PROFINET and the
Industrial Internet
of Things
The Machine Building Show – Sept 2015
Peter Thomas
(Control Specialists Ltd)
Chairman of the
PROFINET & PROFIBUS International Training Centres
(PITC‘s)
The four stages of the Industrial Revolution
1st Industrial Revolution
• Follows introduction of water and steam powered mechanical manufacturing facilities
2nd Industrial Revolution
• Based on mass production achieved by the division of labor concept and the use of electrical energy
3rd Industrial Revolution
• Uses electronics and IT to achieve further automation of manufacturing
4th Industrial Revolution
• Based on Cyber Physical Systems
• IoT
• IIoT
End of 18th century
End of19th century
1970’s
today
Increased networking needed!
2
Industry 4.0 – Why it matters.3
40% of the worldwide manufacturing value is held by emerging countries. This
equates to 6,577 Billion Euros.
Industry makes up 15% of the European economy. This drives research, innovation, productivity, job creation
and exports.
The emerging countries have doubled their share in the
past 20 years.
Western Europe has lost over 10% of worldwide
manufacturing valueTo assume a leading role in
Industry 4.0, Europe will have to invest 90 Billion Euros per annum over the next 15 years.
Source – Roland Berger Strategy Consultants – March 2014
IoT – The Internet of Things4
The Internet of Things (IoT) is an environment in which objects, animals or people are provided withunique identifiers and the ability to transfer data over a network without requiring human-to-humanor human-to-computer interaction (whatis.techtarget.com)
IIoT – The Industrial Internet of Things5
The Industrial Internet of Things (IoT) is the use of Internet of Things (IoT) technologies inmanufacturing.
IoT verses IIoT
Internet of Things (IoT)
Industrial Internet of Things(IIoT)
Impact Revolution Evolution
Current status New devices and standards Existing devices and standards
Connectivity Ad-Hoc Structured
Criticality Important but not critical Mission critical• Analytics• Security
• Data integrity• Response times
Data Volume Medium to High Very High(Big Data – see next slide)
Servicing User User, OEM, Vendor
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Big Data and the 3 V’s7
• Big data is an evolving term that describes any voluminous amount of structured, semi-structured and unstructured data that has the potential to be mined for information. It is often characterised by the 3 V’s:
• The extreme VOLUME of data.
• The wide VARIETY of types of data.
• The VELOCITY at which the data must be must processed.
• Although big data doesn't refer to any specific quantity, the term is often used when speaking about Petabytes (PB) and Exabyte's (EB) of data where:
• 1 PB = 1015 bytes of data, 1,000 terabytes (TB) or 1,000,000 gigabytes (GB).
• 1 EB = 1018bytes of data, 1000 petabytes (PB) or 1 billion gigabytes (GB).
Source: TechTarget.Com
IIoT and the need for Interoperability9
“At the core of Industry 4.0 and IIoT is the need for interoperability—of devices, software, and
entire systems.”
What about Fieldbuses?12
http://global.ofweek.com/news/Fieldbus-market-is-still-twice-as-big-as-industrial-Ethernet-24515
The road to IIoT13
PROFIBUS PA
PROFIBUS DP
• Evolution
• Existing devices
• Existing networks
• Legacy data
Electrical - Hard-wiredPneumatic Manual
PROFINETFieldbuses
What is PROFINET?15
PROFINET is the standard for industrial networking in automation. It connects devices, systems,and cells, facilitating faster, safer, less costly and higher quality manufacturing. It easilyintegrates existing systems and equipment while bringing the richness of Ethernet down to thefactory floor.
Completely standard Ethernet (IEEE802.3).
High speed, operating at 100Mbit/s or faster over copper or fibre-optic cables,
Makes use of existing IT standards. But, is “real-time” and deterministic,
PROFINET is very well thought out to incorporate all the requirements of automation and control systems.
PROFINET is totally compatible with PROFIBUS and provides seamless integration with other fieldbus technologies.
PROFINET – the backbone of Industry 4.0 and IIoT17
Energy Management
Security
DiagnosticsCondition Monitoring
�Safety
� Real time communication
17
� Performance
Industrial Wireless LAN
Flexible topologies
Expandability
Web tools
Open standard
One cable for all purposes
Fast device replacement
Ruggedness/stability
Easy cabling
Media redundancyLarge quantity structures
High transmission rate
Speed High precisionFast start-up
PROFINET addresses each of these imperatives
efficiency
performance
flexibility
PROFINET – The same standard for different industries18
FACTORY AUTOMATION
An exclusive TCP/IP layer enables simple exchange of any data with response times in the range of 100 ms.
PROCESS AUTOMATION
The real-time feature RT handles cyclic signal exchange of I/O data with response times in the range of 10 ms.
DRIVES
IRT enables safe real-time communications in the range of less than 1 ms jitter of less than 1µs.
PROFINET – Enhancements for Process Automation19
Fieldbus Integration
DCS
HART
PROFIBUS PA
FF H1
PROFIBUS DP
PROFINET
Configuration in Run (CiR)
DCS
Remote I/O Proxy
Time sync / stamping
System Master Clock
(GPS, DCF77, …)
Controller 1 Controller 2 Controller 3
Proxy
Device Device
Backup
Clock Master
Scalable RedundancyRedundant Controller
PrimaryBackup
Redundant Network
Device with redundant connectivity
Device with singularconnectivity
PROFINET IRT – High Speed Applications20
PROFINET enables the simultaneous realisation
of Real-Time and IT-communications on one cable
• Isochronous Real Time (IRT) communication for Motion Control Applications with PROFIdrive-profile
• With PROFINET Specification V2.3 we can achieve short and deterministic reaction time: up to 31.25µs, Jitter < 1µs
• Integration of distributed field devices
• TCP/IP for engineering, diagnosis and HMI-connection
IIoT and Security Requirements21
• Security for systems without their own security functions
• Lack of technical resources necessary for security functions
• Security functions have to be integrated in existing systems
• Real-time operation
• Security functions must not slow down critical reaction time
• Ensure deterministic behavior
• Transparent and cost-efficient integration
• Integrate security functions with minimal configuration effort
• Automation experts are generally not security experts
• Robustness
• Withstand temporary exceptionally-high communication loads
Security Strategies22
Great Wall
“Unconquerable” wall single layer of protection
no more checkpoints behind the wall
Defence in Depth
Multiple layers of protection each layer supports the
other layers for every transition between two layers an
attacker must spend time and effort!
���� No single security measure is good enough to prevent intrusions !
Defence in Depth – Multiple layer security23
23
Physical Security
- Physical access to facilities and equipment
Policies & procedures
-Security management processes
-Operational Guidelines
-Business Continuity Management & Disaster Recovery
Security cells & DMZ
-Secure architecture based on network segmentation
Firewalls and VPN
- Implementation of Firewalls as the onlyaccess point to a security cell
System hardening
- adapting system from default to secure
User Account Management
- Administration of operator und userrights (role based access control)
Patch ManagementMalware detection and prevention
- Anti Virus and Whitelisting
Potential Threat
DCS
PROFINET and Security24
General security requirements for automation networks and differences to office-IT
Specific condition and requirements of PROFINET networks regarding security, e.g. real time capabilities
Elements and organization of a Security Management Process
Security concepts for the solution of the requirements � Defence in depth approach
Example configuration
Communication Networks - Scalability
Corporate
IT
Central data backbones
Production Network Production Network
Production Network
25
Communication Networks - Scalability
Corporate IT
Central Data Backbones
Production Network Production Network
Production Network
Field
Corporate
Production
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Communication Networks - Interactivity
Field
Production
Corporate
Produktionsnetz
10101001111
ERP
• Connection to Corporate IT (ERP -Enterprise Resource Planning), Data exchange across production facilities
• Quality data, Track & Trace, Optimisation of production processes
• Remote Services for central Maintenance
27
Communication Networks - Requirements
Field
Production
Corporate
Produktionsnetz
ConditionMonitoring
Energy-management
Cloud
New RequirementsBandwidth Realtime Usability
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The base of today and tomorrow: conformance with IEEE, IETF, IEC etc.
Requirements of the future
Self Configuration
Openness
Bandwidth
• PROFINET uses100 Mbit/s today
• PROFINET will be usable with higher bandwidth
• Scalability is possible
• IP-based communication is supported by PROFINET
• Importance of IP-based communication will increase, e.g. with OPC UA
• Already name based configuration today
• In the future automatic assignment of IP-addresses
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Self-configuring / Dynamic Networks
Machine Builder Plant Operator
Delivers machine with automation solution and network configuration
Integrates machine in plant � requires changes in network configuration
Automation and network configuration intrinsically tied together today
Production Network
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Separation of Automation and Network
Test independent of network configuration
No IT-Services
Commissioning with temporary configuration
Doesn’t want to deal with IP-Addresses
Simply wants to connect the machines
Automation and Network Configuration must be separate in the future
Automation
Machine Builder
Operation
Plant Operator
Integration in existing network
Individual requirements of local IT
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PROFINET and IIoT - Conclusions32
• Seamless enterprise-wide integration, global accessibility.
• Unlimited node count, powerful capabilities, greater scalability.
• Full TCP/IP, internet and web compatibility, with real-time determinism
• Ethernet cabling eases installation, and familiar IT and Internet tools help during operation, maintenance and
diagnostics.
• Wireless and functional safety easily added.
• Protects investments in plant and people by easily integrating all popular automation networks.
• Strategic links with PROFIBUS include common infrastructure, common engineering platforms, common quality
assurance and common application profiles.
• Modular, flexible, comprehensive - use only what you need now.
• Easily extended and expanded as enterprise needs change.
References and UK Support
References
• PROFIBUS & PROFINET International (PI) – www.profibus.com• PROFIBUS Association of Australia (PAA) – www.profibusaustralia.com.au• PROFINEWS – www.profinews.com
UK Support - The PROFIBUS Group
• Regional PROFIBUS & PROFINET Association – www.profibusgroup.com• Certified PROFINET Installer / Certified PROFINET Engineer Training
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