As Ethernet continues to evolve and upgrade as an industrial network, companies are accelerating the integration of industrial automation systems and enterprise applications. What efficiency improvements can be observed by analyzing assembly failure data collected during IT network communications? Or what valuable business intelligence can be gleaned from waste data related to material supplier pricing? The new business models enabled by network flexibility are becoming increasingly difficult for corporate management to ignore.
IIoT requires industrial Ethernet.
The Industrial Internet of Things (IIoT), with its innovations in sensor technology, wireless connectivity, energy harvesting, big data, and cloud computing, is part of the seamless information exchange between devices, systems, and people. It paves the way for manufacturing companies to improve performance, flexibility, and responsiveness throughout the value chain. The development of IIoT requires Industrial Ethernet; through the data provided by Ethernet, big data analytics can offer companies more valuable information.
Given the demands of higher-speed processes on Ethernet and the increased data acquisition required, factories need a redundant network to easily address network issues at the control layer. Network-wide visibility also provides reliable connectivity for edge devices.
A host with a Layer 3 router and a Layer 2 managed switch can meet the needs of the core network. Layer 2 unmanaged switches require expanded port status transparency at the IP address layer and improved port quality of service to adapt to enterprise operating environments requiring extensive network automation. However, the downside is that such switches are expensive and require a relatively long startup time during implementation.
Low-cost managed switches
John Morse of market research firm IHS predicts that "the adoption of low-cost, lower-functionality Layer 2 switches will more economically meet user needs, just as more networks are being expanded to meet the connectivity demands of the IIoT era." A 2014 IHS report on the industrial Ethernet infrastructure components market also noted that "in the long run, as enterprises consider costs, the demand for unmanaged switches will gradually slow down, just like for network hubs."
To provide automation and IT software with greater visibility into port status, Layer 2 unmanaged switches acting as edge switches must support Modbus/TCP and Simple Network Management Protocol (SNMP) communication. This allows Supervisory Control and Data Acquisition (SCADA), Human Machine Interface (HMI) software, and Network Management System (NMS) software to monitor the switch's status in real time.
Ethernet reliability
As more programmable logic controllers (PLCs), input/output (I/O) devices, terminal computers, and HMIs connect to Ethernet, the robustness requirements for Ethernet will increase. This could lead to exponentially higher energy consumption for automation teams that haven't upgraded or gained transparency at the network edge. With the increase in edge devices and improved data acquisition capabilities, the need for manual switch inspections will decrease, as automated connection systems will promptly upload lost data and device information.
Greater network transparency speeds up troubleshooting for automation and IT teams. Edge switch technology supporting Modbus/TCP and SNMP protocols also makes troubleshooting easier. In this converged network model, teams can quickly obtain solutions to network problems.
For example, data from temperature sensors in a factory floor can be important for engineers to perform process analysis, as well as for IT departments to perform cloud storage and business process analysis; both teams can send or receive alerts promptly once data loss becomes apparent.
A network diagnostic model allows viewing real-time port status on SCADA/HMI and the NMS used by central IT.
Enable diagnostics
Even more powerful is the added diagnostic capability, allowing both system control and IT teams to perform diagnostics. For example, they could diagnose a connection interruption between the Ethernet cable and the fifth port of the edge switch's I/O input, which hosts the temperature sensor, and notify the relevant departments for necessary repairs. This is perfectly adequate for an edge switch with onboard agents for Modbus/TCP and SNMP protocols. More intelligent edge switches even provide detailed statistics on each port, including speed, connection counters, multicast packet counts, single-cast packet counts, and error counts. Using an edge switch that also supports SNMP allows IT teams to perform continuous pre- and post-processing status monitoring of their network management systems or software.
To keep pace with the growth in the number of devices and the diversity of data needs, more Ethernet applications like this will emerge, allowing for easy viewing of Ethernet from the device layer to the control layer and the central office.
Related: What is Industrial Ethernet?
Industrial Ethernet is an industrial network developed based on Ethernet and TCP/IP technologies. Previously, Ethernet was generally used as an office network in commercial applications. Currently, Ethernet is gaining popularity in industrial applications, and in the future, Industrial Ethernet may become the main form of industrial control network architecture, creating a seamless, end-to-end network.
Why are people trying to use Ethernet in industrial applications? This is because Ethernet is currently the most widely used type of local area network. Ethernet's huge commercial success, high awareness, and technological advancements mean that using Ethernet in the industrial field will bring many benefits.
1. Using Ethernet is easier than using other fieldbuses.
This is reflected in several aspects: Generally, users have some knowledge and experience with Ethernet, which can reduce the time and money required for user training; the widespread use of Ethernet technology has enabled humans to accumulate a lot of related knowledge, making it easier to solve problems; Ethernet products are diverse, with many related software and hardware products, making Ethernet technology easy to use; there are many types of Ethernet, supporting multiple transmission media and multiple transmission rates to meet the needs of various applications.
2. Ethernet products are relatively inexpensive.
Because of the large market potential of Ethernet, Ethernet products can typically be produced in large quantities. Furthermore, the large number of Ethernet product suppliers leads to intense competition and low product prices, thus reducing costs. While commercial Ethernet products are currently very inexpensive, industrial Ethernet products remain relatively expensive. However, if industrial Ethernet becomes widely adopted, costs and prices will naturally decrease.
3. Ethernet technology has developed rapidly and is technologically advanced, which is unmatched by fieldbus.
In terms of transmission rate, Ethernet currently has a transmission rate of 10 Gbit/s, while fieldbus transmission rates are generally below 10 Mbit/s.
4. Information integration is more convenient.
Since many enterprise LANs use Ethernet, and Ethernet is also used in industrial applications, it makes information integration more convenient. Furthermore, integrating industrial networks with enterprise intranets, and even the Internet, makes the implementation of e-commerce, electronic manufacturing, and other applications easier.
5. Meets the requirements for a flattened control network structure.
Currently, control networks have multi-layered structures; the more layers there are, the more complex the system becomes and the more difficult it is to maintain. If industrial Ethernet is used, it can fully realize the functions required by both the information layer and the control layer networks. Therefore, it may eventually be flattened into a single layer, resulting in a situation where Ethernet "covers everything."
However, the widespread adoption of Ethernet in industrial applications faces two major challenges. First, Ethernet was initially developed for office automation applications, making it a non-deterministic network operating in typically favorable environments. Industrial applications, however, require highly real-time data transmission to prevent accidents; furthermore, industrial environments are often harsh, including strong vibrations, extreme temperatures, high humidity, and strong electromagnetic interference. Second, Ethernet is a general term for networks using Medium Access Control (MAC) with Carrier Sense Multiple Access with Collision Detection (CSMA/CD), and it doesn't inherently provide standard application-layer protocols for industrial applications. Therefore, to meet the requirements of industrial applications, further work must be done on top of Ethernet and TCP/IP technologies. In summary, for the first problem, the solution is to make improvements that enable Ethernet to achieve deterministic communication and function properly in harsh environments. For the second problem, there are three solutions: one is to integrate existing industrial application protocols with Ethernet and TCP/IP; another is to install gateways between Ethernet and existing industrial networks for protocol conversion; and the third is to simply develop a completely new application-layer protocol.
Currently, some of the more influential industrial Ethernet technologies include Foundation Fieldbus High-Speed Ethernet (FFHSE), Ethernet/IP, PROFINET, and Modbus TCP/IP.
The existence of multiple industrial Ethernet networks presents a new problem: the industrial application layer protocols used by these different industrial Ethernet networks are incompatible. Although these protocols can all run on the same Ethernet network, devices developed for different types of industrial Ethernet networks still cannot interoperate. To address these issues, the Object Linking and Embedding (OLE) Foundation for Process Control released the OPC Data Exchange (OPCCDX) standard in June 2003. The OPC Foundation is a non-profit organization dedicated to improving interoperability in automation systems. Its OPC series of standards are based on Microsoft's Component Object Model (COM), Distributed Component Object Model (DCOM), and OLE, and are a series of standards for industrial automation software development.
Currently, in industrial applications, Ethernet is widely used in the information layer network, typically commercial Ethernet. Industrial Ethernet is also widely used in the control layer and is growing rapidly. However, its application in the device layer is still relatively limited. While Ethernet is suitable for connecting complex devices such as frequency converters and robots, it doesn't yet demonstrate its advantages for connecting simple sensors or actuators. Nevertheless, with the rapid development of the Internet, the continuous advancement of Ethernet technology, and the further flattening of factory network architectures, it is possible that Ethernet will become ubiquitous in future industrial applications.
The right approach to the Industrial Internet of Things ecosystem
Is Industry 4.0 merely a hyped-up term overemphasized by technology providers for sales purposes, or is it an industry trend that will be realized in the next few months or years?
Numerous signs indicate that Industry 4.0 is a major trend in the industry. Industry 4.0, also known as the Fourth Industrial Revolution, includes the widespread application of automation technologies and greater data interaction in digital factories. The name Industry 4.0 originates from the earlier stages of manufacturing—mechanization, electrification, and electronic informationization.
Industry 1.0 was the era of mechanical manufacturing, specifically the era of mechanical equipment manufacturing introduced in the 18th century; the period was roughly from the 1760s to the mid-19th century.
This involved mechanizing factories using water power and steam engines. The result of this industrial revolution was that machine production replaced manual labor, and the economy and society shifted from a model based on agriculture and handicrafts to one driven by industry and machinery manufacturing. At that time, the concept of electrical automation control for machinery did not yet exist.
Industry 2.0 is the era of electrification and automation, that is, the era of electrification and automation in the early 20th century; the time period is roughly from the second half of the 19th century to the early 20th century.
This refers to the large-scale production of products driven by electricity, based on the division of labor. Because of electricity, we entered an era of production using relays and electrically automated controlled machinery. This industrial revolution, through the successful separation of component production and product assembly, pioneered a highly efficient new model for mass production.
Industry 3.0 is the era of electronic information technology, which began in the 1970s and continues to this day.
Building upon the Industry 2.0 upgrade, the widespread application of electronic and information technologies has significantly enhanced the automation of manufacturing processes. Production efficiency, yield rates, division of labor, and equipment lifespan have all seen unprecedented improvements. During this stage, factories extensively utilize machinery controlled by truly electronic and information technology systems such as PCs, PLCs/microcontrollers for automated production. From this point onward, machines gradually replace human labor, taking over not only a considerable proportion of manual labor but also some mental labor.
The Industry 4.0 concept is one of the ten future projects identified in the German government's 2013 High-Tech Strategy 2020, and has been elevated to a national strategy aimed at supporting the research and innovation of a new generation of revolutionary technologies in the industrial sector.
Industry 4.0 is an era of convergence between the physical world and the virtual network world. However, there are few German companies responding to Industry 4.0, partly because the main idea of the so-called Cyber-Physical System (CPS) convergence was proposed by the United States several years ago. In the next 10 years, the intelligentization based on Cyber-Physical Systems (CPS) will usher humanity into the Fourth Industrial Revolution, led by intelligent manufacturing. The digitalization of the entire product lifecycle and manufacturing process, along with module integration based on information and communication technologies, will form a highly flexible, personalized, and digitalized new production model integrating products and services.
The Industry 4.0 concept encompasses many related technologies and service models, such as cloud computing, big data analytics, cyber-physical systems (CPS), machine learning, augmented reality (VR), and the Internet of Things (IoT). In the Industry 4.0 era, manufacturing companies will build and operate smarter factories than ever before, easily meeting customers' customized needs. This model is known as the Industrial Internet of Things (IIoT).
Technological Collaboration
Driving Industry 4.0 typically requires technological collaboration. For example, Cyber-Physical Systems (CPS) support cloud services, enabling intelligent objects and cloud-based programming modules to interact; big data analytics capabilities are making machines increasingly intelligent; and other emerging technologies such as Artificial Intelligence (AI), Augmented Reality (VR), and 3D printing solutions are providing factories with unprecedentedly agile, precise, and efficient manufacturing environments.
McKinsey points out that Industry 4.0 is not just a fancy slogan; the convergence of trends and technologies is expected to reshape manufacturing methods.
During the development process, the amount of data, computing power, and connectivity have increased significantly; data analysis capabilities and business intelligence (BI) have made remarkable progress; the usability of new human-computer interactions has been enhanced; and the achievements of the digital revolution are significant—for example, the emergence of advanced machine technology and 3D printing technology.
McKinsey advises companies to closely monitor the progress of Industry 4.0 in order to seize the new opportunities created by related technologies. Traditional manufacturing business models are being replaced by new ones. To reap the benefits of Industry 4.0, companies must be well-prepared for the upcoming digital transformation.
Platforms supporting Industry 4.0 applications need open systems to adapt to changing market demands and industry trends. They should also leverage emerging technologies in the coming years.
The factory of the future will be an organic entity that can be transformed and shaped in a timely manner, connecting more entities than ever before, such as customer service centers, raw material supply chains, and distribution channels. Today's manufacturing environment is typically composed of incompatible combinations of automation technologies, hindering data sharing between manufacturing systems. Smart factories will leverage IoT cloud platforms to gain intelligent control over the entire enterprise's manufacturing operations.
Machine learning algorithms can identify production patterns and extract feedback, which can be used to optimize production operations. Predictive analytics can identify systemic failures throughout the factory so that equipment can be repaired or replaced in a timely manner to avoid production delays.
In modern production environments, factory data is delivered to the cloud, which provides visualization and powerful analytics tools to enable higher-level business operation processes.
For example, a large UK manufacturer with factories around the world is aggregating data from all its factory automation platforms to transmit various equipment data and real-time data to a unified public cloud platform and create custom views. This will allow the company to see all business operations from a holistic perspective, facilitating improved production efficiency.
The key driver of Industry 4.0 technologies enabling smart factories is the promotion of personalized production, which, unlike mass production, can meet customers' immediate needs and provide highly customized products.
The Power of Ecology
The potential of the factory of the future comes not from within the enterprise, but from outside. As Industry 4.0 proves to be applicable to individual companies, executives in IT, operations, and business units need to view this trend from a more holistic perspective. They need to realize that the greatest return on investment should come from building an Industry 4.0 ecosystem, encompassing design, production, transportation, and product use.
By connecting with Industry 4.0 ecosystem partners, each component of the ecosystem can deliver greater market value. Analogous to a biological concept, cells cannot function alone but rely on a mutually beneficial, symbiotic organic whole. The Internet of Things, especially cloud services, can provide the necessary organizational structure to help each part work efficiently and collaboratively, creating business models and intelligent operations that can benefit from interconnected ecological relationships.
A key technological component of Industry 4.0 ecosystem partners lies in application programming interfaces (APIs). By opening up their APIs to partners, manufacturers can facilitate the creation of various applications that partners require.
To achieve this, companies need to deploy an IoT platform, which enables partners across the ecosystem to share service-oriented APIs using a PaaS model. Applications will be able to quickly perform business analysis on different resources and data types, whereas previously this required dedicated programmers. It will also easily adapt to cloud provider-specific APIs for data extraction, differential storage, distributed computing, and machine learning.
By leveraging APIs and cloud computing, enterprises will build and share a new generation of manufacturing-oriented IoT applications, which will be central to Industry 4.0 or the Industrial Internet of Things (IIoT). This not only provides greater intelligence and efficiency but also transforms business models.
To build a smart factory capable of manufacturing unique, highly customized products, consumers and businesses need to explore and leverage the full potential of Industry 4.0. A new API platform specifically designed for the latest manufacturing revolution is emerging, which will help companies quickly develop, manage, and even monetize their products.
