Automation and Drives

Turin, June 27-30, 2006 Automation and Drives

GG-Kennung
WFCS 2006
oder Produktname

Customer needs

WLAN vs.
determinism

Roaming in industrial
application

RCoax cable

Practical
implementation A PROFINET IO application
Results
implemented on Wireless LAN
Giorgio Santandrea
Siemens SpA Automation & Drives AS/PT/SE 1
 Automation and Drives

Customers information

WFCS 2006 Customers name: TECNOS CANNON Group

TECNOS is leader on polyurethane foaming plants

Customer needs for automotive industry

WLAN vs.
determinism The application: plant for foamed seat cushions
Roaming in industrial
application

RCoax cable

Practical
implementation
Example of a
Results plant from
TECNOS website

2
 Automation and Drives

Customer needs

WFCS 2006
The plant is made by a ring (80m long) along which there
are 21 trolleys
Customer needs Each trolley has 2 Control Technique drives (DP slaves)
WLAN vs. and should move independently from the others
determinism

Roaming in industrial
Two trolleys cannot be closer then 5 cm.
application
The complete system should be controlled by a single
RCoax cable
CPU, without any kind of intelligence on trolleys
Practical
implementation

Results

3
 Automation and Drives

Customer needs (2)

WFCS 2006
In the past the customer has used a PROFIBUS solution
based on sliding contacts

System performance were enough only for a little number

Customer needs
of trolley
WLAN vs.
determinism Customer want to have at least:
Roaming in industrial IO Update rate <= 64ms
application
Quantity of date to exchange with each trolley: 128 bytes
RCoax cable

Practical
implementation

Results
Solution:
PROFINET IO implemented
on a Wireless LAN network 4
 Automation and Drives

Solution system architecture

CPU315 PN +
WFCS 2006 CP 343-1 Advanced

IO Controller SCADA

W788-1RR PROFINET IO
Customer needs
RCoax 1 section 80m long
WLAN vs.
determinism

Roaming in industrial
application

RCoax cable
IO Device
Practical
implementation SCALANCE W788 RR as access point with iPCF function
Rcoax cable as antenna all around the ring
Results
21 trolleys, each one with:
IWLAN/PB Link PN IO as proxy between PROFINET IO and
PROFIBUS DP
2 non Siemens PROFIBUS DP slave 5
 Automation and Drives

Detail of the trolley configuration

WFCS 2006

Customer needs

WLAN vs.
determinism

Roaming in industrial
application

RCoax cable

Practical
implementation PROFIBUS DP
PROXY
Results
PROFINET
Slave DP non Slave DP non
Siemens Siemens

6
 Automation and Drives

GG-Kennung
WFCS 2006
oder Produktname

Customer needs

WLAN vs.
determinism

Roaming in industrial
application

RCoax cable

Practical
implementation

Results

7
 Automation and Drives

WLAN vs. determinism

WFCS 2006
WLAN is based on a shared and poor medium

The access control is typically based on CSMA; in a certain

Customer needs time only one client can transmit

WLAN vs. When a high number of collision happened the network

determinism
performance could be very low
Roaming in industrial
application

RCoax cable Logical Link Control (LLC)

2
Media Access Control (MAC)
Practical
implementation
1 Livello Fisico
Results

DCF (Distributed Coordinated Function) CSMA/CA

PCF (Point Coordinated Function) Polling

8
 Automation and Drives

The 802.11 protocol

WFCS 2006

Customer needs

WLAN vs.
determinism
(PCF)
Roaming in industrial
application

RCoax cable

Practical
implementation

Results

9
 Automation and Drives

Contention service:
Distributed Coordinated Function (CSMA)
WFCS 2006 Each client waits the
medium idle for at least a
time = IFS

Customer needs If the medium is still idle,

WLAN vs. the client waits until the
determinism current transmission
Roaming in industrial
ends and, after IFS, start
application an exponential backoff
RCoax cable
Collisions could be avoid
Practical by RTS/CTS technique
implementation
(Collision Avoidance)
Results

IFS: Inter Frame Space 10

 Automation and Drives

Contention free services:

Point Coordination Function (PCF)
WFCS 2006

PCF is implemented above the DCF

Customer needs The critical traffic is managed by the access point simply
using a polling technique scheduled by a round robin
WLAN vs.
determinism
algorithm

Roaming in industrial The rest of the traffic share the medium with CSMA/CA
application

RCoax cable Each time slot is divided into 2 periods; the first in which
PCF is applied and the second one in which DCF is used
Practical
implementation

Results

11
 Automation and Drives

PCF implementation

WFCS 2006

Customer needs

WLAN vs.
determinism

Roaming in industrial
application
The use of a mixed solution (PCF and DCF) can lead to a
RCoax cable high jitter between a Contention Free Period Repetition
Practical
Interval and the next one
implementation
In order to have controlled jitter it could be used a
Results
solution based on a pure PCF

iPCF = Industrial + PCF

12
 Automation and Drives

The roaming time in industrial applications

WFCS 2006
The roaming mechanism is not
defined into the 802.11 standard

Inside the standard are explained

Customer needs some topics related to roaming:
Scanning (active / passive)
WLAN vs.
determinism Association
Authentication
Roaming in industrial
application Roaming time is obtained by
adding this 3 times and its not
RCoax cable
easy to estimate
Practical
implementation Some of these times could be
reduced:
Results
Scanning on fixed and specified
channels
Use simple security techniques
(such as WEP) in order to reduce
authentication time
13
 Automation and Drives

Roaming times: some examples

WFCS 2006 Scan on defined channels

iPCF functionality Roaming time <= 50ms
Security based only on WEP

Customer needs

WLAN vs.
determinism

Roaming in industrial
application

RCoax cable

Practical
implementation

Results

14
 Automation and Drives

The key of the solution: RCoax cable

WFCS 2006
Used as antenna connected to SCALANCE W
Optimal and stable coverage in the proximity of the cable
No interferences to/from other Wi-Fi networks
Customer needs
Two different versions for 2.4GHz and 5GHz
WLAN vs.
determinism Easy to install thanks to his flexibility
Roaming in industrial
application

RCoax cable

Practical
implementation

Results

15
 Automation and Drives

RCoax transmission diagrams

WFCS 2006 IEEE 802.11b

Customer needs

WLAN vs.
determinism IEEE 802.11g

Roaming in industrial
application

RCoax cable

Practical
implementation

Results

16
 Automation and Drives

GG-Kennung
WFCS 2006
oder Produktname

Customer needs

WLAN vs.
determinism

Roaming in industrial
application

RCoax cable

Practical
implementation

Results

17
 Automation and Drives

The solution adopted

CPU315 PN +
WFCS 2006 CP 343-1 Advanced
Win CC

PROFINET IO
W788-1RR
Customer needs
RCoax 1 section 80m long
WLAN vs.
determinism

Roaming in industrial
application

RCoax cable

Practical
implementation SCALANCE W788 RR as access point with iPCF function
Rcoax cable as antenna all around the ring
Results
21 trolleys, each one with:
IWLAN/PB Link PN IO as proxy between PROFINET IO and
PROFIBUS DP
2 non Siemens PROFIBUS DP slave 18
 Automation and Drives

The Rcoax installation

WFCS 2006

Scalance
W788-1RR

Customer needs
To have a less obstacles
WLAN vs.
determinism influence we started
with 802.11b standard
Roaming in industrial
application
The maximum distance
RCoax cable
between RCoax and
Practical client antenna is about
implementation
Working 1.5m
Results area

Theoretically the
working area should be
as in the picture
19
 Automation and Drives

Some pictures from the plant

WFCS 2006

Customer needs

WLAN vs.
determinism
1,5m
Roaming in industrial
application Rcoax cable
RCoax cable

Practical
implementation
Client antenna
Results

20
 Automation and Drives

The commissioning phase

WFCS 2006
We started with IEEE 802.11b (DCF) because the distance
between client antenna and RCoax cable was not too high

Customer needs Signal strength on the each client was quite good but very
unstable, there were a lot of data rate changing
WLAN vs.
determinism
The high number of clients and this signal situation leaded
Roaming in industrial to a high traffic volume and a lot of transmission errors
application

RCoax cable Sometimes some trolleys lost the connection with the PLC
IO Controller
Practical
implementation

Results

We decided to activate iPCF functionality

with a fixed data rate at 5.5 Mbit/s
21
 Automation and Drives

Signal strength on a client

WFCS 2006
Situation with 802.11b standard, without iPCF

Customer needs

WLAN vs.
determinism

Roaming in industrial
application

RCoax cable

Practical
implementation

Results

22
 Automation and Drives

Signal strength on a client

WFCS 2006
Situation with iPCF activated, at 5.5Mbit/s

Customer needs

WLAN vs.
determinism

Roaming in industrial
application

RCoax cable

Practical
implementation

Results

23
 Automation and Drives

Some other pictures from the plant

WFCS 2006

The client cabinet

Customer needs

WLAN vs.
determinism

Roaming in industrial
application

RCoax cable

Practical
implementation

Results

24
 Automation and Drives

Results

WFCS 2006

The system has been working properly since last

November
Customer needs
The PROFINET IO update rate is 64ms with 128 bytes
WLAN vs.
determinism
exchanged with each trolley on each CPU cycle

Roaming in industrial The customer is satisfied with this solution and is going to
application
install a twin plant just beside this one
RCoax cable

Practical
implementation

Results

PROFINET IO could be implemented also

on WLAN network with good results!
25
 Automation and Drives

Thank you

WFCS 2006

Customer needs

WLAN vs.
determinism

Roaming in industrial
application

RCoax cable

Practical
implementation

Results

26