az120 industrial network protocols - freescale semiconductor

TM

Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2009.

(Part 1) Industrial ControlAZ120 Industrial Network Protocols

July, 2009

Alexandra DopplingerGlobal Industrial Segment Lead –

Factory Automation & Drives

TMFreescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2009. 2

Agenda

►Factory Automation Market•

Target Applications•

Freescale Alignment with Trends•

Industrial Network Protocols used in Factory Automation ApplicationsMarket OverviewFreescale and Protocol Vendor Support

–

PowerQUICC®, QorIQ™, mobileGT®, i.MX and ColdFire®

processors

►Protocol Description, Solutions and Enablement•

Industrial Fieldbus ProtocolsPROFIBUS, CANopen, DeviceNet, Modbus RTU

►These topics are continued in “Industrial Network Protocols (Part 2)”•

Industrial Ethernet ProtocolsPROFINET, EtherNet/IP, Modbus TCP, EtherCAT

•

Industrial Wireless ProtocolsZigBee®, WirelessHART™, ISA100.11a


Factory Automation Market

Industrial Peripherals

Industrial Drives

Human Machine Interface (HMI)

Industrial Networking

Industrial Control

Factory Network

http://news.thomasnet.com/images/large/539/539874.jpg

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http://images.google.com/imgres?imgurl=http://product-image.tradeindia.com/00208545/s/Stepper-Motor-Drive.jpg&imgrefurl=http://unisys.tradeindia.com/Exporters_Suppliers/Exporter14236.350C.16603P/Stepper-Motor-Drive.html&h=120&w=120&sz=4&hl=en&start=173&usg=__i6YSb_0DlY_KMhzheknJMxvq7Lc=&tbnid=V_lEfESALt942M:&tbnh=88&tbnw=88&prev=/images%3Fq%3Dmotor%2Bdrive%2Bautomation%26start%3D162%26gbv%3D2%26ndsp%3D18%26hl%3Den%26sa%3DN


Factory Automation – Industrial Control and Networking

►Factory Automation equipment is ruggedized for harsh environment and communicates with industrial protocols

► Industrial Control•

Programmable Logic Control (PLC)•

Programmable Automation Control (PAC)•

DCS•

Process/temperature control•

Motion/position control

► Industrial Networking (wired and wireless)•

Routers and Gateways•

Managed and Unmanaged Switches•

Converters and Hubs


Factory Automation – Freescale Alignment with Trends

Market Trend Freescale Alignment with Customer Requirements

Reuse software, hardware, and tools across platforms

►

A history of shipping industrial products 10 to 15 years, with high quality and strong customer support

►

Processor performance from 80 to >3000 DMIPS in harsh environments, from -40C to 85C ambient

►

Increasing enablement to leverage ruggedized Power Architecture®, ColdFire® and i.MX processor portfolios

Reduce power consumption

►

DSC portfolio for cost-effective and efficient motor control►

MPU <1 W max, 400 DMIPS and <4 W max, >1000 DMIPS, with power management

Migrate from fieldbus to standardized Ethernet and wireless

► Many devices support both legacy fieldbus and industrial Ethernet and/or wireless

► Increasing 3rd party support for key protocols

Cost-effective safety and security

►

Secure SRAM, on-chip data fusing to protect against IP cloning►

Hardware encryption to protect against network data hacking ►

Parity, watchdog and ECC protection against soft errors

TM

6Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2009.

Industrial Network Protocols

Used in Factory Automation Applications


World Market – Industrial Protocols

►Market share change from 2005 to 2010:•

Ethernet (all versions) +8%•

Modbus RTU (non-Ethernet version) -3%•

CAN -2%•

Others +/-

1% Source: IMS Research, November 2006

2005 2010 CAGRIndustrial Nodes 13.5 M 24.8 M 13%

Market Share (2010) > 20% > 10% < 10%Network Protocols Ethernet PROFIBUS,

DeviceNet, AS-Interface, Foundation Fieldbus, CC-Link

Others


Most Significant Industrial Network Protocols

►

Standard Ethernet TCP/IP protocols most common of Ethernet-based nodes•

6.5 Mu Ethernet TCP/IP nodes installed by 2006; 24 Mu by 2011; CAGR 24.3%

►

Many deterministic industrial Ethernet protocols use a form of IEEE®

1588•

For clock synchronization through the Ethernet network

Field Bus (Discrete or I/O oriented) Industrial Ethernet*Most popular fieldbus solution. 23.3M nodes installed by 2007; 24% growth (PTO 2008). Supported by Siemens.

1.6 Mu PROFINET nodes installed by 2008; 40% growth (PTO 2009) Supported by Siemens.

CIP application layer on CAN. Very popular and still growing.Supported by Rockwell.

CIP application layer on Ethernet. Growing fast. Supported by Rockwell.

Modbus RTU is a widely used fieldbus solution, but losing share.Developed by Schneider.

Modbus TCP/IP is a widely used Ethernet solution, but growing less rapidly in many markets (Schneider)

CAN

Very popular SAE-sponsored standard but losing share in factory automation market

May dominate due to technology and ease of use. Predict >1 Mu by 2011. Supported by Beckhoff.

IEEE® 1588


NRT

RT

IRT

Deterministic1 to 100 ms Cycle Time

Deterministic< 1 ms Cycle Time

Real-time Determinism in Industrial Networks

Non-deterministic> 100 ms Cycle Time

•Sensors•Valves•Data scanner•Inventory Management

•Motor Drives•Motion Control•Synchronized Servos

•Conveyor belts•Picker arms•PLCs, I/O Control

Target Applications Protocols

NRT

RT

IRT

DeterministicJitter matters for Sync1 to 100 ms Cycle Time

Deterministic< 1 us Jitter

< 1 ms Cycle Time

Non-deterministicJitter doesn’t matter> 100 ms Cycle Time

IEEE® 1588 Precision Time ProtocolVERY Jitter sensitive; Cycle Time does not matter

Number of Applications

RT

IRT


Processors for Industrial Control, Networking and HMI

Process Control~100 DMIPS< 0.5 W< $5

I/O Control200 –

400 DMIPS< 1

W< $10

PLC/PAC and HMI300 –

800 DMIPS< 1.5 W< $10 -

20

High-End PLC/PAC500 –

1500 DMIPS< 2.5 W –

5 W> $15

2 0 0 8 2 0 0 9

High-End Networking1000 DMIPS and up4W -

10 W> $20

MCF5225xMCF5227x

MCF5445x

i.MX35x

i.MX25x

MPC8360MPC837x

MPC8544MPC8536

MPC8313

MPC5121e/23

MPC8314/15

MPC8610

i.MX31i.MX27L

MPC551x*

ARM®ColdFire®

Power®

LCD Control

MPC8640

MCF52235

MCF532x

i.MX51xMPC5xxx

P1020 QorIQ*

P1011 QorIQ

P2020 QorIQ*P2010 QorIQ

Pin Compatible

P10xx QorIQ

MCF5xxx


Protocol Vendor Support for Industrial ProtocolsIndustrial Network Protocol

ColdFire PowerQUICC

DoGav Systems

IEEE® 1588


IXXAT Automation GmbH

► IXXAT is a German-based leading supplier for embedded communication systems for industrial and automotive applications

•

Established in 1987 with 20 profitable growth years2006 sales of $16.7M worldwide70 employees (most are developers)Represented globally in >15 countriesWeingarten, Germany and New Hampshire, USA

•

Contact Bill [email protected] Bedford Center Rd., Bedford, NH 03110603-471-0800 X102

•

Download free eval from www.ixxat.com

►PowerQUICC®

Processors•

IEEE®

1588 (available)•

POWERLINK (under development)•

CANopen (under development)

►ColdFire®

Controllers•

EtherNet/IP™

(available)•

DeviceNet™

(available)•

CAN and CANopen (available)•

IEEE 1588 (available)•

POWERLINK (under development)

Application

CPU

Protocol Stack

CAN or Ethernet Interface

I/O

mailto:[email protected]

http://www.ixxat.com/


Real Time Automation

►RTA is a USA-based leading supplier of industrial protocols and solutions

•

Established in 1999 by John Rinaldi15 employees in Milwaukee, Wisconsin, USAFocus on networking, control and developers"Media is irrelevant“

•

Contact John [email protected]

•

Download eval info from www.rtaautomation.com

►PowerQUICC®

Processors•

EtherNet/IP™

(available)•

DeviceNet™

(available)•

Modbus (available)•

PROFINET RT (under development)

►ColdFire®

Controllers•

EtherNet/IP™

(available)•

DeviceNet™

(available)•

Modbus (available)•

CANopen•

PROFIBUS/PROFINET

ROYALTY FREEPOWERQUICC ETHERNET/IP

CLIENT & SERVERANSI C SOURCE CODE


http://www.rtaautomation.com/


DoGav Systems Ltd.

►DoGav Systems Ltd. is an Israel-based software solution provider who has provided microcode support for PowerQUICC >10 years

•

Established 198410 years experience in PowerQUICC microcode design servicesOver 24 years of experience with Freescale/Motorola

•

USA sales based in New York, USA•

~5 Employees in Petach

Tikva, Israel

►Contact David Gabbay•

[email protected]

+972-3-933-7197•

18 Nahum St. Petach

Tikva, 49247 Israel•

www.dogav.net

► PowerQUICC®

processor support (CPM & QE)•

PROFIBUS DPv1 (alpha demo available)



National Semiconductor

►National Semiconductor is a USA-based supplier of industrial Ethernet PHYs

•

Represented globally•

Contact Fred Weber, Product Marketing Manager, Interface Division

[email protected](631) 673-4097

•

www.ethernet.national.com

►PowerQUICC®

, i.MX and ColdFire®

Processors with Ethernet MAC•

10/100 Precision PHYTER adds IEEE®

1588 Time Sync Protocol

•

NATIONAL DP83640 PHYTER jitter <3 nsTypical competitor PHY has ~20 ns jitter

•

MCF5234 / M5234BCCKIT eval board

TX

RX

TX

RX

TX

RX

TX

RX

10BASE-T

100BASE-TX

or

100BASE-FX

MII

Port

B

MII

Port

A

10BASE-T

100BASE-TX

or

100BASE-FX

Channel B

Channel A

LatencyTX_CLK->TD T2.6.1 60nS

RD->CRS(ON) T2.9.1 200nSRD->CRS(OFF) T2.7.1 240nSRD->RXD1 T2.6.2 260nSX1->TD T2.26.4 170-190nS

RD->CRS(ON) T2.27.3 200nSRD->CRS(OFF) T2.27.4 280nSRD->RXD T2.27.5 400-420nS

RM

II

DP83848

MII


http://www.ethernet.national.com/

TM

16Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2009.

Industrial Fieldbus Protocols

PROFIBUS, DeviceNet™, Modbus RTU, CANopen


PROFINET Trade Organization (PTO)

►PTO supports PROFIBUS and PROFINET•

Evolved from original PROFIBUS International (PI)•

Open standards for factory automation, safety, drives and motion

control

►PROFIBUS International (PI) formed 1989:•

25 Regional PROFIBUS Associations since 1989•

1300 member companies include all major PLC/DCS vendorsSiemens, GE Fanuc, Hilscher, Invensys, Yaskawa, Turckwerks Industrial Automation, Softing, Woodhead…

–

>400 engineers in 40 working groups •

Accredited Competence Centers


► World’s leading fieldbus•

>20 million PROFIBUS devices

installed•

Open standard started by Siemens in 1989► RS485-based differential physical signaling

•

PROFIBUS ASIC contains stack and MAC► Multiple PROFIBUS versions

•

DP, FMS, PA► Supports up to 127 nodes at 1000 Mbps

•

244 Bytes/Message, 12 Mbaud► Master/Slave “polling”

type network

►Key Points•

World’s leading fieldbus•

Very fast•

ASIC based with RS485 differential physical signaling

►Advantages•

High speed•

Highly deterministic •

ASIC implements communications stack •

Universal acceptance in Europe►Disadvantages

•

Higher cost than other fieldbus options•

No bus power•

Traditional master/slave model

Fieldbus - PROFIBUS

www.profibus.com


OSI Model

Data Unit Layer Function

Host Layers

Data

Application Communication Language

Presentation Not used

Session Not used

Segments Transport Not used

Media Layers

Packets Network Not used

Frames Data Link Physical Addressing (MAC and LLC)

Bits Physical Two-wire Interface

PROFIBUS uses only OSI layers 1-2 and 7


Industrial Control, Networking and HMI


I/O Control200 –

400 DMIPS< 1

W< $10


800 DMIPS< 1.5 W< $10 -

20


1500 DMIPS< 2.5 W –

5 W> $15

2 0 0 8 2 0 0 9


10 W> $20

MPC8360

ARM®ColdFire®

Power®

LCD Control

P102x QorIQ*

P101x QorIQ

Pin CompatibleMPC832x

►PROFIBUS can run fully on PowerQUICC processors with programmable QUICC Engine™

controller•

MPC8360, MPC8323 and QUICC Engine-

based QorIQ devices

Implement data-link and network layers with programmable QUICC Engine

•

DoGav Systems demonstrated MPC8323 alpha microcode at FTF, Jun/08

►All other devices support PROFIBUS by connecting 3rd-party ASIC


► Industrial automation protocol based on Controller-Area-Network (CAN)

•

Developed by CAN-in-Automation (CIA) user group as a standardized solution for distributed automation systems

European standard CENELEC EN 50325-4 (2002)SAE sponsored CAN Protocol J1939

►

Master/Slave connection set•

Cyclic/COS data transfer modes•

Peer-to-peer messaging (not connection-

based)

•

Object oriented•

Extensive parameter group data definitions

►Key Points•

Supports exchangeability and interoperability of devices from different manufacturers

•

DeviceNet and CAN share same physical signaling, MAC and bitwise arbitration collision control

►Advantages•

Widely available with protocol stacks and tools for consumer, medical and industrial applications

•

Largely broadcast data at various rates►Disadvantages

•

Complex specification•

Little conformance testing available

Fieldbus – CANopen and CAN

www.can-cia.de/canopenwww.sae.org/products/j1939.htm

http://www.can-cia.de/canopen

http://www.sae.org/products/j1939.htm


CANopen Reference Model

Application

Device Profilefor Generic I /O

ModulesCiA DS 401, V 2.1

Device ProfileDrives & Motion

ControlCiA DSP 402,

V2.0...

Interface and Device Profile for IEC 61131-3 Programmable

Devices CiA DSP 405, V2.0

...

CANopen Application Layer and Communication Profile ( CiA DS 301, V 4.02 )

and Framework for CANopen Managers and

Programmable CANopen Devices ( CiA DSP-

302, V 3.3 )

CAN Physical Layer

( ISO 11898 )

CAN Data Link Layer ( ISO 11898 )

CAN Bus


Object Dictionary

CANopen Device Model

Application Process

Logical addressing scheme for accessing communication and application parameters, as well as data and functions

Device functionality

-

Functions

- Data

-

Parameters I / O

Sig

nals

Proc

ess

CA

N B

us

Communication Interface

NMT, SYNC, Emergency, Time Stamp Messages

TPDOs

RPDOs

Client SDOs

Server SDOs


Industrial Control, Networking and HMI – CAN Support


I/O Control200 –

400 DMIPS< 1

W< $10


800 DMIPS< 1.5 W< $10 -

20


1500 DMIPS< 2.5 W –

5 W> $15

2 0 0 8 2 0 0 9


10 W> $20

MCF5225xMCF5227x

i.MX35x

i.MX25x

MPC5121e/23

MPC551x*

ARM®ColdFire®

Power®

LCD ControlMCF52235

MCF532x

MPC51x

P10xx QorIQ

MCF5xxx

►CANopen can run fully on these processors with on-chip CAN controller

►Other devices support CAN by connecting external CAN controller

•

Freescale CAN PHY MCZ33897


► DeviceNet is CIP Application Layer on CAN► Trunk line with drops► Supports up to 64 nodes with multiple

masters► Node removal/insertion under power► Cable includes power and data► 125K, 250K and 500K baud rate► Supported by non-profit Open DeviceNet

Vendors Association (ODVA)

►Key Points•

Application layer on CAN•

Two types of messages –

Explicit and I/O

•

Object-based representation•

CIP –

Common Industrial Protocol

►Advantages•

Standard set of services and messaging•

I/O messaging is simply I/O data exchange

Both sides agree on message contents•

Explicit messaging transfers specific dataPacket contains message identification

Fieldbus – DeviceNet™

www.odva.org

http://www.odva.org/


DeviceNet Object Model

DeviceNet Network

Discrete IOObject

IdentityObjectModbus Slave

Object

Modbus MasterObject

ASCII DataObject

DeviceNetObject

Analog IOObject

Connection Object

AssemblyObject


Object Representation

CIP Application Layer Explicit, I/O, Routing

Application Object Library

SemiDevices

PneuValve

ACDrives

PositionControllers

OtherProfilers

DEVICENET CONTROLNET Future ?UPD TCP

Future ?ETHERNETCONTROLNETCAN

CIP

PhysicalLayer

Transport Data Link

ApplicationLayer

ApplicationLayer

IP

Encapsulation


CIP Object Library

► Register► Discrete Input Point► Discrete Output Point► Analog Input Point► Analog Output Point► Presence Sensing► Parameter► Parameter Group► Group► Discrete Input Group► Discrete Output Group► Discrete Group► Analog Input Group► Analog Output Group► Analog Group► Position Sensor ► Position Controller Supervisor

► Position Sensor ► Position Controller Supervisor► Analog Input Group► Analog Output Group► Analog Group► Position Sensor ► Position Controller Supervisor► Position Controller► Block Sequencer► Command Block► Motor Data► Control Supervisor► AC/DC Drive► Acknowledge Handler► Overload► Soft Starter


Industrial Control, Networking and HMI – DeviceNet Support


I/O Control200 –

400 DMIPS< 1

W< $10


800 DMIPS< 1.5 W< $10 -

20


1500 DMIPS< 2.5 W –

5 W> $15

2 0 0 8 2 0 0 9


10 W> $20

MCF5225xMCF5227x

i.MX35x

i.MX25x

MPC5121e/23

MPC551x*

ARM®ColdFire®

Power®

LCD ControlMCF52235

MCF532x

MPC5xxx

P10xx QorIQ

MCF5xxx

►CANopen can run fully on these processors with on-chip CAN controller

►Other devices support CAN by connecting external CAN controller

•

Freescale CAN PHY MCZ33897


► 1960s technology► Simple, concise communication strings► RS232/422/485 physical layer► Devices modeled as Registers and Coils► Well-defined instruction set► 1 Master, 254 Slaves► No formal certification

►Key Points•

All devices in the system should support Modbus

•

Handy configuration tool•

Most customers can use it•

Easy access to gateways for other networks

► Advantages•

Open and widely distributedFree tools on the web

•

Clear/concise command set•

Large installed base•

Low-cost implementation► Disadvantages

•

Low speed -

not real time•

Source/destination network model•

Very difficult to troubleshoot

Fieldbus - Modbus RTU

www.modbus.org+1 508-435-7170

[email protected]

http://www.modbus.org/



Industrial Control, Networking and HMI – Modbus RTU Support


I/O Control200 –

400 DMIPS< 1

W< $10


800 DMIPS< 1.5 W< $10 -

20


1500 DMIPS< 2.5 W –

5 W> $15

2 0 0 8 2 0 0 9


10 W> $20

MCF5225xMCF5227x

i.MX35x

i.MX25x

MPC5121e/23

MPC551x*

ARM®ColdFire®

Power®

LCD ControlMCF52235

MCF532x

i.MX51xMPC5xxx

P10xx QorIQ

MCF5xxx


Summary

Freescale aligns with Factory Automation market requirements

Many devices support both legacy fieldbus and industrial Ethernet protocolsPowerQUICC®, QorIQ™, mobileGT®, i.MX and ColdFire® processorsSolutions, enablement and 3rd party protocol stacks available

PROFIBUS, CANopen, DeviceNet™, Modbus RTUPROFINET, EtherNet/IP™, Modbus TCP, EtherCATZigBee®, WirelessHART™, ISA100.11a

Devices are ruggedized with long life and reliabilityIndustrial products ship 10+years, with high quality and strong customer supportProcessor performance from 80 to >3000 DMIPS, for fanless operation at -40C to 85C ambient

Energy EfficiencyMPU <1 W max @ 400 DMIPS and <4 W max @ >1000 DMIPS, with power managementDSC portfolio for cost-effective and efficient motor control

Cost-effective safety and security on-chipProtect against IP cloning, network data hacking and soft errors

Part 2 of this presentation continues protocol description, solutions and enablementIndustrial Ethernet Protocols: PROFINET, EtherNet/IP™, Modbus TCP, EtherCATIndustrial Wireless Protocols: ZigBee®, WirelessHART™, ISA100.11a


Q & A

►Thank you for attending this presentation. We’ll now take a few moments for the audience’s questions and then we’ll begin the question and answer session.

az120 industrial network protocols - freescale semiconductor

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