Open communication standards

Key to success for Industry 4.0

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Stéphane POTIER Technology Marketing Manager

B&R Automation

stephane.potier@br-automation.com

Perfection in Automation www.br-automation.com

First industrial revolution

Mechanization of production using water and steam power

Second industrial revolution

Mass production with the help of electric power

Third industrial revolution

Digital communication technologies to automate production

Fourth industrial evolution

Interconnected systems for smart production

Fourth industrial evolution

Industry 4.0

Smart Manufacturing

The Connected Machine©

The Industrial Internet

One concept, several initiatives worldwide

Industry 4.0

The goal of Industry 4.0 is the smart and connected factory with

Internet of Things and Cyber Physical Systems as technology basis.

Internet of Things (IoT) is the Interconnection of uniquely

identifiable embedded computing devices (smart objects) within the

Internet infrastructure.

Cyber Physical Systems (CPS) are systems using computations

and communication deeply embedded in and interacting with

physical processes.

Computerization of the manufacturing industry

Industry 4.0

Concept of Industry 4.0 is to interconnect machinery, sensors and

control systems together via intelligent networks to achieve:

• Dynamic response to product demands, enable rapid manufacturing

of new products.

• Real-time optimization of manufacturing production and supply chain

networks, highly flexible production.

• Strong customization of products, mass customization.

• Self-optimization, self-configuration and self-diagnosis.

• Active support of the manufacturing process by smart products

themselves

Connecting machines with intelligent networks

Networked Manufacturing

Horizontal value network

Industry 4.0 Working Group

Industry 4.0 will involve networking

and integration of several different

companies through value networks.

This collaborative partnership will only

be possible if a single set of common

standards is developed.

Standardization as a prerequisite for Industry 4.0

http://www.forschungsunion.de/p

df/industrie_4_0_final_report.pdf

Distributed intelligence based on standards

Networks incorporate entire manufacturing process

Connecting ERP, MES, SCADA and PLCs

• Interoperability standard

developed by the OPC Foundation

• Manufacturer-independent

standard for exchanging data

• Multi-platform service-oriented

architecture

• Scalable from smart

sensors/actuators to mainframes

• International standard IEC 62541

OPC Unified Architecture (OPC UA)

OPC UA in PLC

• OPC UA Server in PLC for vertical

communication to SCADA, MES

and ERP

• OPC UA Client in PLC enables

vendor-independent horizontal

communication from PLC to PLC

• PLCopen-compliant function blocks

• Guaranteed semantic

interoperability

OPC UA Client / Server in the PLC

Distributed intelligence based on standards

OPC UA standard for ERP, MES, SCADA and PLCs

Distributed intelligence based on standards

Standard for real-time field network

Connecting sensors and actuators

A real-time standard for the field network

• OPC UA is based on TCP/UDP/IP

• Not suitable for real-time data

exchange

• Field network usually require

high level of determinism

• POWERLINK fulfills perfectly

requirements for real-time field

network

Why POWERLINK

• Maximum performance

• Absolute openness

• Based on Standard Ethernet

• Designed for Integrated Automation

• International standard IEC 61158-13

Worldwide market leader

• Worldwide leader for real-time Ethernet solutions

• 3,100 OEMs trust in POWERLINK

• More than 900,000 POWERLINK systems installed

An 100% open standard

• POWERLINK is completely free of patents and without licenses

• POWERLINK is open source – downloadable on sourceforge.net

27.000

Designed for integrated automation

Remote

I/Os Safety Motion

Vision

Robotics

Pneumatic

Integrated Automation

Controller

Visualization

Decentralized

controller Sensors Encoder

Distributed intelligence based on standards

POWERLINK standard for field level networks

OPC UA down to the sensors

• Deterministic data are exchanged in the POWERLINK isochronous

phase

• With POWERLINK a dedicated bandwidth is reserved for non real-time

data exchange, can not degrade real-time data exchange

Combining OPC UA and determinism of field network

OPC UA down to the sensors

Efficient non real-time data exchange with POWERLINK

OPC UA down to the sensors

OPC UA client/server down to the sensors

Distributed intelligence based on standards

POWERLINK standard for field level networks

Integrated safety

The Industry 4.0 Working Group has stated:

• Safety is the first priority area for Industry 4.0

• Safety strategies must be designed for open collaborative

subsystems belonging to different manufacturers and operators

• Industry 4.0 will require the deployment of integrated safety

• openSAFETY is ideal solution for integrated safety in an open multi-

vendor environment

Critical factor for the success of Industry 4.0

openSAFETY is open and independent

• The world’s first 100% open safety protocol

• Totally independent from technical and legal aspects

• Supported by the international user organization EPSG

One safety standard for all networks

TCP/IP

EtherCAT POWERLINK PROFINET

Distributed intelligence based on standards

Standard for integrated safety

Distributed intelligence based on standards

OPC UA – POWERLINK - openSAFETY

Open standards for Industry 4.0

OPC UA – POWERLINK - openSAFETY

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