernet Switch
                                                                                                                                                            mechanism for time
                                                                                                                                                            synchronization.
                                                                                                                                                              Thus, depending on
                                                                                                                                                            the application area,
                                                                                                                                                            IEEE 1588 can be used
                                                                              Common Cycle                                                                  instead of IEEE 802.1AS,
                                                                                                                                                            with or without a specific
                Good time synchronization is a prerequisite for the TSN Time-Aware Scheduler.                                                               profile. In the future,

    12                                                                                                                            in d u s t r ial et h er ne t b o o k     7.2019
IEEE 802 does not intend to limit this freedom    reception (IEEE P802.1Qci10). In addition,         the network installed and operated by the rail

                                                                                                                                                        Applications
 of choice in regard to which protocol needs to    this mechanism allows discarding real-time         operator is now being utilized.
 be used for time synchronization. In any case,    data streams that use more than their reserved
 regardless of the synchronization protocol that   bandwidth, thus allowing the policing of           Summary and outlook
 is used, the quality of clock synchronization     streams.                                           The standardization process in the area
 that is achieved is very high in order for all       Finally, TSN can make use of already existing   of time-sensitive networking is not yet
 devices in the network to start-and-end cycles    Layer 2 security mechanisms, such as MACsec        completed and is expected to take a few
 and time slices at the correct points in time.    (IEEE 802.1AE11). This allows ensuring the         more years. Accordingly, there are various
                                                   authenticity of the sender so that only verified   TSN mechanisms that are currently still in the
 Preventing interfering traffic                    Ethernet frames are forwarded. This way, it        active standardization process. It is equally
 In a system in which all participants behave      is possible to handle a multitude of attacks       imaginable that additional mechanisms will be
 as expected, the TSN standards previously         and scenarios with erroneously configured          added to the already existing TSN family in the
 described offer all of the mechanisms required    network participants. With TSN, deterministic      future. Central mechanisms of the TSN protocol
 for deterministic data transmission. However,     data transmission with standardized Ethernet       family have, however, been completed and
 the mechanisms discussed so far require a         according to IEEE 802.1 and 802.3 is possible      have been demonstrated successfully.
 complete reception of frames, as well as          for the first time.                                  These mechanisms, such as the Time-Aware
 (partial) frame processing in a forwarding           Using TSN to guarantee the transmission         Scheduler, can already be integrated in
 switch or receiving end device. As a result,      latency of the CBTC data allows us to utilize      products and their benefits can be used
 misconfigured devices or malicious network        the CBTC network to carry the CCTV data from       immediately. Equally, through the IEEE
 participants can significantly interfere with     the station system, which reduces the number       802 standardization process, backwards
 the operation of TSN mechanisms such as the       of trackside APs needed on our example 30km        compatibility is ensured: TSN networks that
 Time-Aware Scheduler by sending data frames       length of metro line by 60 devices.                are already installed can still be used in the
 with erroneously assigned CoS priorities or by       This is a significant saving when all of        future. Therefore, TSN is no longer a future
 excessively stressing the resources assigned      the associated cabling and network switches        technology – its time has come.
 to them.                                          that are no longer required are also taken
 In order to counter this, an additional TSN       into account; by using TSN to guarantee the        R. Weatherburn – Vertical Marketing,
 mechanism is currently being developed            delivery of the CBTC data, all of the Ethernet     Transportation, C. Burns - Field Application
 within the IEEE 802.1 working group which         equipment is no longer required. In addition,      Engineering Manager, Transportation and
 allows discarding data frames that have           the costs associated with using leased lines       Dr. O. Kleineberg – Advanced Development,
 been erroneously assigned at the time of          for data backhaul are no longer required, as       Belden Corporation.

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Fast, reliable internet access
Applications

                      for trains leverages technology
                New cabling and connector technology is making fast, reliable Internet access possible on trains. A powerful
               data infrastructure is necessary to deliver the performance that customers expect, and new tool-free assembly
               and installation options provide PushPull convenience and weight reduction using only a single twisted pair.

               TRAIN TRAVELERS NOW EXPECT INTERNET                                                                                           As a result, there is no need for a permanent

                                                                                                                        SOURCE: HARTING
               access that provides a high-performance                                                                                    detachable connection to a housing via
               experience. They want to surf privately during                                                                             connectors, and Ethernet connections can be
               the train journey or use the compartment as                                                                                quickly and cheaply brought directly to the
               a mobile workstation. Railway operators are                                                                                circuit board. The combination of the modular
               increasingly offering an appropriate data                                                                                  preLink system and Etherrail cable is the ideal
               infrastructure to meet customer requirements.                                                                              matchup for cabling rolling stock. With easy-
                                                                                                                                          to-install connectors and cables, trains can be
               Importance of system cabling                                                                                               equipped with future-ready Gigabit Ethernet
               Solutions to ensure reliable and fast Internet                                                                             and make an important contribution towards
               in trains relies on new cabling systems and                                                                                providing the infrastructure for the mobile
               advanced technology solutions.                                                                                             workplace of the future.
                  Data networks in trains and buses can
               be implemented reliably and in future-                                                                                     Ethernet single twisted pair (SPE)
               proof manner using the preLink system and                                                                                  The goal of Ethernet via Single Twisted Pair
               EtherRail cables that are part of the HARTING                                                                              cable and small connectors according to IEC
               technology portfolio, and specially designed                                                                               63171-3 is to achieve weight savings while
               for railway requirements. With Ethernet via                                                                                offering identical performance. Under IEEE
               only one pair of wires, operators can reduce       Rail customers expect reliable Internet access.                         802.3bp (1000 BASE-T1), cable lengths up
               their operating costs and optimize their                                                                                   to 40 meters can transmit 1 Gbit/s -- while
               production with the tool-less PushPull system.     offers unparalleled flexibility and investment                          the cable length is about one-third less than
                  The central component of the preLink            security, especially over long periods of use                           conventional 8-wire Ethernet cable.
               system is the termination block, which allows      within railway technology scenarios. The                                   A standard Ethernet cable with four wire
               the cable connection to be performed quickly,      system simultaneously simplifies assembly,                              pairs for 1/10 Gbit/s Ethernet weighs about
               simply and reliably. The small size of the         making it both faster and more reliable.                                45 kg per kilometer. In contrast, a Single Pair
               preLink contact block makes it possible to                                                                                 cable with the same bandwidth weighs only
               prefabricate data cables separately from the       M12 connector technology                                                30 kg per kilometer. Since several kilometers
               train car and then install them in the former.     A current innovation that is being implemented                          of cable are installed in the cars of passenger
               A minimum hole diameter of just 12 mm is           in transportation systems is use of M12                                 trains alone, this offers a considerable savings
               sufficient to insert and route the cables.         sockets, which can now be connected via                                 potential in terms of vehicle weight.
                  Once the cables have been laid, the             preLink as well. The newly designed sockets
               appropriate connector is attached, depending       can be used both as a loose cable coupling                              Tool-less installation
               on the network device to be connected. Here,       as well as a housing feedthrough and be                                 HARTING PushPull technology simplifies
               both RJ45 and M12 D- and X-coded connectors        securely screwed here. The second innovation                            assembly and service in the railway sector
               (socket or pin) are available for data             is a preLink printed circuit board socket that                          while improving reliability. The solutions
               transmission of up to 10 Gbit/s. This unique       allows the user to connect pre-assembled                                consist of the circular M12 PushPull connector
               diversity of mating faces, in conjunction with     preLink cables directly to the printed circuit                          in a rugged metal housing, as well as the
               standardised preLink connection technology,        board without the need for detours.                                     lightweight, easy-to-use rectangular variant
                                                                                                                                          4 connector. Securely transmitting power,
                                                                                                                       SOURCE: HARTING

                                                                                                                                          data and signals up to Category 6A presents
                                                                                                                                          no difficulties with M12 and with variant 4.
                                                                                                                                             The advantage of PushPull connectors
                                                                                                                                          (circular or rectangular versions) lies in the
                                                                                                                                          tool-free installation. The connectors are
                                                                                                                                          simply gripped and attached. The connectors
                                                                                                                                          produce an audible “click” indicating that they
                                                                                                                                          have been securely locked and correctly mated
                                                                                                                                          – while saving up to 75% of installation time.
                                                                                                                                          Both connectors feature robust IP protection
                                                                                                                                          class 67 and are tested in accordance with fire
                                                                                                                                          protection standard EN 45545-2.

               Modular preLink components with powerful EtherRail cable assemblies for data networks on railways.                         Technology report by HARTING.

    14                                                                                                         in d u s t r ial et h er ne t b o o k       7.2019
10,000 40
                   Trade Visitors   Presentations
                                                      200
                                                    Industry Leaders

IEB113_p9.indd 9                                                       11.07.1928 16:30
EtherCAT G offers I/O response
Technology

                     for high-performance machines
              EtherCAT G uses 1 Gbit/s data transmission of standard Ethernet; while the EtherCAT G10 variant, presented
             as a proof-of-concept technology study, achieves data rates of up to 10 Gbit/s. The considerable increase in
             data rates compared with standard 100 Mbit/s EtherCAT significantly increases the possible data throughput.

                                                                                                                                                                                 SOURCE: BECKHOFF
             ETHERCAT REACHES A NEW PERFORMANCE LEVEL
             with the EtherCAT G technology extension
             through its capability to superimpose itself
             on Gigabit Ethernet for data-intensive
             applications. Compatibility with the globally
             established standard EtherCAT, which uses
             100 Mbit/s, and the same familiar ease of
             use are both guaranteed. Efficient operation
             of parallel network segments is possible with
             the branch concept introduced for EtherCAT
             G.Using the branch concept, EtherCAT G (1
             Gbit/s) enables a 2 to 7-fold increase in
             performance in relation to communication
             times and up to 10 times the bandwidth,
             depending on the application. 100 times the
             bandwidth is even possible with EtherCAT G10.

             Fully compatible extension
             With EtherCAT G, systems can leverage the high
             Ethernet data rates available today – without
             any changes to the EtherCAT protocol itself.
             The telegram sent by the EtherCAT master thus
             continues to pass through all network devices.
             Every EtherCAT slave reads the output data
             addressed to it on the fly and places its input
             data in the forwarded frame, but now with
             data rates of 1 to 10 Gbit/s. As before, the last
             device in a segment (or branch) will detect
             an unused port and send the telegram back
             to the master. The full-duplex property of the
             Ethernet physics is utilised for this capability.
                All other EtherCAT properties are fully          With the branch concept, mixed operation of EtherCAT, EtherCAT G and EtherCAT G10 is possible in one network.
             retained. Devices with three or four ports
             (junctions) make flexible topologies possible       necessary for physical access to the cables                   network and vice versa. However, all EtherCAT
             that can be adapted to machine architectures.       have been replaced by Gbit/s variants. The                    G devices will switch back to the 100 Mbit/s
             Machine modules can be plugged in or out            master therefore requires no new software,                    mode in such a mixed network. In order to
             by Hot Connect as required. An internal             just one Gbit/s port – which usually exists                   prevent this, the new branch concept makes
             network diagnostic function helps to minimise       in any case. The existing familiar cable types                EtherCAT branches possible, which enable the
             machine or plant downtimes and thus to              can also continue to be used: Cat.5e cables for               parallel operation of 100 Mbit/s segments in
             increase availability with familiar efficiency.     EtherCAT G or Cat.6 cables for EtherCAT G10.                  a 1 or 10 Gbit/s network through appropriate
             The integrated distributed clocks concept also        EtherCAT G slaves can be operated on an                     speed implementations. A branch of an
             remains available and enables synchronisation       existing EtherCAT master, provided it has                     EtherCAT G segment can be implemented on
             accuracies of better than 100 ns between            the Gbit/s port. Several special protocol                     a 100 Mbit/s network using the new EK1400
             devices. Conformity with the Ethernet               extensions for EtherCAT G are currently being                 EtherCAT G Coupler, allowing the extremely
             standard IEEE 802.3 is also guaranteed.             prepared that will allow for even higher-                     wide range of standard EtherCAT Terminals
                                                                 performance use. However, the extensions                      to be used within the EtherCAT G network
             Rollout of EtherCAT G                               required for this on the master side will not be              environment. The 1 Gbit/s speed of EtherCAT
             Performance and ease of use have been               mandatory for the network to be operational.                  G communication segment is retained.
             the hallmarks of EtherCAT communication.                                                                            The branch concept offers another crucial
             The same applies to EtherCAT G. Not only            Branch concept for mixed operation                            efficiency benefit: minimised propagation
             the protocol, but also the fundamental              EtherCAT and EtherCAT G can be operated                       times. The CU14xx multi-port branch
             mechanisms and the configuration options            within the same network, i.e. EtherCAT G                      controllers are designed for this purpose
             remain the same. Only the function blocks           slaves will work in a 100 Mbit/s EtherCAT                     and enable the interconnection of several

   16                                                                                                            in d u s t r ial et h er ne t b o o k   7.2019
EtherCAT and EtherCAT G segments. Individual                     to be transmitted within a few microseconds.
branches are addressed with a single telegram                    This would hardly be possible without the high
from the master, which will then be processed                    performance of EtherCAT G.
simultaneously. This makes shorter signal                           These two sample calculations illustrate the
propagation times possible and shorter                           boost in performance or the savings in data
communication and cycle times, because the                       transmission time that can be achieved with
telegram of a segment travels directly from the                  EtherCAT G and the branch concept.
branch controller back to the master and not
through all other connected segments as well.                    Accelerating communication times: 128
                                                                 servo axes in 34 µs
Disclosure and availability                                         • A machine network with 128 servo axes
In the coming months, the FB1400 EtherCAT                              was selected as the initial application.
G piggyback controller board will be available                      • A "standard data width" of 8 bytes in and
for the EL9820 EtherCAT evaluation kit.                                out per device results in a total of 1024
The FB1400 will have an FPGA with a fixed                              bytes in and out per cycle. With classic
configuration as an EtherCAT G slave controller                        EtherCAT devices, taking into account
(ESC). If necessary, customers can then also                           hardware propagation delay times and
create and use their own ESC configurations                            telegram lengths, a communication time
with the planned IP core for EtherCAT G. This                          of 237 µs will result.
will give EtherCAT users as well as master                          If standard EtherCAT devices are now
and slave manufacturers ample opportunity                        replaced by EtherCAT G devices, the
to evaluate the new technology. Availability                     communication time can be reduced to 150 µs
of the EK1400 EtherCAT G Bus Coupler is                          just on account of the shortened frame length
scheduled for the second half of 2019. It                        due to the higher data rate. If the branch
will offer branch controller functionality and                   concept is used and the complete network
enables direct connection of all EtherCAT                        is divided into eight EtherCAT G segments
Terminals as well as all other EtherCAT                          with 16 servo drives each, a communication
products in EtherCAT G networks. Further                         time of only 34 µs can be achieved – i.e.
products will follow, such as 3-port and 8-port                  communication is now 7 times faster.
branch controllers, an EtherCAT G junction,
an EtherCAT G10 branch controller and an                         Using the bandwidth advantage: scanning
EtherCAT G10 piggyback controller board.                         200 analog inputs with 100 ksamples/s
  A disclosure and introduction of the                              • An measurement Condition Monitoring
EtherCAT G/G10 protocol by the EtherCAT                                application where a 10 km-long conveyor
Technology Group (ETG) is planned for this                             belt is monitored.
autumn. As with EtherCAT more than 15 years                         • Application consists of 200 analog
ago, all ETG member companies will be able to                          channels (±10 V) with 100,000
use the extension and benefit from it.                                 samples/s (10 µs measurement interval)
                                                                       per channel, which have to be scanned
Applications & performance                                             with a cycle time of 1 ms.
For most present-day applications the                              The present-day solution consists of four
high performance of standard EtherCAT is                         independent 100 Mbit/s EtherCAT networks,
fully adequate. Accordingly, EtherCAT G                          each with 26 two-channel analog input
communication was developed with extremely                       terminals with oversampling function
large-scale applications and many devices                        (EL3702). Eight telegrams with 1313 bytes
in mind as well as the increasing use of                         each are required in every EtherCAT network,
particularly data-intensive devices such as                      resulting in a required bandwidth of 322
vision cameras, complex motion systems or                        Mbit/s. Thus, each of the four networks
measurement applications with high sampling                      utilises 88% of the available bandwidth.
rates. Machine vision, condition monitoring                         If the four EtherCAT networks are now
or the innovative transport systems XTS                          replaced by an EtherCAT G network and the
and XPlanar require transmission of several                      EK1100 Bus Couplers by EK1400 EtherCAT G
hundred bytes of process data per cycle for                      Bus Couplers (branch controllers), it is possible
each device. In conjunction with short cycle                     to continue to use existing standard EtherCAT
times of less than a millisecond, the high                       Terminals. With the same cycle time (1 ms),
transmission bandwidths provided by EtherCAT                     bandwidth utilisation of only 350 Mbit/s
G are called for in this context.                                results in just one EtherCAT G network. The
   The first practical EtherCAT G application                    remaining bandwidth of 650 Mbit/s enables
is the XPlanar transport system. This planar                     an extension of the channels and the support
motor system enables motion control and                          of even higher analog sampling rates.
highly precise positioning of passive free-
floating movers with six degrees of freedom.                     Dr. Guido Beckmann, Sr. Management Control
Due to the continuous position feedback                          System Architecture and Thomas Rettig, Senior
required for the unique new system, extremely                    Management Control System and Communication
large data quantities are produced that have                     Architecture, Beckhoff Automation.

                     7. 2019   i n d u str i a l e th e r n e t b o o k                                              17
Mobile automation solutions
Technology

                      for intelligent machinery
              The challenge for manufacturers of agricultural and construction machinery is how to implement intelligent
             semi autonomous machine functions quickly and maintain them long term. Working with a control system
             partner provides automation technology solutions similar to what is found in industrial manufacturing.

                                                                                                                                                                                              SOURCE: B&R
             Builders of agricultural and construction machinery can leverage all the benefits of state-ofthe-art automation including safety technology and cloud connectivity.

             MANUFACTURERS OF AGRICULTURAL AND                            networked machines, cloud connectivity,                          Rugged control and HMI
             construction machinery face the challenge of                 digital process chains and integrated safety                     The situation faced by agricultural and
             implementing intelligent (semi)autonomous                    and security are growing increasingly                            construction machinery builders has prompted
             machine functions quickly and maintaining                    important for mobile equipment as well.                          B&R to apply its automation technology
             them long term.                                              Big-name manufacturers are driving these new                     to mobile machinery. A great deal of the
               The costs of developing such solutions                     functions forward in the area of agricultural                    technology developed over the past 35
             in-house are prohibitively high, however.                    and construction machinery.                                      years for industrial use translates very well
             A technology partner with a comprehensive                       To remain competitive, small and mid-sized                    to agricultural, construction and municipal
             automation system is therefore a perfect fit                 manufacturers must follow suit. The question                     applications.
             for small and mid-sized mobile equipment                     is: how? Establishing an in-house engineering                      Essentially, all that remained for B&R was
             builders.                                                    department from the ground up to perform the                     to make its controllers and HMI units suitable
               Today’s agricultural and construction                      necessary R&D is an enormous investment. The                     for mobile use. Rugged X90 control and I/O
             machinery is equipped with advanced                          much easier alternative for manufactureres                       control system technology can withstand
             functionality that is very similar to what is                is to work side-by-side with an experienced                      temperatures from -40 to 85°C as well as
             found in industrial manufacturing. State-                    technology partner to complete automation                        shocks and vibrations while it is also resistant
             of-the-art technology such as intelligently                  tasks.                                                           to salt, UV light and oil. The modular control

   18                                                                                                                        in d u s t r ial et h er ne t b o o k   7.2019
SOURCE: B&R
        solution is fully interoperable with the rest of
        B&R's technology platform.

                                                                                                                                                                                    Technology
          As a result, it is programmed using the
        Automation Studio engineering tool and is also
        capable of hard real-time communication via
        the POWERLINK industrial Ethernet protocol.

        Scalable hardware platform
        The hardware platforms have been designed to
        be modular and scalable. For the X90 system,
        modular means that the machine manufacturer
        can select from a variety of option boards to
        implement the functions needed, including
        additional I/Os and interfaces. Scalable
        means users are able to choose from a range
        of performance classes – ensuring consistent
        solutions for basic to high-end machines.

        Ready-made software components
        There is more to the solution than the
        hardware alone. The mapp Technology toolkit
        provides more than 200 preprogrammed
        software functions in Automation Studio. The        The X90 control system technology enables mobile machines to be equipped with functions that make them
        use of mapp technology provides solutions           compatible with the Industrial IoT.
        for web-based HMI, control, service, data
        monitoring and more.                               Integrated safety                                        Smart machines
          It also makes it easy to implement serial        Safety technology plays a key role in                    The X90 control system enables mobile
        kinematic systems like those found in an           automation and should not be underestimated.             machines to be equipped with functions that
        excavator arm. Application engineers simply        Manufacturers can find helpful information on            make them compatible with the Industrial
        drag and drop the desired functions into           the topic in the Machinery Directive 2006/42/            IoT. The X90 system can collect data, analyze
        the application and enter the corresponding        EC, which also applies to mobile machinery in            it locally and send it to an edge server or
        parameters.                                        the European Economic Area, Switzerland and              directly to the cloud via OPC UA. Condition
          There’s no need for the programming work         Turkey. It also contains harmonized standards            monitoring and remote maintenance can also
        that would traditionally be necessary. All         that apply internationally.                              be implemented.
        mapp functions are linked to one another and         Developing integrated safety solutions                    This allows both builders and operators to
        exchange data automatically. This significantly    in-house is costly and complex, however.                 track the health and performance of tractors,
        reduces the development overhead for new           The technology relieves mobile machine                   excavators and other vehicles at all times. The
        applications.                                      manufacturers of this burden. With                       goal is to help agricultural and construction
          The product platform has also been designed      the integrated safety solution, safety                   machine builders of all sizes stay competitive.
        so that, once application software has been        applications can be created from pre-certified           The benefits of safety technology and cloud
        written, it can run on any hardware. This          software blocks. The user simply links the               connectivity are all easily within reach.
        makes it easy to switch from a basic to a          blocks together in the Automation Studio
        high-end machine. For customers, that means        development environment, considerably                    Stefan Taxer, Product Manager - Mobile
        future-proof return on investment.                 reducing the programming overhead.                       Automation, B&R Industrial Automation.

                                                                                             WHILE OTHERS THINK
                                                                                             ABOUT THE IIOT
                                                                                             … we are already there.

                                                                                             Networks and computers for a smarter industry.

                                                                                               Powerful computers designed for your needs
                                                                                               Secure and reliable networks – anywhere, anytime
                                                                                               Vertical integration from SCADA to field device

                                                                                             www.moxa.com

25_ME_AZ_IIOT_IEB_230x96+3mm_E_DU15032019.indd 1                                                                                                                      15.03.19 11:28
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