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 Technical Topic Webinar

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Data Communication – The Backbone

of Industrial Automation
Friday 27 August 2021 | Technical Topic Webinar

Presented By

Dr. Imtiaz Madni | EIT Lecturer

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Introduction – Dr. Imtiaz Madni

Dr. Imtiaz Madni comes from a solid technical background with a diverse
working experience in the energy industry as an electrical system engineer
and electrical project manager. He has a demonstrated history of working in
the manufacturing, electrical systems, renewables, and higher education
industries.

With a Ph.D. in Electrical and Electronics Engineering, Imtiaz has a background

in generating innovative ideas and strategies to improve processes that
provide a deeper understanding of multifaceted problems that companies
encounter in their daily operations. Together with renowned scientists and
high-end industry collaborators, Imtiaz is working on the energy
transformation of Australia.

Before moving to Australia, he was working as a post-graduate researcher at

the Chinese Academy of Sciences in China.

Find him at: https://www.linkedin.com/in/imtiaz-madni-a8aa652a

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Agenda

1 Welcome & Introduction

2 Basics of data communication

3 The ISO model

4 Major medium access methods

5 Concepts used at application level

6 Summary/Conclusion

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Elements Used During Communication

Communication Communication
module module

Data

Transmission
Medium Transmission

Data

Reception Reception

Transmitter/Receiver Transmitter/Receiver

The data comprises physical elements (light, sound, images, electrical voltage, etc.)
to which a direction has been attributed.

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Transmission Methods
Data can be transmitted in analog format:
Continuous progression of value

Or in digital format:
Discontinuous progression of value (sampling)

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Transmission Types
Simplex transmission: Unidirectional

Half duplex transmission: Alternate bidirectional

Full duplex transmission: Simultaneous bidirectional

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Transmission Types

◼ Serial transmission:
The link usually requires 3 wires: send, receive and earth. The
bits in a byte are transmitted one after the other.

◼ Parallel transmission:
The bits in a byte are transmitted simultaneously.
Used for short distances. As each channel tends to cause interference on
neighbouring channels, the quality of the signal deteriorates rapidly.

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Serial Transmission Types

◼ Synchronous serial transmission:

Data is transmitted continuously.
A synchronization signal is transmitted in parallel with the data signals.

◼ Asynchronous serial transmission:

Data can be transmitted in an irregular fashion, although the interval
between 2 bits is fixed.

Synchronization bits (START, STOP) encapsulate the data.

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Communication Requirements

1 MB 1 Level 3
minute Information system
Company
1 KB
Production
1s Level 2
management
AMOUNT Workshop
OF DATA TO BE Supervision
TRANSMITTED REQUIRED
SPEED OF
REACTION Level 1
Control system
Machines

Level 0
1 bit 1 ms Sensors Components
Actuators

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Communication Networks and Buses

Data networks
(Data Bus)
Control of
process

Local area ne tworks

(Field Bus) Ethernet
TCP/IP
CANopen FIPWAY
Fieldbus FTP-
FIPIO Ethernet
(Device Bus) HTTP...
Modbus Plus TCP/IP
Sensor actu ator Profibus-DP Modbus
DeviceNet
machine
Control of

bus Interbus
(Sensor Bu s)
Modbus
AS-i

Simple Sophisticated

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Common Network Strategies and Protocols

◼ Core Networks:
Ethernet TCP/IP & Modbus
Levels 2 and 3: Information and control system (inter-PLC)
to be extended to fieldbus level (level 1)

CANopen
Like an internal device and panel bus (e.g.: Automation Island)

ASi
For the connection of sensors/actuators (level 0)

Modbus RS 485
When Ethernet is not suitable (price, topology, etc.)

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Common Network Strategies and Protocols

◼ Legacy networks
FIPIO, Modbus Plus, Uni-Telway, Seriplex

◼ Connectivity networks
A pragmatic approach when the market imposes a solution

DeviceNet (Allen-Bradley) - Profibus (Siemens) - Interbus (Phoenix) etc.

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The Standard ISO Model
ISO = International Organization for Standardization
STATION
Modbus or APPLICATION 7 Network administration (starting and stopping the
Unite... LAYER network, message handling)
PRESENTATI ON Entity used for PC/MAC dialogue
LAYER 6
SESSION 4 Organize and synchronize the exchanges between users of
LAYER 5
the network
Network TRANSPORT 4 End-to-end checking: restart on errors which have been
concept LAYER signalled or otherwise by the network layer
Example:
TCP/IP NETWORK 33 Switching in a mesh network: establishment of route
LAYER
LINK 2 Sub-layer: error correction, acknowledgement
LAYER Sub-layer: management of access to physical medium
Bus
concept PHYSICAL 1
LAYER Twisted pair, shielded twisted pair, coaxial cable, optical
fibre...
TCP: Transmission Control Protocol (Layer 4)
IP: Internet Protocol (Layer 3)

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Frames in Relation to the ISO Model
Modbus RTU frame
Request to read words W5 and W6 at slave address 7

Bytes 1 1 2 2 2

Slave Function No. of first No. of words

address code word to be read CRC 16
=7 =3 =5 =2

Ethernet TCP-IP frame

Bytes 8 6 6 2 20 20 46 to 1500 4
Preamble

Application layers
Source
Destin.

TCP
addr.
addr.

LLC

FCS
IP

FTP, HTTP , SMTP, Modbus etc.

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Popular Transmission Media
The MEDIA establish the transmission quality:
•speed
•distance
•electromagnetic immunity
•bandwidth

Most commonly used media: Cost of

medium
Pair of twisted wires Low
The simplest to install, and the least expensive.
Coaxial cable
This consists of a copper conductor, surrounded by grounding shielding. There is a plastic insulating
layer between the conductor and the shielding. The coaxial cable has excellent electrical properties
and is suitable for high speed transmission.
Optical fibre
Electrical signals are not carried by a copper cable, but an optical fibre transmits light signals.
This is suitable for use in harsh industrial environments. Transmission is reliable over long distances. High
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Electrical Standards for Twisted Pairs

RS232:
Point-to-point link via 25-pin SUB-D connector. Distance < 15 meters, speed < 20 Kbps.

RS422A:
Full duplex (simultaneous bidirectional) multi-drop bus on 4 wires. 2 transmission wires,
2 reception wires.
Good immunity to interference. Max distance 1200 meters at 100 Kbps.

RS485:
Same characteristics as RS422A but on 2 wires.
Half duplex (alternate bidirectional) multi-drop bus on 2 wires.

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Communication Topologies
POINT-TO-POINT TOPOLOGY (Between 2 units GRID TOPOLOGY (Devices are linked to one another,
in communication) forming a “spider’s web”.
There are a number of
possible paths for reaching a node)

STAR TOPOLOGY (Several units RING TOPOLOGY (All the units are connected in
communicating via series in a closed loop.
their own line line Communications must pass via all
with a Central unit) the units to arrive at the receiver)

TREE TOPOLOGY (This is a variant of

BUS TOPOLOGY (The network consists of a main line
the star topology)
to which all the units are connected)

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Medium Access Techniques
Master - Slave Located at the link layer level

The MASTER is the entity which grants access to the medium.

The SLAVE is the entity which accesses the medium after requesting it
from the master.
Polling
What do you want to say?

Nothing to declare
MASTER SLAVE
Response

Eg: Profibus-DP
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Medium Access Techniques
Token Ring Located at the link layer level

The members of a logical RING gain access to the network upon receipt of a token.

The TOKEN is a group of bits that is passed in a rotating address sequence from one
node to another.

Address 2

Address 3
Address 1

Eg: Modbus Plus Address 4

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Medium Access Techniques
Random access Located at the link layer level
Carrier Sense Multiple Access
A set of rules determining how network devices respond when two devices
attempt to use the medium simultaneously (called a collision).
CSMA/CD is a type of contention protocol: competition for resources

Informal discussion between

undisciplined individuals: Address 2

As soon as there’s a silence,

the one who wants to talk
begins to speak. Address 3
Address 1

Address 4

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Modbus Ethernet TCP/IP
• Developed by Modicon for use with process control systems.

• Estimated by Control Engineering Magazine that over 40 % of industrial interfacing is

done using this protocol

• All new state-of-the-art fieldbus systems have a Modbus gateway

• Original intent: to link Modicon PLC’s with intelligent terminals

• Typically used on a multidrop bus

• Half-duplex, Master/Slave operation

• Single master with up to 247 slaves

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Modbus Ethernet TCP/IP
The DoD finances a project about
TCP - IP ''packet switching"
1960 Ethernet

Development of the ARPANET network (IBM) 1970 Experimental version of Ethernet

defined by XEROX

1975 Ethernet principles defined by XEROX

The INTERNET is launched: 1980 First specification of Ethernet by
TCP/IP developed in current formats XEROX, DEC and INTEL

1982 Version 2 of the Ethernet specification

TCP/IP becomes the standard for 1983
long-distance networks 1985 IEEE 802.3 standardization of
CSMA/CD networks
Growth rate 15% 1987
Growth rate 60% 1996 Modbus
1999 Schneider Transparent Factory

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Modbus Ethernet TCP/IP and OSI Model

Ethernet only covers the first 2 layers of the OSI model

BootP
7 APPLICATION Modbus HTTP FTP
DHCP ---
7

6 PRESENTATION EMPTY
6 PRESENTATION EMPTY

5 SESSION EMPTY
5 SESSION EMPTY

4 TRANSPORT TCP
EMPT
4 TRANSPORT Y
EMPTY

3 NETWORK IP
EMPTY
3 NETWORK EMPTY

2 LINK = LLC + MAC CSMA/CD

2 LINK = LLC + MAC CAN 2.0 A and B + ISO 11898

1 PHYSICAL Ethernet
CAN 2.0 A and B =V2 or11898-1
ISO 802.3 and 2

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Modbus Ethernet TCP/IP
Modbus Messaging Protocol Frame Structure

Address Field also called “Unit Identifier”

(Used to be called the “Slave Address”)

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Modbus Ethernet TCP/IP
Modbus Functionality and Memory

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Modbus Ethernet TCP/IP
Modbus Memory Structure
• Function codes indicate which
section of memory
• Data offset Is relative to beginning
of that section
– E.g. Function Code 01 Is read coil status
– Memory address starts at beginning of
coil status area
– Number of points to read specified
includes that location
• Other names:
– Coils: Output Discretes (R/W)
– Input Status: Input Discretes (R)

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Physical Layer for Modbus Ethernet TCP/IP

Topology: Free
Bus, star, tree or ring

Maximum distance: Depends on medium and speed

Minimum: 200 m on 100 base TX
Maximum: 40,000 m on 10 base F

Speed: 10 Mbps - 100 Mbps - 1 Gbps

1 Gbps in office automation

Max. no. of devices: Depends on medium

Minimum: 30 per segment on 10 base 2
Maximum: 1024 on 10 base T or 10 base F

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Physical Layer for Modbus Ethernet TCP/IP

Ethernet is available on three types of medium:

Name Description Speed Max. Max. no. of

length stations/segment

Coaxial 10 base 5 Thick Ethernet 10 Mbps 500 m 100

cable
10 base 2 Thin Ethernet 10 Mbps 185 m 30

Shielded 10 base T Twisted pair 10 Mbps 100 m 1024

twisted
pair 100 base TX Twisted pair 100 Mbps 100 m ???
cat. 5

Optical fibre 10 base F 2 fibres 10 Mbps 2000 m 1024

100 base FX 2 fibres 100 Mbps 2000 m ???

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Physical Layer for Modbus Ethernet TCP/IP
Twisted Pair Used increasingly, even at 100 Mbps
UTP - Insulated pairs of copper wires twisted together
Multiple colour-coded pairs enclosed in a plastic sleeve
Faster than coaxial cable
STP - Indivisible pairs enclosed in a shielding with
aluminium foil
Category 5 (Cat 5) – The most common for IT networks
Cat 5 = 100 Mbps (specification pending)
Cat 3 = 10 Mbps
Category 6 and above – Can go up to 10Gbps

Uses RJ45 connector

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Physical Layer for Modbus Ethernet TCP/IP
Optical Fibres
• Optical fibres are popular because they are secure (absence of electrical currents),
compact and immune to noise and electromagnetic interference.

• They support very long segment lengths (max. 2 km).

• They are often used as backbones.

Three component parts:
Core – Carries the light beam (glass or plastic)
Cladding – Glass tube which reflects any interference light
in the core
Coating – Protects the core and the optical cladding

Multimode fibre is the most popular type as it is the least

expensive and easier to use.
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Common Application Layer Protocols

HTTP: HyperText Transfer Protocol = Web

File transfer in HTML format

FTP: File Transfer Protocol

File transfer based on the client/server model

SNMP: Simple Network Management Protocol

Network management: Configuration, monitoring, administration

DNS: Domain Name Service

Translates the symbolic name of a network node into an IP address

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Common Application Layer Protocols

BOOTP: Bootstrap Protocol

IP address assignment by a server

TELNET: Terminal interfacing with devices in half duplex mode

Encapsulated ASCII format

UNITE: Protocol based on the client/server model created by Telemecanique

MODBUS: Protocol based on the client/server model created by Modicon

I/O scanning: Period I/O updated by automatic sending of Modbus requests

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Summary

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Summary

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Upcoming EIT Technical Topic Webinars

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