“Driven by Industry 4.0 and the Industrial Internet of Things, industrial automation technology has shifted to digitalization. The production site is constantly changing. All production locations are realizing network connections; they can communicate with each other, between different departments of the company, and even communicate with the outside world across the company. Through condition monitoring, optimization of mechanical devices and technical systems, overall production efficiency can be greatly improved. However, this requires all participants in the enterprise (whether human or machine) to maintain communication at all times to exchange massive amounts of data and various parameters.
Author: Thomas Brand, ADI Field Application Engineer
Driven by Industry 4.0 and the Industrial Internet of Things, industrial automation technology has shifted to digitalization. The production site is constantly changing. All production locations are realizing network connections; they can communicate with each other, between different departments of the company, and even communicate with the outside world across the company. Through condition monitoring, optimization of mechanical devices and technical systems, overall production efficiency can be greatly improved. However, this requires all participants in the enterprise (whether human or machine) to maintain communication at all times to exchange massive amounts of data and various parameters.
Figure 1. Application examples of various participants in a networked factory.
Figure 2. From a simple analog sensor to a smart sensor. The intelligent analog sensor includes the entire signal chain and processing unit.
In the past, the connection was relatively simple. It was enough to transmit analog sensor signals from various systems to the central controller and perform digital processing. However, in the industry 4.0 era, sensors also began to use digital technology. After adopting so-called smart sensors that can be integrated into any position of a complex network, the amount of recorded data can be transmitted in digital form through the network. As shown in Figure 2, in addition to the actual measurement parameter detection, these smart sensors integrate the main signal conditioning and processing parts in a single package structure.
In addition, smart sensors are usually already equipped with a bus interface. By digitizing the measurement parameters, more data can be transmitted at a faster speed. Another advantage is that the signal transmission is more reliable. Through digital signal transmission, signal changes and interference can be reduced or even completely eliminated. In addition, under ideal circumstances, bus-enabled sensors can be connected to the network via plug and play, which means that the control unit will automatically detect these sensors. If one sensor fails, the other sensors will continue to operate normally.
However, all of these require a universal, highly reliable, real-time available network to extend from individual sensors and actuators to machines, and ultimately to the entire system. Ethernet, especially industrial Ethernet, has become an important communication standard. Compared with the previous fieldbus, industrial Ethernet has decisive advantages, for example, it can efficiently and synchronously transmit a larger amount of data on a shared transmission medium. In addition, industrial Ethernet provides the possibility to build the entire communication based on a unified foundation, supplementing traditional Ethernet through real-time expansion to achieve determinism.
Last year, ADI introduced the fido5000 series of real-time Ethernet multi-protocol (REM) switch gateway chips for such applications. This series of products uses two Ethernet ports that support TSN to implement (for example) linear, ring, star, and redundant star network topologies. In addition, any host processor can be connected to the switch chip through its configurable memory bus interface. Although various standards are constantly changing, because the fido5000 REM switch flexibly supports every current industrial Ethernet protocol, it helps developers design new products for the future.
These advantages are achieved through JUMO Group; JUMO Group is a German family SMB operating on a global scale, located in the Fulda region. JUMO develops and produces a variety of products and system solutions for measuring, controlling and analyzing physical quantities and chemical quantities for many industries such as food, air conditioning, mechanical engineering, chemistry and pharmaceuticals, packaging, and water and wastewater. In these industries, a variety of process data needs to be transmitted through large networks anytime and anywhere. For fido5000, this is the ideal application scenario and the reason why it is used in the latest JUMO design DICON touch.
JUMO DICON Touch
DICON touch is a 2-channel process and programming controller, which can be viewed through the TFT color Display and supports intuitive touch operation. In addition to providing previous RS-422/RS-485 MODBUS® RTU, Ethernet and PROFIBUS® DP interfaces, the latest DICON touch can also be connected to and communicate with PROFINET controllers. The above-mentioned functions are realized through the integrated fido5000 2-port switch, which supports the construction of simple network topologies. The network application has a variety of integrated features, including registration data evaluation, setting configuration, and Web server functions for online visualization; in addition, it also supports PROFINET real-time data exchange. The certification can ensure compliance with the PROFINET standard and compatibility with applications from different manufacturers.
Figure 3. DICON touch 2-channel process and programming controller-the first JUMO product equipped with a PROFINET interface.
ADI and JUMO have established a long-term cooperative relationship. In 2016, through the acquisition of Innovasic, ADI expanded its industrial Ethernet product line. This allows ADI to help customers implement a series of industrial Ethernet applications. The cooperation with JUMO has demonstrated this, and this has had a positive impact on the cooperation between the two parties. By cooperating with JUMO, ADI has become a true design partner from a single component supplier. Klaus Otto, product manager of JUMO GmbH, said: “ADI is a very good partner. We have provided us with extremely strong professional support in the development of the PROFINET interface for the multi-channel process and programming controller JUMO DICON touch.”
ADI attaches great importance to this partnership and will continue to expand further in the future. The way that ADI cooperates, and the characteristics of using their respective advantages to achieve a win-win situation, make it stand out among these partners. For example, ADI provides its partners with comprehensive industry 4.0 professional technical support by adopting the latest technologies and solving major challenges in the early stages.
In the end, ADI continued to develop, surpassing the scope of traditional semiconductor companies, breaking the boundaries of silicon chip technology, and investing heavily in software, system expertise and special technology development. This accumulation of knowledge is combined with various select functions covering the entire signal chain from sensor to cloud. Solve various challenges from the system level. This speeds up the development process and shortens the time to market. Therefore, we will enhance our competitiveness by developing next-generation products earlier. Whether ADI provides assistance as a passive partner, or as an active partner, actively providing technical, experience and other support, we try our best to meet all the needs of our partners.
Especially in the process of developing DICON touch, ADI provides a solution that can meet the needs of designing all devices based on the Ethernet protocol PROFINET. The challenge is to develop a universal device that can provide customers with countless possibilities. DICON touch adopts a powerful modular concept design: it provides a simple plug-in card and an integrated PHY for standard Ethernet, or provides an external plug-in card with PROFINET function. Klaus Otto said: “During development, we paid special attention to a single PROFINET solution. There is no similar solution with these functions on the market.”
In addition to the fido5000 REM switch chip, the integrated RapID platform is also used in the development of DICON touch. This platform demonstrates a complete solution for embedded design with fido5000. It integrates fido5000 switch chip, communication processor, JTAG interface, PHY, and memory such as Flash®, SDRAM and EEPROM on the same circuit board. The next-generation RapID platform will use a more powerful and energy-efficient ARM® Cortex®-M4 processor as the communications processor, and more processing functions can be performed on this processor as needed. During the development of DICON touch, JUMO was very interested in the features of the existing RapID platform, such as the common pre-certified industrial Ethernet protocols provided by the platform. The RapID platform supports downloading all relevant information, such as circuit diagrams and layout data, which greatly reduces development time. The RapID platform also provides a dynamically integrated web server, which can read or change network parameters, as well as input and output data in a simple way; DICON touch also has this feature. The platform can also configure PHY through RMII and I²C interfaces. In addition, since the firmware has been mirrored on DICON touch, the PROFINET module can be updated at startup.
Figure 4. The RapID platform based on fido5000 can be used as an evaluation kit.
Therefore, the flexible configuration of the RapID platform for DICON touch also supports firmware updates and network access. For DICON touch development, there are endless possibilities for innovation. For example, standard blinking LEDs will not be provided on Electronic devices, which is an important feature of PROFINET. On the contrary, the entire LED Display of DICON touch will flicker.
During the development of DICON touch, network security was also an important factor. The network security of industrial controllers cannot be achieved through general solutions. Instead, a long-term approach needs to be taken based on system risk assessment. As part of the security strategy, ADI has tried its best to improve the security of Ethernet components. Therefore, the current industrial Ethernet and TSN solutions are the focus of the company’s security development work. The RapID platform based on fido5000 is supplemented with multiple security features, which can provide key management, secure boot, secure update and secure memory access to resist network attacks.
ADI uses the fido5000 series and the RapID platform to provide partners with excellent application solutions to help customers meet future requirements such as real-time functionality, reliability and security. Therefore, ADI can not only provide customers with high-quality products, but also provide development cooperation or development support. This cooperation advantage is confirmed by the new JUMO DICON touch process controller. Through the concerted efforts of both parties, the project was completed on schedule and a safe and reliable forward-looking solution was successfully obtained.
About the Author
Thomas Brand joined ADI in Munich, Germany in 2015, when he was still studying for a master’s degree. After graduation, he participated in ADI’s trainee program. In 2017, he became a field application engineer. Thomas provides support to large industrial customers in Central Europe and focuses on the field of industrial Ethernet. He graduated in electrical engineering from the Union University of Education in Mosbach, Germany, and then obtained a master’s degree in international sales from the Konstanz University of Applied Sciences, Germany. Contact information:[email protected]