1. One Controller - Any Bus Connecting Programmable Automation Controllers,Measurements, Sensors, Networks and PLCs Ian Bell National Instruments

2. 2 Agenda Industrial Communications Overview Why Connect a PAC to Industrial Networks and PLCs? 3 Methods to Connect to Any PLC or Device  Basic Analogue and Digital I/O  Industrial Network Communication  OPC

3. 3 Industrial Communications Overview Industrial communications connect industrial devices such as PLCs, sensors and actuators Common Industrial Networks DeviceNet PROFIBUS Modbus TCP Modbus Serial CANopen FOUNDATION fieldbus Interbus CC-Link LonWorks HART PROFINET Ethernet/IP

4. 4 PAC Architecture Ruggedness and reliability of PLC Software capabilities of PC Modular and diverse I/O Software Capabilities Ruggedness and Reliability PLC PC PAC

5. 5 Why Connect PACs to Industrial Networks and PLCs?  High-speed analogue measurements  High-resolution analogue measurements  Advanced analysis (digital filtering, frequency analysis)  Custom hardware performance with FPGA technology High-speed closed-loop control FPGA-based processing and analysis  Custom Sensors/Measurements

6. 6 PLCsPACs 3 Methods to Connect to Any PLC Industrial Communications Basic I/O Analogue/Digital OPC

7. 7 Basic I/O Cheap, Easy, Fast and Effective Available on every platform Analog and digital I/O options PLC users can easily integrate analogue and digital I/O into their code Allows PACs to act as intelligent devices

8. 8 Basic I/O Advantages  Fast, deterministic, little or no software overhead Considerations  Doesn’t scale well  Point-to-point wiring (parallel)  Can’t communicate lots of data

9. 9 Example Automated Filling of Aerosol Cans Existing PLC system was being used to automate the filling of aerosol cans PLC did not have the capability to do high- speed analogue for pressure measurements NI CompactRIO PAC was used for high-speed pressure measurements on 8 channels (2 k per channel) CompactRIO and PLC were integrated using digital I/O

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11. 11 PLCsPACs 3 Methods to Connect to Any PLC Industrial Communications Basic I/O Analogue/Digital OPC

12. 12 Methods for Industrial Communications Ethernet/Serial Plug-In Interfaces Gateways over Ethernet, Serial Versatility Performance/Determinism

13. 13 Plug-In Communication Boards CAN and CANopen DeviceNet FOUNDATION fieldbus Serial (RS232, RS422, RS485) Third-party PROFIBUS (Comsoft) Support for PXI, PCI, PCMCIA, and CompactRIO Plug-In Interfaces

14. 14 Plug-In Communication Boards Advantages  Direct, deterministic communication with the processor  Timing and synchronisation with other I/O (DAQ)  High-level API support for LabVIEW and other programming languages Considerations  Many smaller buses and protocols are not supported  Many only available on PC and PXI (real-time supported) Plug-In Interfaces

15. 15 Example : PROFIBUS PROFIBUS master/slave for PXI and PCI More than 2 million nodes Popular in Europe and Asia Recommended: Comsoft DF PROFI II interfaces

16. 16 cRIO-PBMaster/Slave and cRIO-PBSlave cRIO PB Master/Slave module  Supports operation as DP Master or DP Slave  Ships with configuration tool configurator II for DP Master configuration  Ships with GSD file to configure any DP Master system cRIO PB Slave module  Supports operation as DP Slave  Ships with GSD file to configure any DP Master system

17. 17 Ethernet-based Industrial Protocols Modbus TCP/IP Ethernet/IP EtherCAT Profinet

18. 18 Why Ethernet: Protocols Modbus TCP/IP Traditional Industrial Protocols PROFInetPROFIBUS DeviceNet EtherNet/IP Modbus Ethernet Physical Layer CanOPENEtherCAT

19. 19 Modbus TCP/IP Overview First industrial protocol on Ethernet (introduced 1999)  Based on Modbus developed by Modicon in 1979  Widely adopted and open Ethernet standard Advantages  Uses standard Ethernet (hardware and TCP/IP transport layer)  Open and relatively simple Disadvantages  Not a hard real-time protocol  Does not deliver determinism

20. 20 Ethernet-based Industrial Protocols Modbus TCP/IP Ethernet/IP EtherCAT Profinet

21. 21 EtherNet/IP Overview Dominant bus for Rockwell Automation  Managed by Open Device Vendors Association (ODVA)  Extends DeviceNET concepts to Ethernet Advantages  Uses Ethernet transport layer (TCP and UDP) Disadvantages  Can overload networks with UDP messages if not correctly configured, recommend managed switches with IGMP snooping

22. 22 Ethernet/IP Terminology TCP/IP Used to set parameters and initiate implicit communication Explicit Messages UDP/IP multicast Used to communicate I/O data Normally set-up for cyclical updates Implicit Messages

23. 23 Communication from NI PAC to ControlLogix and ComapctLogix PLCs Ethernet/IP Uses explicit messaging Available for download from NI Labs

24. 24 EtherNet/IP VIs for LabVIEW Provides VIs for communication to “Logix” PLC Tags  Directly read and write tags on Allen Bradley ControlLogix and CompactLogix PLCs Runs on LabVIEW for Windows and LabVIEW Real- Time (Pharlap and VxWorks) Explicit Messaging Good for low numbers of tags

25. 25 EtherNet/IP VIs for LabVIEW Advantages  Simple method to communicate to Rockwell PLCs  LabVIEW initiated communication (no need to change PLC code)  Good for communicating low number of tags  Uses TCP/IP and does not require IGMP snooping to prevent network flooding Disadvantages  Not recommended for high tag counts Inefficient packing of data into Ethernet (slower communication) Increased processor burden on PLC  Can only communicate to Rockwell Logix PLCs No SLC support, no third party EtherNet/IP device support

26. 26 Third-Party Gateways Wide variety of communication buses and protocols supported Ethernet or serial-based Perfect for non-PXI, PCI, and PCMCIA systems Ethernet PROFIBUS DeviceNet EthernetIP ControlNet Gateways over Ethernet, Serial

27. 27 Example Adding Vision for Food Processing Optimisation Needed NI Compact Vision System to calculate the mass/volume of the food item coming through on the conveyor belt Ethernet/IP connectivity was a requirement EthernetIP Modbus TCP

28. 28 PLCsNI PACs 3 Methods to Connect LabVIEW to Any PLC Industrial Communications Basic I/O Analogue/Digital OPC

29. 29 What Is OPC? Universal language for reading and writing data OPC Client: Read and write to OPC OPC Server: Translates between OPC and device- specific protocols English Windows PC

30. 30 OPC Client Allen-Bradley OPC Server Siemens OPC Server Mitsubishi OPC Server PLCs Device-Specific OPC Server Windows PC Ethernet/IP PROFINET CCLink OPC Client OPC Driver OPC Client

31. 31 NI OPC Servers for Third-Party PLCs OPC support for more than 100 PLCs Connects with LabVIEW DSC OPC client  Evaluation version included with DSC Servers included for: Allen-Bradley AutomationDirect Cutler-Hammer GE Hilscher Modbus Omron Philips Siemens Toshiba WAGO Yaskawa Yokogawa …and more! ni.com/opc

32. 32 OPC Advantages  Most universal  Least device-dependent  Ideal for HMI and SCADA applications Considerations  Slower, not deterministic, single-point only  Can require PC-based OPC servers  Not for safety or critical communications

33. 33 ABCO Adds LabVIEW to PLC System ABS brake testing system PXI for high-speed encoder measurements Added to existing Allen-Bradley PLC assembly line OPC used for communication between PXI and Allen-Bradley PLCs “ The ease by which NI can speak to the Allen-Bradley hardware saved me valuable time on this delivery-critical job.” -Arif Bustani, electrical engineer ABCO “ The ease by which NI can speak to the Allen-Bradley hardware saved me valuable time on this delivery-critical job.” -Arif Bustani, electrical engineer ABCO

34. 34 Summary PACs add flexibility to connect to anything Use PACs to add any measurements to existing system 3 Methods to Connect PAC to Any PLC:  Basic Analogue and Digital I/O  Native Industrial Communications  OPC

35. 35 Online Resources ni.com/comm ni.com/pac ni.com/labs www.modbus.org – Modbus TCP/IP www.odva.org – Ethernet/IP www.ethercat.org – EtherCAT www.profibus.com/pn - PROFINET