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A Comprehensive Discussion of Fieldbus

2026-04-06 03:40:07 · · #1
Abstract: This paper analyzes the reasons for the emergence of fieldbus, elaborates on its concept, architecture, and characteristics, presents the current development status of fieldbus, proposes countermeasures to meet this technological revolution in the field of automation control, and illustrates specific development and application methods of fieldbus with examples. Keywords: Fieldbus, Distributed Architecture, Communication Protocol, Openness, Interoperability, LonWorks I. Introduction Fieldbus has only recently emerged in the control field, yet its momentum has been rapid and shows no signs of abating. So, what exactly is a fieldbus? What is a fieldbus control system? What are the characteristics and advantages of a fieldbus control system compared to the distributed control system (DCS) that still dominates the industrial control field? Can it be used before a unified fieldbus standard is established? If so, which of the more than 40 fieldbuses should be chosen? This paper will discuss these questions, exploring the causes of fieldbus from the perspective of the development history of control systems; elaborating on the concept, architecture, and characteristics of fieldbus; presenting the current development status of fieldbus; proposing countermeasures to address the current situation of numerous fieldbus development options; and illustrating specific development and application methods of fieldbus with examples. II. The Emergence of Fieldbus Looking at the history of control system development, it's easy to see that each new generation of control systems was a solution to the shortcomings of the older generation. Ultimately, driven by user demand and market competition, they gained market dominance. The emergence of fieldbus and fieldbus control systems is no exception. 1. Analog Instrument Control Systems Analog instrument control systems dominated in the 1960s and 70s. Their significant drawback was low analog signal accuracy and susceptibility to interference. 2. Centralized Digital Control Systems Centralized digital control systems dominated in the 1970s and 80s. They used microcontrollers, PLCs, SLCs, or microcomputers as controllers. The controller internally transmitted digital signals, thus overcoming the low accuracy of analog signals in analog instrument control systems and improving the system's anti-interference capability. The advantages of centralized digital control systems are ease of control calculation and judgment based on the overall situation, and unified scheduling and arrangement of control methods and control timing. The disadvantage is that it places high demands on the controller itself, requiring sufficient processing power and extremely high reliability. When system tasks increase, the controller's efficiency and reliability will decrease sharply. 3. Distributed Control System (DCS) Distributed control systems (DCS) dominated the market in the 1980s and 90s. Its core concept is centralized management and decentralized control, separating management from control. A host computer is used for centralized monitoring and management, while several slave computers are distributed to the field to achieve distributed control. These host and slave computers are interconnected via a control network to facilitate information exchange. Therefore, this distributed control system architecture effectively overcomes the shortcomings of centralized digital control systems, which require high controller processing power and reliability. The realization of distributed control in DCS benefits from the development and application of network technology. Unfortunately, different DCS manufacturers, aiming for monopolistic practices, adopted their own proprietary and closed control communication networks. This made it difficult to achieve network interconnection and information sharing between DCS systems from different manufacturers, as well as between DCS and upper-level Intranet or Internet information networks. Therefore, from this perspective, a DCS is essentially a closed, proprietary, and non-interoperable distributed control system, and DCS is expensive. Under these circumstances, users urgently demanded open and cost-effective network control systems. 4. Fieldbus Control System (FCS) FCS was born in response to the above trend. It uses the open and interoperable fieldbus network to interconnect various field controllers and instruments to form a fieldbus control system. At the same time, the control function is completely decentralized to the field, reducing installation costs and maintenance costs. Therefore, FCS is essentially an open, interoperable, and completely distributed control system, which is expected to become the mainstream product of the 21st century control system. III. Fieldbus and Fieldbus Control System 1. Concept of Fieldbus Fieldbus is a real-time control communication network that interconnects the lowest level field controllers and field intelligent instruments in automation. It follows all or part of the communication protocols of the ISO OSI Open Systems Interconnection Reference Model. FCS is a real-time network control system that interconnects the lowest level field controllers and field intelligent instruments in automation using an open fieldbus control communication network. 2. Difference between Fieldbus and Local Area Network (1) In terms of function, fieldbus connects the lowest level field controllers and field intelligent instruments in automation. Small batches of data information, such as detection information, status information, and control information, are transmitted on the network cable. The transmission rate is low, but the real-time performance is high. In short, fieldbus is a real-time control network. Local area networks (LANs) are used to connect computers in a local area. Large amounts of digital information, such as text, sound, and images, are transmitted over the network cable. The transmission rate is high, but real-time performance is not required. In this sense, a LAN is a high-speed information network. (2) Comparison by implementation method: Fieldbus can use various communication media, such as twisted pair, power line, optical fiber, wireless, infrared, etc., and has low implementation cost. LAN requires dedicated cables, such as coaxial cable, optical fiber, etc., and has high implementation cost. 3. Fieldbus control system architecture The lowest level Infranet control network is FCS. Each controller node is distributed to the field, forming a completely distributed control architecture. The network topology is arbitrary and can be bus, star, ring, etc. The communication medium is not limited and can be twisted pair, power line, wireless, infrared, etc. The Infranet control network formed by FCS can easily interconnect with the Intranet enterprise intranet and the Internet global information network to form a complete three-level enterprise network architecture. 4. Characteristics of Fieldbus Control Systems (1) Openness and Interoperability Openness means that FCS will break the monopoly of large DCS manufacturers, bringing equal opportunities for small and medium-sized enterprises to develop. Interoperability enables the "plug and play" function of control products, thus giving users more choices for industrial control products from different manufacturers. (2) Thorough Decentralization Thorough decentralization means that the system has high reliability and flexibility, the system is easy to reorganize and expand, and easy to maintain. (3) Low Cost To measure the overall cost of a control system, not only should its construction cost be considered, but also the total investment throughout the entire life cycle of the system from installation and commissioning to operation and maintenance should be examined. Compared with DCS, FCS's open architecture and OEM technology will greatly shorten the development cycle and reduce development costs. Moreover, the thoroughly decentralized distributed structure will change the 1-to-1 analog signal transmission mode to the 1-to-N digital signal transmission mode, saving a lot of A/D, D/A conversion devices, wiring installation costs and maintenance costs in the analog signal transmission process. Therefore, overall, the cost of FCS is much lower than that of DCS. It can be said that openness, decentralization, and low cost are the three most significant characteristics of fieldbus. Its emergence will bring about an epoch-making change to traditional automatic control systems. The depth and breadth of this change will exceed any previous revolution, and it will surely usher in a new era of automatic control. IV. Current Status of Fieldbus Development Fieldbus development is rapid, and it is currently in a stage of fierce competition among numerous players. More than 40 fieldbuses have been developed, such as Interbus, Bitbus, DeviceNet, MODbus, Arcnet, P-Net, FIP, and ISP. Among them, the five most influential are FF, Profitbus, HART, CAN, and LonWorks (performance comparison is shown in Table 1). 1. FF (Foundation Fieldbus) was launched by the American Instruments Association (ISA) in 1994. Representative companies include Honeywell and Fisher-Rosemount. It is mainly used in instrumentation for petrochemical and continuous industrial process control. The distinctive feature of FF is that its communication protocol adds a user layer on top of the ISO OSI physical layer, data link layer, and application layer, achieving interoperability through an object dictionary (OD) and a device description language (DDL). Currently, FF-based fieldbus products include pressure and temperature transmitters from Smar (USA), the ProcessLogix system from Honeyweill & Rockweill, and PlantWeb from Fisher-Rosemount. 2. Profibus (Process Fieldbus), launched by Siemens in Germany in 1987, is primarily used in PLCs. Products fall into three categories: FMS for communication between master stations; DP for communication between slave stations in the manufacturing industry; and PA for communication between slave stations in the process industry. Because Profibus's fieldbus products were developed as early as ten years ago, and due to the limitations of computer network technology at the time, most were based on IT network standards. As application areas expanded and user requirements increased, fieldbus products could only be partially modified and supplemented within the existing IT protocol framework. This resulted in the addition of many conversion units (such as various couplers) within the control system, which limited the product's future development. 3. HART (Highway Addressable Remote Transducer): Introduced by Rosemount in 1989, primarily used in intelligent transmitters. HART is a transitional standard that transmits digital signals by superimposing sine waves of different frequencies (2200Hz represents "0", 1200Hz represents "1") on a 4-20mA power signal line, thus ensuring compatibility between digital systems and traditional analog systems. Its lifespan is expected to be within the next 20 years. 4. CAN (Controller Area Network): Introduced by Bosch 6 in 1993, used in automotive monitoring, switch control, manufacturing, etc. The media access method is a non-destructive bit arbitration method, suitable for small networks with high real-time requirements, and the development tools are inexpensive. Motorala, Intel, and Philips all produce independent CAN chips and 80C51 chips with CAN interfaces. CAN bus products include AB's DeviceNet and Advantech's ADAM data acquisition products. 5. LonWorks (LON Local Operating System), launched by Echelon in 1991, is mainly used in building automation, industrial automation, and the power industry. LonTalk's full 7-layer protocol uses PP CSMA (Predictive P-Persistent Carrier Sense Multiplexing) for media access, employs network logical address addressing, and a priority mechanism ensures real-time communication. Its security mechanism uses a confirmation method, thus enabling the construction of large-scale network control systems. Echelon's Neuron chip is essentially a network-based microcontroller. Its powerful network communication processing capabilities, coupled with object-oriented network communication, significantly reduce the time and cost developers need to spend on constructing application network communication systems. This allows developers to focus on their expertise in application layer control strategy development. Therefore, many industry experts consider the LonWorks bus a promising fieldbus. LonWorks-based bus products include Action's Flexnet and Flexlink. V. Our Countermeasures 1. Should We Develop FCS? With FCS booming abroad, how should China's industrial control industry embrace this transformation in the automation field? The answer can be found by analyzing the development history and current state of China's industrial control industry. China's domestic industrial control products, such as PLCs and DCSs, have long lagged behind foreign counterparts. The fundamental reason is that a few large foreign companies adopt a closed structure for their industrial control products to maintain their monopoly. China can only master their key core technologies through import and assimilation, thus missing market opportunities and always falling behind and being controlled by others. The open strategy of fieldbus technology undoubtedly brings a once-in-a-lifetime opportunity for equal competition to my country's industrial control industry in the international market. When the rules of the game change and everyone is on the same starting line, it depends on who gets there first, seizes the market, takes the initiative, and ultimately leads the market. Therefore, we should seize this opportunity, take the lead in launching fieldbus products with Chinese characteristics, create our own international brand of industrial control products, and thus open a new chapter in the development of China's industrial control industry. 2. Which FCS should we adopt? Since we have decided to adopt FCS, which fieldbus should we adopt given the wide variety of fieldbuses? Analyzing the reasons for the diversity of fieldbuses will help clarify this issue. The diversity of fieldbuses is caused by two main factors: first, industry habits, such as Profibus being used in the PLC industry and FF in the instrumentation industry; second, conflicts of interest, as each industrial control manufacturer is unwilling to abandon its own standard and lose the market share it has already occupied. Obviously, it is too early to completely unify fieldbus standards. In view of this, the following strategies are recommended for the development of China's industrial control industry: (1) Short-term goal: Based on the specific characteristics of the target industry, such as building automation and process automation, select one (or two) fieldbuses with good performance in this field, and conduct research and development. On the one hand, take the lead in launching products with unique features, occupy the market, and generate application value and social benefits; on the other hand, focus on mastering the essence and core of fieldbuses, and adapt to changes. If the selected bus fails to become the final standard bus, due to the essential commonality between buses, it can be quickly converted to the final standard bus. (2) Long-term goal: After mastering the essence of each bus, leverage its strengths and avoid its weaknesses, formulate China's own fieldbus standards, and revitalize China's national industrial control industry. VI. Development Examples For the building automation industry, given the outstanding performance of LonWorks fieldbus in this field, we have developed a product based on LonWorks general network intelligent controller node and a visual control configuration platform—Visual Control Configuration. The key feature of this product is that most LonWorks product developers abroad are still at the stage of integrating the Neuron C programming environment provided by Echelon. To develop efficient control applications using Neuron C, one needs not only familiarity with this high-level instruction language itself, but also a deep understanding and mastery of the internal hardware structure of the Neuron1 chip, memory address space allocation, and other technical aspects. This is clearly unrealistic for end users and field technicians. The Visual Control Configuration platform effectively solves this problem. Using a flowchart-like graphical representation, the control configuration language, conforming to the International Electrotechnical Commission (IEC) 1131-3 standard, transforms the control program into a graphical representation of the control strategy conceived by engineers. The connections between elements represent the data flow of the control algorithm. Experienced field control technicians can complete the development of control strategies in a short time without specialized training, making it convenient and efficient. Currently, we have successfully developed the access control system for the Nanning Bank of Communications by applying this Visual Control Configuration software platform and nodes of the LonWorks general-purpose network intelligent controller in an engineering project. VII. Conclusion The era of fieldbus is approaching. Let us embrace the opportunities and challenges of this turn of the century with enthusiasm and initiative.
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