Building a SMART Network for
the Industrial IoT
Richard Wood
Product Marketing Manager
Industrial Ethernet Infrastructure
April 29, 2015
IIoT Webinar Series

Confidential
Agenda
Smart Factory Introduction – Market Trends
Smart Factory Challenges
SMART Factory Best practices
Case Studies

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Smart Factory Introduction
Market Trend

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Megatrend – Internet of Things (IoT)
“The IoT refers to devices, systems, and services
communicating with each other via the Internet to
enable smarter operations and new applications.”

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Industry Trend – Industry 4.0 (IIoT)
IoT in Manufacturing - The Next Industrial Revolution
Objective
Utilize a combination of
cyber and physical systems
to build up highly efficient
Smart Factory
Industry 4.0

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 Interconnected ERP, MES, and industrial automation systems
together
 The goal is to reach High Efficiency by reducing defects,
unplanned downtime, waste, and waiting
Smart Factory is
“The Factory of The Future”
MES
Machine (PLC)
Manufacturing Prodution
Production Planning
ERP (PLM)
Product Development
Device (Sensor)
Manufacturing Prodution
Smart Factory
Network Integration

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SMART Factory Example
Real-Time Interactive Communication
Network Integration

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Integration with Enterprise Networks
 Industrial Ethernet is the Common Platform
• Interconnect devices, systems, and services
• Transmit data for analysis, decision making and control
Source: IEEE, 2014
SMART
FACTORY
Network Integration
Enterprise Network
Data Center

Industrial Network Top 3 Challenges
How do we…
Simplify Installation
& Deployment
Minimize Error
Probability
Accelerate Error
Discovery & Repair
• Optimized Network
Topology
• Quick Mass
Configuration
• Device Durability
• Network
Redundancy
• Cyber security
Protection
• Instant Active
Alarm
• Easy SCADA
Integration
• Remote Visualized
Network
Management
Top Strategies

SMART Factory Overview
Secure Infrastructure
Easy Centralized Management
High Availability
Robust Design
Enterprise InTegration

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Factory is Vulnerable to Cyber Attacks
Source: ICS-CERT 2013 Report, Region: the U.S.
Cyber attacks may come from both outside AND inside factory
Security

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Industrial Security Concerns
PLC/IO Network
Control
Network
Field Site / Factory
Control Room
Attack from
public network
Unauthorized
connection
Malfunctioning PLC
Broadcast
Storm
• VPN function for data encryption
• VPN server for dynamic remote access
• Standard protocol: IPSec, L2TP, PPTP
• Protect unauthorized connections to
critical devices (PLC, RTU, DCS)
• Isolated broadcast packets from
malfunctioning device to entire network
VPN tunnel Firewall
Security

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Quick Mass Configuration
 How do we reduce industrial network installation
& configuration time?
• Industrial Network Configuration Tools
Client ITS System Integrator
Current
Solution
Configure 20+ switches
individually thru Web UI
Pain
Point
Cost a lot of time and
manpower to complete
the configuration
Sequential IP setting
Redundancy
VLAN
…
Smallest IP
Current With Tools 10
times faster
Management

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Visualized Network Management
 How can maintenance engineers monitor & manage
large scale industrial networks?
• Visualized NMS
Industrial NMS Enterprise NMS
Design for… Industrial Engineers, Maintenance Engineers IT expert
Connection Physical link (Down to “port”) Logical link
Information
Dispaly
Visualization & List List
Response Real time Periodic
Management

Network Availability/Reliability

Network Topology
Typical Enterprise Star Topology
• Single point of failure
• Long, costly wire/fiber runs
Availability

Network Topology
Typical Industrial Ring Topology
• No single point of failure
• Reduced wiring costs
Availability

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Build Up a Highly Reliable
Communication Network
 How do you choose the best redundancy for your application?
Network switch/recovery time < Max. acceptable system downtime
(Grace Time)
Non time critical
< 1 s
Real Time
< 100 ms
Isochronous Real Time
< 1ms
Applications
Non time critical
applications
Process Automation
/ Factory Automation
Motion Control
Grace Time
Reliability Availability

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Optimized Network Topology
Redundant
Technology
Type Mesh Ring
Pros
• Good reliability
• High resilience
• Standard protocol
• Better performance and recovery time:
~millisecond level
• Lower cost
Cons • Slow recovery time ~second level • Limited Scale
Available
Technology
RSTP
General
Fast Recovery
(millisecond level)
RSTP
(20 ms @ 250 devices)
Applied
Environment
Commercial Harsh environment, Industrial automation
Backup Link
Root
Source: Moxa
Industrial
Preferred
Availability

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Fast Boot-up is Critical to
Increase Network Availability
• PLC Boot-up Time*: ~20 sec
• Most Switches: 40 sec ~ 1.5 min.
•Industrial Ethernet Switches: 10 sec
The time for switches to boot-up should be
shorter than the PLC in order to improve the
stability of the network
* Siemens S7300, Allen Bradley CompactLogix 1769
 Higher system availability, lower
maintenance cost
 Prevention of unnecessary alarm
messages
Benefits
Ready !
Ready !
Ready !
Not yet!
Availability

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Seamless Communications
 Allows mobile devices (like AGVs) to be
constantly connected to a wireless network
 Reduces downtime and ensures all data gets
through
Availability

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Zero Packet Loss - Overview
 Traditional Approach Vulnerable to Packet Loss
• Single-RF devices
• When interference disrupts data transmission, communication is
disabled
• Dual-RF devices
• The secondary frequency is activated and data transmission
resumes
• However, packet loss will occur during the switching period.
• Threshold setting will generate a “ping-pong” effect between two
bands making the switching mechanism very inefficient
Availability

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Zero Packet Loss: Concurrent Dual-Radio
Technology
 Eliminates the possibility of wireless interference
• Duplicate packets and transmit via two independent
modules simultaneously
• When interference interrupts data transmission on the
primary channel, concurrent transmission via the
secondary frequency eliminates packet loss
 Increase the throughput by reducing the number
of resend request
Availability

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Harsh Industrial Environments
Robust Industrial Design

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Pipeline Monitoring System, Russia
Moxa Inside
Example: Switches Operating 24/7 in
Harsh Environments
Drilling System, Saudi-Arabia,
Robust Industrial Design

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Integration with Control Level Network
 SCADA Integration?
• Plant field SCADA to control and manage devices through
industrial protocols
• Some switches support industrial protocols in order to
integrate with SCADA
• PROFINET
• Ethernet/IP
• Modbus TCP
There are industrial automation specific
switches that enable industrial protocols
by default - Plug-n-Play!
Systems Integration

Integrating from Device to Enterprise
Confidential
Systems Integration
Device
Servers
Gateways
Core
Switches
Edge
Switches

Case Studies
Best Practices

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Facility Management >> Country: Taiwan
 NMS enables SCADA to monitor network status
 The switches have 3 GbE ports for creating a
GbE redundant ring and GbE uplink
 Ring and Chain technologies allow Gigabit
redundancy < 50 ms
Solution & Benefits
 A semiconductor plant invested in
thousands of dry pumps for an exhaust
system to protect workers from toxic gases
 Solutions needed to simplify pump system
control and monitoring
Background & Requirements
Environmental Monitoring for
Air Purification Systems

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Warehouse Automated
Guided Vehicle System
Facility Management >> Country: Germany
 A wireless solution saves wiring cost, and
supports wireless AP, bridge, and client modes
for easy deployment and mobility
 Enables wireless VLAN and secure polling
 Supports fast roaming for millisecond-level
handover
Solution & Benefits
 A factory in Europe chose an industrial
access point to control and monitor
numerous AGVs to support their fast
growing warehouse management
system
Background & Requirements

Thank You
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