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Abstract: Wireless communication technologies can bring great benefits to industrial automation systems. But because of
the high data losses and transmission errors caused by channel fading and interferences, the hard real-time and reliability
requirements of industrial automatic control are difficult to be guaranteed. An industrial wireless control communication
network and protocol is put forward. The functions of each protocol layer are introduced. Service differentiating, resource
reserving and cross-layer and cross-network schedule mapping mechanisms are used to provide the real-time and reliable
communications. The performance analysis shows it can satisfy the requirements of industrial field monitoring and control.
Key Words: Industrial Automatic Control, Industrial Wireless Control Communication Network and Protocol, Real-time,
Reliability, Performance Analysis
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Automatic control application is very important in subsequent packets required), subject to deadlines; 2)
industrial plants. Designing real-time and reliable presence of important acyclic packets like alarms, which
communication networks and protocols for industrial need to be reliably transmitted with bounded latencies;
control applications is one of the key research issues and and 3) most packets are short, on the order of a few bytes.
the developing directions of industrial wireless
communication. In this paper, based on the work on WSN, 2.2 Analysis of Wired Fieldbus Protocol
Chinese WIA-PA, wireless FF and ISA SP100, we Wired fieldbuses are now the main communication
analyze the main functions of industrial wireless control technologies in industrial automation. To support the
communication network and protocol, give out effective communication requirements of industrial automation
implementing methods to support hard real-time and tasks, the protocols of most wired fieldbuses are usually
reliable information transmission both for automatic field different from the ISO OSI communication reference
monitoring and production process control. model and modifications are made according to the
requirements. For example, the protocol of Foundation
2 REQUIREMENS OF INDUSTRIAL AUT- Fieldbus (FF) includes the Application Layer (APL), Data
OMATIC CONTROL APPLICATIONS Link Layer (DLL) and Physical Layer (PHL) and the
Industrial wireless control communication network and additional User Layer (USL) above the APL[2] (See Figure
protocol orients to automatic monitoring and control 1). The FF USL provides standard device models, user
applications of production processes. Analysis of application object models and their description and
automatic tasks and performance requirements is the organization technologies, such as standard function
designing guide to wireless control communication blocks (FB), device description (DD) and its language,
network and protocol. object dictionary (OD), network and system management.
FF user layer The user layer
(FB,DD OD) (automatic object, device object)
2.1 Industrial Automatic Control Application Fieldbus Message
Specification (FMS)
The application
The application layer
layer Fieldbus Access Sublayer
Just like wired fieldbuses, industrial wireless control (FAS)
management
The presentation
Security
and
networks lie in production field. They connect field layer
The session layer
computers, control systems and enterprise management Fig.1 Protocol model of FF and industrial wireless control
communication
information systems. The measuring information of
The FF APL is divided into Fieldbus Message
production processes from sensors is passed to controllers
Specification (FMS) and Fieldbus Access Sublayer (FAS).
and control commands to actuators. The information of
FMS provides a group of services and standard message
production field is also delivered to the upper level
formats for transmitting the information of user
computers and maintenance and configuration information
applications and accessing the application objects and
is passed to the field devices from high level networks.
their descriptions. FAS provides communication services
Then an industrial automation system is established and
for FMS through virtual communication relations (VCRs).
automatic maintenance, monitoring and control tasks can
be implemented through the information interactions The FF DLL specifies data transmissions between devices
between the field devices and computers. in a field network. The communication activities of FF are
divided into predefined periodic and non-predefined
Different from commercial and office networks, the
communication. The network channel access and
production processes in a plant are deterministic, so the
communication schedule are implemented by the link
field devices, network topology and the communication
active scheduler (LAS) through passing tokens. The
tasks are deterministic. The delivered information includes
predefined periodic communications are initiated by
signal alarm, measured data, such as temperature and
Compel Data (CD) tokens sent by the LAS periodically to
pressure, set value and control command, uploading and
the devices according to the system schedule table. The
downloading.
non-predefined communications are initiated by Passing
Automatic monitoring and control of production process Tokens (PT) sent by the LAS with different priorities
require strict real-time and reliability. The underlying between two predefined communications according to the
communication networks must provide real-time link active device list.
information transmitting services that are both predictable
The PHL implements the mechanical and electrical
and reliable, i.e., make certain guarantees on eventual
interfaces between field devices and fieldbus and provides
delivery of packets and transmission times. Some
physical signals for the message sending and receiving.
important characteristics of industrial control traffic are: 1)
presence of periodic traffic (bounded jitter between
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There is no network layer in wired fieldbus protocols. The 3 REAL-TIME AND RELIABLE PROTOCOL
communicating field devices are usually connected
together in the same network segment. Sensor data is Providing real-time and reliable transmission services are
delivered to controllers and control commands to actuators QOS problems in traditional communication network. In
directly without forwarding. The communi- cation delay is Internet, QOS are support mainly through resource
thus reduced and real-time performance is improved. reservation and differentiate services[5]. The end-to-end
QOS is supported through network-centric and
2.3 Problems with Current Wireless Standards end-device-centric methods[6]. In industrial wireless
control communication network and protocol, different
Real-time and Reliability Support
automatic tasks should be provided with different
Predefined periodic, non-predefined real-time automatic communication services. Service differentiating, resource
tasks and non-real-time management and maintenance reserving should be provided in each protocol layer and
tasks are the main communication activities in industrial cross-layer and cross-network QOS mapping mechan-
automation systems. Predefined periodic communica- isms should be used to guarantee the real-time and
tions require hard real-time and non-predefined real-time reliability communication requirements.
tasks need real-time and reliable communication services.
Industrial wireless control communication network and 3.1 Wireless Communication Devices
protocol must satisfy their real-time and reliable
The communication devices in industrial wireless control
requirements. But in the published industrial wireless
networks are divided into field devices, handheld devices,
standards, there is no corresponding mechanism to support
routing devices and gateways according to their functions.
predefined periodic and priority-based communications. In
Field devices include wireless sensors, actuators, and
these standards, the DLL just provides CSMA/CA-based
controllers. Field and handheld devices are used for
channel access. The deterministic and real-time
monitoring, control and maintenance of production
requirements can’t be fulfilled. In IEEE802.15.4 and
processes and devices. Routing devices includes dedicated
IEEE802.11, although Guaranteed Time Slot (GTS) and
wireless routers and some wireless field devices with
Point Coordinate Function (PCF) polling mechanisms are
routing capability. They can forward packets from field
offered to serve predefined tasks, but the deterministic can
devices and other routing devices. Gateway connects field
not be guaranteed and communication delay and jitter are
and routing devices to upper level management and
too long[3,4]. Furthermore, low-power consumption is one
supervisory networks.
of the characteristic of wireless devices. Sleeping period is
Some wireless field devices require low power consum-
involved in the communication processes to save power.
ption to guarantee long life of the battery. Other field
The sleeping period extends communication and sampling
devices, which are involved in periodic communications,
cycle of control algorithms and thus influences the
and routing devices must communicate constantly and
performance of closed loop control.
don’t require saving power.
Packet Forwarding
In industrial wireless control networks, because of channel 3.2 Network Topology
fading, external interference and limitation of Different from wired fieldbuse, the messages of wireless
transmission power, the communication distances are field devices are usually forwarded by one or more
usually short, i.e. several meters. And as for the harsh intermediate devices. Multi-hop communications and
environment of industrial field, some wireless field networks must be provided. Thus industrial wireless
devices can not communicate with each other directly control network includes star, tree and mesh topologies.
because of obstacles or interferences between the devices. The star and tree networks are many-to-one networks that
The communication information must be forwarded by one one routing device forwards information from field
or more nearby devices. Thus industrial wireless devices and other routers. In order to guarantee reliability,
communication networks are often multi-hop and the industrial wireless control network also adopts mesh
information transmissions are multi-path to guarantee the topology in which field devices and routers have more than
reliability. Mesh network is a common topology of one communicating paths to forward their data. The
wireless communication. Packet routing and the Network multi-path of information forwarding in mesh network can
Layer are needed. Thus, communication delays and jitters support reliable communications in case of interferences.
will be longer. The performance of predefined periodic
Industrial wireless control networks are divided into
and hard real-time communications is more difficult to
several subnets. In each subnet, there is a central device
guarantee than just in a single network segment or in a
responsible for subnet organization and at least one
one-hop network.
routing device for packet forwarding. Gateways forward
So, the absence of predefined periodic and priority messages between the wireless field networks and high
communication supports and corresponding real-time level management and control networks (See Figure 2).
routing method makes current wireless protocols not
suitable for industrial production process control.
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The APL
High level managem ent High level m anagement High level management
network network network
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M A C sup erfram e S y s te m m a cr o c y c le
a c tiv e p o r tio n i n a c t iv e p o rt io n
p e rf o r m i n g s o f a u t o m a t i c o b j e c t s
beacon beacon
PCP
C o m m u n ic atio n s o f a u to m a tic o b jec ts
Fig.3 MAC superframe of industrial wireless control M A C s u p e rf ra m e
S y s te m m a c ro c y c le
communication processes can really happen according to P r e d e f in e d a u to m a t ic a p p li c a ti o n
USL automatic applications are mapped into high priority Fig.6 Cross-subnet mapping of predefined communication
messages in the DLL. They access the channel prior to the The PHL
non-real-time ones. Non-real-time applications are The primary tasks of the PHY are: coding bits into
delivered through low priority slotted CSMA/CA. The physical signals and decoding signals into bits, conveying
joining of field devices, managements, maintenances and those signals from one physical location to another,
configuration of the network and system are implemented specifying the radio frequency and transmission power. In
in this way too. So, the communication requirements of the order to improve compatibility with other industrial
USL applications are mapped into the DLL. Resources are wireless technologies, the PHL adopts IEEE802.15.4
reserved for predefined periodic tasks, different priority PHL specification. Because of the short packets of
services are provided for non-predefined real-time industrial monitoring and control applications, 250kbps
communications in the DLL. Acknowledging, Retrying, data rate is enough for information transmissions.
frequency hopping and error correcting can guarantee the Security and management
reliability of messages under interferences. The message
error control and checking can guarantee the integrity.
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N −1
In addition to these key functions of protocol layers, there
are also security and management functions distributed in T SQ = ∑ (T
i =1
SDQi + T Slot ) . (3)
each layer. System and network security and management
TSDQi is the queuing delay of ith message; TSlot is the time
are fulfilled through the functions and services in each
slot of the superframe. Because non-predefined messages
layer. Error control and retry can be used in the layers too.
are delivered in slotted CSMA/CA, each message sending
4 PERFORMANCE ANALYSIS will occupy one time slot.
4.2 Performance of Forwarding Communications
4.1 Performance of Direct Communications
When there are interferences or obstacles between
First, let’s see the simple case that wireless sensors,
wireless field devices, the devices can not communicate
actuators and controllers are in the same subnet, and they
with each other directly. The transmitted information must
communicate with each other directly without forwarding.
be forwarded by routing devices.
In this case, the communication delay just includes the
time of message processing, queuing and transmitting Predefined Periodic Automatic Applications
between the devices. There is no message forwarding For predefined periodic automatic applications, the
process and latency. cross-subnet DLL PCPs in routers ensure the deterministic
Predefined Periodic Automatic Applications of forwarding communications. If the forwarding device
and destined device are in the same subnet with the
Suppose TSU is the time the source object begins to send a
sending device, a forwarding PCP is allocated in the same
message, TSD the beginning time of its DLL PCP, TSDP is
superframe with original PCP. If the destined device is in
the message processing time of source device, TSDS is the
different subnet, a PCP must be allocated in the
sending time of the DLL, TSDT is the message transmitting
superframe of destined subnet that involves routing and
time in wireless channel, TDDR is the message receiving
destined devices. The arrangement of original and
time of destined DLL and TDDP is the time destined device
forwarding PCPs must consider the system schedule and
processes the message and passes it to the USL object.
the time sequence.
Then, the communication delay TP is:
In this case, the communication delays of predefined
T P = T SD − T SU + T SDP + T SDS + T SDT + T DDR + T DDP . (1) periodic automatic applications are (only two hops):
Because the time of message processing, sending and
TFP = T FD − TSU + TFDR + TFDP + TFDS + T FDT + TDDR + TDDP (4)
receiving in the device and transmitting along the channel
are related to CPU processing and network transmission TFD is the beginning time of the forwarding PCP in the
speeds which are deterministic. So the whole superframe of the same or destined subnet, TFDR is the
communication delay TP is deterministic and very small. message receiving time of the forwarding device, TFDP is
The communication requirements of predefined periodic the message processing time, TFDS is the message sending
automatic application can be guaranteed in the same delay of the forwarding device and TFDT is the transmitting
subnet. time.
Non-predefined Real-time Automatic Applications Just like direct communication, the time of message
processing and transmitting are deterministic and short, so
As for non-predefined real-time automatic applications,
the forwarding delay TFP is deterministic. The message
the messages contend the wireless channel with short
can be transmitted within one communication cycle.
intervals and backoff windows, thus they can get the
channel first. When the traffic in the network is light, the Non-predefined Real-time Automatic Applications
real-time communication can be transmitted immediately. The messages of non-predefined real-time automatic
Then the communication delay is (if not colliding with applications are forwarded with high priority. If the
PCPs): forwarding and destined devices are in the same subnet
with source device, the forwarding device contends the
T R = T SDP + T SDS + T SDT + T DDR + T DDP . (2)
channel of the same subnet to forward the message. If the
When the traffic is heavy and there are a great number of destined device is not in the same subnet with source
real-time messages to be sent in the subnet, real-time device, the forwarding device receives the message and
messages must be queued and contend to access the then contends the channel of the destined subnet to
channel with each other and the additional queuing delay forward the message.
is produced. The queuing delays are relative to the number
When the network traffic is light or in the best case, the
of the real-time messages and are not deterministic.
source and the forwarding device get the channel
Suppose there are N real-time messages in the network at
immediately when they have real-time message to send.
the same time. In the best case, the message is the first one
Then the message queuing delay of one hop forwarding is
accessing the channel. So, the queuing delay is TSQ = 0. In
zero. The whole communication delay is:
the worst case, the messages may be the last one getting
the channel. Then the additional queuing delay TSQ is TFR = TR + TFDR + TFDP + TFDS + TFDT . (5)
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In the worst case, the message is the last one to get the required communication services for industrial automatic
channel and to be forwarded. If the destined device is in monitoring and control applications and will support
the same subnet with source device, the communication wireless communication technologies to really step into
delay of the message is: industry factories. Industry plants will share the fruit of
TFRS = TSQ + TSDS + TSDT + TFDR + TFDP + TFDS + TFDT . (6) wireless communication technologies and gain huge
economical benefits.
If the destined device is in different subnet and the number
of high priority real-time messages in the destined subnet But there are still some detailed problems to be solved in
is M, the communication delay is: the protocol, such as the implementations of PCPs in the
M DLL, real-time packet routing in multi-path mesh
TFRF = TFRS + ∑(TDDQj+ TSlot) . (7) networks. Cross-layer and cross-network schedule
j =1
mapping also needs more effective methods. Except
TDDQi is the queuing delay of jth message in destined qualitative analysis, the proposed protocol needs thorough
subnet. simulation and test to verify its availability. These are our
So, when non-predefined real-time messages are future research work.
forwarded, the routing devices must contend the channel to
transmit the messages. The additional delay is relative to REFERENCES
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