Beruflich Dokumente
Kultur Dokumente
NOVEMBER 2007
controller network
(future)
field network
CC-Link motion network
CC-Link/LT
Executive Overview
With the support of Mitsubishi, CC-Link has grown to become the leading
fieldbus in Asia and one of the largest globally when measured by installed
base. In 2007, the CLPA announced a new and powerful control level net-
work, named CC-Link IE. This open-technology network, based on fiber
optic 1GB Ethernet, will be managed by the CLPA along with the CC-Link
This new network also marks a new direction for the CLPA. Formerly it
had developed only sensor and device-level networks. Beginning with its
release of CC-Link IE, the organization has announced a roadmap to fur-
ther expand its scope to include all types of automation networks. CLPA
will be developing additional high-performance networks in the future
based on Ethernet for motion control and high performance fieldbus appli-
cations. This will significantly expand the scope of the CLPA, and also
expand the value of its technology to CLPA members.
Mitsubishi in Automation
Mitsubishi Electric is an industrial giant. Its most recent sales figure is over
$30 Billion, and through subsidiaries and related companies it employs al-
most 100,000 people around the world. The company is organized around 9
major business units (see figure). While these units each have their own
business area, they collaborate internally in their business processes. This
provides an important advantage to Mitsubishi in the factory automation
market, because the company has internal as well as external customers. As
we shall see, Mitsubishi is both a demanding customer and a supplier when
it comes to automation products. The tough demands of their own corpo-
rate quality and production programs have a hand in forming Mitsubishi
automation products, which are used throughout their own manufacturing
processes.
very low product return rate, despite the innovative design and manufac-
turing it employs.
can, which can bring them into competition with their own channel part-
ners and customers. By contrast, Mitsubishi is focused on creating best-in-
class products. This strategy is unusual for a company with such a broad
range of automation products. Besides the fact that services can be a profit-
able business, other automation companies use their service business to
gain deeper understanding of their customer’s “pain points” and insight
into improved products and solutions.
PLCs and ships more PLC units than any other company in the world ac-
cording to ARC’s most recent market data (see figure). The company also
has leading shares in supplying this equipment to many key vertical indus-
tries, including the automotive, flat panel display, electronics,
semiconductor, food, beverage, and pharmaceutical industries.
the ultra-modern world of flat panel display manufacturing, one of the fast-
est growing and fasted changing manufacturing industries today. Second,
examine changes in a far more mature and traditional manufacturing in-
dustry – automotive.
Flat panel displays have become dominant technologies not only in IT ap-
plications, but in home entertainment and communication. Part of their
success comes from huge product improvements and cost reductions that
have been achieved in recent years. Japanese manufacturers (Sony and
Sharp are examples) have led this field.
The focus on high quality requires that extensive test and quality data be
captured and retained for analysis. In flat panel manufacture, the size of a
“mother glass” increases all the time, and the largest ones are now 3 meters
square. It is important to process such large pieces with precision. But as
larger units are produced and production ramps up,
As flat panel glass size increases the quantity of recipe, test and quality data that must
and production ramps up, the be processed simply explodes.
volume of test and quality
information that needs to be Finally, these production processes change frequently
managed simply explodes. as improvements or new products are introduced.
Manufacturers who want to stay competitive must be
able to quickly adjust their factory production configurations in response to
these changes. Startup, installation and engineering costs that are excessive
cannot be tolerated because changes occur far too frequently. In summary,
the requirements for effective utilization, precision, real-time coordination
These two examples show that regardless of how new or mature the appli-
cation, manufacturers need greater agility, speed, and must process ever
larger amounts of information from production operations. Automation
networks act as the “nerves” carrying this vital information throughout a
manufacturing operation. Expanding the capacity and agility of this factory
“nervous system” is an important way to design for the needs of the future.
The results of these customer requirements are networks with distinct au-
tomation services and configurations. However these networks are
increasingly built from commercial fiber optic and Ethernet technologies,
with suitable adaptations for factory floor service. We see several different
types of industrial adaptations of Ethernet, some of which use ASIC tech-
nology to provide a particular level of service. We also observe a set of
network protocols designed specifically for industrial applications (exam-
ples are MODBUS, MODBUS TCP, CIP, Profinet, EtherCAT, etc.).
The next higher network level is sometimes called the controller level (see
figure). In the past, Mitsubishi has employed a proprietary controller net-
work, called MELSECNET. The controller network
level performs peer-to-peer communications be-
tween PLCs and between PLCs, CNCs, robots,
OITs and other controllers, PCs and servers. Its role
is critical for integrating “islands of automation”
into a single smooth-running production line.
While this network must provide services to enter-
prise applications, its core function is to maintain a
coordinated flow of information critical to the pro-
Automation Network Levels duction process itself. Hence Mitsubishi’s strategy
was to maintain tight control over the MELSECNET network. The MEL-
SECNET network has been widely used in industries such as automotive,
flat panel display, etc. as it is a high speed, high volume, reliable network
for manufacturing lines. In particular network provisioning based on
rameters simplifies MELSECNET setup.
CC-Link features fast response time, large data transfer capabilities and a
very high level of determinism. For instance, a network of 64 stations can be
updated in approximately 4 ms. The CC-Link network is suited for large
applications as well as distances up to 1.2 km, and further using repeaters.
CC-Link features an easy-to-use memory mapped profile, enabling simple
network configuration as well as various RAS (Reliability, Availability, and
Serviceability) functions and diagnostic features. One of the key reasons
why CC-Link is so widely used is its high degree of determinism, stable
scan time, and high immunity to electromagnetic noise. In fact, all certified
products must pass noise testing as part of CC-Link conformance testing.
In 2007 the CLPA introduced a new and far more powerful network, which
is named CC-Link IE (IE for “industrial Ethernet”). CC-Link IE provides a
high performance industrial Ethernet based controller network that can
seamlessly communicate throughout the plant floor. The first step in
CLPA’s future roadmap is the release of this controller level network. This
network was developed by Mitsubishi in conjunction with the CLPA Tech-
nical Task Force. Mitsubishi has transferred the rights to this network to
the CLPA. This new network will be managed and products certified by the
CLPA, similarly to CC-Link. CLPA certified products can now interact at
the controller level as well as the sensor/device network level. Besides
opening up this new level of integration to CLPA members, CC-Link IE will
bring unprecedented levels of performance to automation applications.
Properties of CC-Link IE
CC-Link IE uses a fiber optic, 1GB Ethernet physical layer, standardized as
IEEE 802.3z and popularly known as 1000BASE-SX. CC-Link IE uses an IEC
61754-20 LC standard connector. The use of 1 GB Ethernet at the controller
level is unprecedented. Many IT Ethernet networks now use 1GB data rates
at the backbone, but CC-Link IE will bring this new level of throughput to
industrial plant-floor control networks.
Network control switching is also a key feature for network stability. Even
if one control station fails, another station will automatically take over the
control of the network and maintain communication. Furthermore, if two
stations fail simultaneously, the network will separate and one station will
take control of each segment.
The transient communication service is also open and available to other ap-
plications. Transient communication will serve two purposes in CC-Link IE.
It is used for intermittent automation communication (for example applica-
tion download by an engineering tool) and will also be used for other
protocols so that the network can operate with multiple protocols. The
CLPA has announced a roadmap to implement TCP/IP as the first addi-
tional protocol using the transient communication service.
Earlier we noted that while industrial automation networks are now built
using IT foundations, manufacturing automation requires adaptations in
order to meet the application needs of the factory floor. CC-Link IE is de-
signed to specifically address these requirements in a number of ways (see
table). While clearly CC-Link IE is designed as a controller network critical
for production, yet it employs the latest standards-based technologies dep-
loyed in the world of IT such as 1GB Ethernet. While CC-Link IE addresses
the needs of the factory floor, how “open” is it? The question of openness is
important to end users because the term implies that the network will have
a long life and will be able to grow and improve over time rather than en-
counter some technological “dead end”. So let’s turn specifically to the
question of openness.
Furthermore, the
CLPA has announced
a similar strategy in
terms of future CC-
Link IE field and mo-
tion networks. As
these networks adopt
The CLPA roadmap to upgrade the technology of its fieldbus and motion
control networks means that CLPA members (including Mitsubishi) will be
able to benefit because their new products can leverage higher levels of per-
formance, while at the same time address a broader range of automation
applications.
Summary
The CLPA is now moving towards a full range of automation solutions
based on the latest high-performance standards-based Ethernet networks.
CLPA partners stand to benefit from this, especially the smaller firms who
otherwise could not afford the research and development costs of this level
of high technology. The CLPA roadmap, of which CC-Link IE is the newest
component, will offer new opportunities for growth to all CLPA members,
large or small.
The direction set by CC-Link IE also addresses the critical end user re-
quirements for higher performance, more choice, and greater scalability. As
CLPA grows, its technology solutions will increasingly offer a “one stop
shop” encompassing all the automation requirements of manufacturers:
control networking, fieldbus, sensor networks, and motion control. While
the CLPA has traditionally focused only on the CC-Link factory fieldbus,
this will not be the case in the future. Beginning with CC-Link IE, the CLPA
is moving to address all the needs of modern factory automation.
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