Your Source for Process Control Instrumentation. Industrial Wireless: Overview

Transcription

1 Industrial Wireless: Overview

2 Wired Industrial Wireless: Overview What happens if one of these becomes disconnected???

3 What is Wireless? It is about creating, getting, giving, understanding and learning from information. Wireless enables information gathering with minimal cost, effort, and engineering time. Shedding wires provides manufacturers with the freedom and flexibility to solve difficult challenges.

4 Industrial Wireless is Wireless = Wire replacement Less Wire = Less Time & Less Expense $$$ Wireless replaces wire as the physical layer

5 Available Wireless Technologies: Radio Satellite Cellular Explosive growth in the personal communications market has dramatically reduced costs and increased quality of underlying components and technologies.

6 What types of information can be transmitted via Wireless technology? Discrete I/O Analog I/O Temperature Pulse A.B. DF1 DeviceNet Interbus CANopen Modbus Profibus Ethernet

7 What types of information can wireless handle? Ethernet: Remote work stations, Remote I/O, Bridging Networks Work-force management Wireless Workers enabled via laptops, pocket & tablet PCs and other handheld devices HMI interface, , documents, spreadsheets, etc. Standards include WiFi: a,b,g & Bluetooth

8 What types of information can wireless handle? Ethernet: Video surveillance: Fence line, Gate, Machine, Worker, or Process monitoring. POE = Power over Ethernet

9 Wireless Ethernet IEEE Standard Wi-Fi Wireless Fidelity, W-LAN Wireless Local Area Network, and Wireless Ethernet a = 5GHz band up to 54 Mbps. Escapes potentially crowded 2.4Ghz band (not globally accepted) b = 2.4GHz band up to 11 Mbps DSSS modulation G = 2.4GHz band up to 54Mbps (worldwide standard) Backward compatible with b Both (a) & (g) use OFDM frequency hopping technology designed for scenarios where there are often multi-path channels (i.e. the transmitted signal arrives at the receiver using various paths of different length). Typically Requires (2) Antennas

10 Wire = Cost $$$ Trenching Boring Concrete/Blacktop Scaffolds & Trays Seals Cables Conduit

11 Wire = Cost $$$ Engineering Time Permits, Delays, Labor Corrosion issues High Installation costs High Maintenance costs Constantly increasing costs High failure rate of connectors Difficulty in troubleshooting connectors. General purpose wiring cost $25-$45 per foot and X-proof or I.S. wiring $80-$150 per foot.

12 RF Wireless today vs. yesterday Yesterday Licensed radios, Walkie talkies Decades of trusted service Today Shared Medium, High speed License free open user ISM band radio (Industrial, Scientific, & Medical) with Microprocessor controlled radio telemetry with greater emphasis on filtering and noise immunity. Military grade electronics & Rugged industrial enclosures with hazardous area classifications. Your Source for Process Control Instrumentation

13 VLF LF MF HF VHF UHF SHF EHF

14 RF Wireless ISM Bands today: Your Source for Process Control Instrumentation 900 MHz (902MHz 928MHz) Lower throughput, better range and penetrating power Proprietary protocols 2.4 GHz = (2.4GHz GHz) Frequency well above typical industrial noise 2/3 distance of 900Mhz WiFi & Bluetooth 5.8 GHz = (5.15GHz 5.85GHz) Frequency far above typical industrial noise 2/3 distance of 2.4Mhz WiFi Note: Laws of physics dictate Higher Frequency = Higher data rate

15 Wireless Data How it works? Your Source for Process Control Instrumentation Wireless data = modulating, or coding conventional binary data (1s and 0s) onto a radio frequency carrier. The most common transmission technologies are: FHSS (Frequency Hopping Spread Spectrum) DSSS (Direct Sequence Spread Spectrum) Only the transmitter and receiver know the next pseudo-random frequency hop.

16 Wireless Data How it works? Your Source for Process Control Instrumentation The most common Transmission technology is called FHSS (Frequency Hopping Spread Spectrum) Very strong signal is created by focusing transmission power into one frequency channel at a time. interference tolerant technology and very reliable in high EMI/RFI areas. Secure, the constantly and pseudo-randomly jumping frequencies make it almost impossible for someone to tap into the signal. To an unintended receiver, FHSS appears to be short-duration impulse noise

17 Wireless Data How it works? Your Source for Process Control Instrumentation Another Transmission technology is called DSSS (Direct Sequence Spread Spectrum) DSSS spreads data across a wide portion of the frequency band, effectively creating one channel for faster data rates. Because DSSS relies on processing to address interference, it is more susceptible to background noise interference. Less transmitter power = Shorter distances, saves power. Secure, a randomly generated chipping-key is required to group the information packets and decode and reassemble on the receiver side.

18 Wireless Data How it works? Your Source for Process Control Instrumentation Frequency Hopping Direct Sequence

19 How does Frequency Hopping deal with interference? Interference may knock an update down. The next transmission is sent milli or micro seconds later on the next frequency. 902MHz 928MHz

20 The Key to Wireless = Successfully managing the RF energy Pitching and catching while minimizing loss Understanding the nature of RF signals How far can you go? What obstructions will cause trouble? Will the environment affect the signal? What interference may be concerning?

21 Wireless Range? NO WORRY ZONE the Electricians territory Wireless links up to 1000 COMMON SENSE ZONE Success with experience links up to one-half mile. PERFORMANCE ZONE Path Engineering required links up to 23 Miles

22 Wireless Reliability Three Factors influence Wireless Reliability: 1. RF Attenuation - Path loss from Reflection or Absorption due to Weather, Nature, or Man Made Obstacles. 2. Interference or noise from nature or other legitimate traffic. 3. Transmitter Power or signal strength.

23 Wireless Reliability Path loss - RF Attenuation or (absorption) Weather Climate: Humidity absorbs RF very quickly

24 Wireless Reliability RF Attenuation or path loss (absorption) Nature

25 Wireless Reliability RF Attenuation or path loss (absorption) Man-Made Wood, Brick and Glass are OK - Earth & Water are trouble - Metal & Rock tend to bounce.

26 Wireless Reliability Path loss - Reflection or (multi-path) Remember, all industrial environments are different and may offer a unique set of obstacles to effective RF communication

27 Wireless Reliability Interference or noise from nature or other legitimate traffic

28 Wireless Reliability Transmitter Power or signal strength ISM Signal strengths from 2.5mWatt to 1 Watt - providing distance and boring power

29 Line-of-Sight Your Source for Process Control Instrumentation

30 Obstacles in your Line of Sight rule of thumb % of Rated Distance vs. Obstacles tolerance < 10% lots of Obstacles 10-49% some Obstacles >50% no Obstacles Radio Path Patterns Between Antennas

31 Reality of the Situation Canyons of Steel

32 Why Wireless? Easily pull together geographically scattered assets.

33 Why Wireless? Lower installation costs (up to 90%) Faster commissioning (typically 1 out of 50 wires improperly terminated) Avoid limitations of wired networks. Pay-as-you-go architecture; provides ability to gracefully scale the network. Meet Regulatory requirements Reduce Maintenance and Operational costs by improving information flow.

34 Why Wireless? Eliminate potentially dangerous walk around manual data collection methods. Improve frequency and reliability of field data. Enhance plant flexibility: Relocate instruments (No demolition of panels or conduit) Mobile applications Temporary installs

35 It s Always the Antenna: Omnidirectional antenna The Omnidirectional or Collinear antenna provides a signal in a full 360 Ideal for applications where you want to transmit from a central node to users scattered all around the area Signal tends to radiate on a flat horizontal plane. Radiation pattern for Omnidirectional or Collinear Antenna

36 It s Always the Antenna: Yagi array antenna Semi-directional; used when longer distances must be achieved. A Yagi with more directors has a greater gain and antenna becomes longer. Radiation pattern for Yagi Directional Antenna

37 It s Always the Antenna: Parabolic dish antenna Highly directional, this antenna type transmits/receives signals in a very narrow angle. it is ideal for very long distances and provides minimum interference with other wireless networks. Radiation pattern for Parabolic Dish Antenna

38 It s Always the Antenna, and sometimes it s the mount!: Always properly and securely mount the antenna. Loose fitting or poorly designed brackets will be blown into a different direction with the first storm. An Omnidirectional antenna blown at an angle off vertical will reduce the received signal strength.

39 Can I use Solar Power? Yes, must be used with battery and required size depends on the I/O used. Batteries are sized for a number of sunless days with 50% safety factor. IL & WI in the 2-3 kwh/m2/day solar radiation region Not good.

40 Wireless is commonly used for: Tank level/inventory management Energy consumption measurements Environmental compliance tracking Corrosion rate monitoring/detection Safety showers & Eye Wash station activation Wind speed and Direction Water/waste treatment measurements Pump control

41 Wireless is commonly used for: Leak & Smoke detection Rupture disc, Safety relief valve & Steam trap monitoring Bearing temperature & Vibration monitoring for Rotating equipment Personnel and Asset tracking Voiceover IP for communicating Well drilling/grouting (mobile equipment) Asset monitoring/proactive maintenance

42 Wireless Unique Solutions: Remote monitoring of : Lagoons Ponds Pits Holding tanks

43 Wireless Unique Solutions: Rotating equipment: Dryers & Kilns Your Source for Process Control Instrumentation

44 Lesman offers a Three tier solution: Your Source for Process Control Instrumentation 1. Phoenix Contact = low cost modules designed as cable replacement for Conventional I/O, Serial Data and Ethernet or any combination thereof. Point-to-Point Wireless I/O for Monitoring and Control Two-way Wireless Communications for Handling Digital data

45 Lesman offers a Three tier solution: 2. Honeywell XYR 5000 Battery-Powered Wireless Transmitters for Process applications

46 Lesman offers a Three tier solution: 3. Honeywell XYR 6000 Self-Healing, Self-Propagating, network of nodes achieve blanket coverage of area (Wireless Cloud). Each node can communicate with any other providing redundancy. Wi-Fi & RFID Mission critical wireless mesh network

47 Lesman s Wireless Services: Site & Topology Surveys Terrain Analysis Package (TAP) Your Source for Process Control Instrumentation

48 Lesman s Wireless Services: Pre-installation support Startup and Commissioning Panel Assembly Maintenance Lesman University Your Source for Process Control Instrumentation

49 Why Not Wireless? (FUD) Fear Uncertainty and Doubt Bleeding edge technology Security nightmares IT Department hassles Licensing problems Users typically begin with very minimal needs, which often grow quickly once they begin to realizing the benefits of the technology.

50 The next Revolution in Manufacturing will be built on information - Wireless technologies allows for limitless measurement possibilities! Wireless in the Near future Advance Cellular technologies, SP100, Wireless HART, Analog TV bands become available???

51 Where in the plant could you use wireless? What data aren t you getting now, that wireless would give you access to? Remember, You can t control what you can t measure

52 Thanks for your time today!