Industrial networks back to the future.

We are all talking about OPC UA TSN, Cloud computing, I4.0, etc. But who is talking about our physical local networks? We are all excited about the new possibilities that all new network technology gives us. However, the questions to ask are: are our local networks ready for this? Are we ready for all this? Who is focusing on the local industrial networks? Who is responsible when it fails?

Looking back in time, we had small isolated control islands – so called “trusted zones” - not connected to the outer world. They were quite easy to understand, monitor and manage. The communication was based on PROFIBUS, DeviceNet, Unitelway and similar RS485 based networks. Everything was regulated and there were limitations of what you could do in the network. Then the Ethernet based protocols started to gain more market share - we started to talk about Industrial Ethernet. All vendors hooked up and we got PROFINET, EthernetIP, Modbus TCP, EtherCat etc. We connected more and more “things” to our networks. However, it was still standardized systems. E.g. regarding PROFINET everything was and still is handled by the PI-Organization.

But soon the idea arose that it makes no sense to have all these different protocols to cross talk through gateways units. That was the time when overlaying structures were formed and OPC UA was established to overcome the gateway situation. This means we can now communicate between our units in a standardized way, what offers great benefits.

After this, the focus changed to the lower level components e.g. Sensors, Motors, etc. The IT-thinking started to sneak deeper into our control networks. Why do I need to talk to the PLC to get the value I want from the sensor? Why do I need to involve a control programmer to perform changes in a system, why can’t I talk directly to the sensor? This was the time, when the idea of OPC UA TSN (Time Sensitive Networking) was born. The aim is to be able to communicate in a standardized way and reach devices even of lowest levels, using common high-level technologies. But who will then have the overall control of the local network?

Take a look at the below image, from reality.The mission in this case, was to check the quality of the master network at a plant in Germany. See the Zone marked in Blue Below. When a topology scan was made, the whole system was found. The people on site was very surprised to see the how complex the system was. And in turn also the small system is influenced by the big. So to be able to analyse and secure the function of your small zone you need to know the complete network. Remember there is no small isolated islands anymore. Do you hve a complete overview of your factory network?

What happened, looking back to the future?

Our safe small PROFIBUS and PROFINET spheres became invaded. Causing many new problems. The network load started to raise fast. One vendor connected his devices and was happy. The next one did the same. And the next. And The next… But who had the overall responsibility of the network? And which tools where provided to monitor if the local network was performing in a stable way?

When the netload increased, it also caused higher demands of the physical installation and use of components. Our systems became more sensitive for disturbances. There were lots of problems arising in the local networks. Problems that caused failures and downtimes costing lots of money, as production could no longer be guaranteed. And who had to go there and solve the problems, was it control programmers, IT department, the supplier or the maintenance department?

According to my experience:

The funny thing is, although the environment is more complex on the factory floor, many factories have more tools to monitor the office network than they have to monitor the factory network. Why? The answer is quite simple, everything has happened too fast. The industrial revolution 4.0 has come to us at an enormous speed, never seen before. The local maintenance technicians and engineers have not got the right training to completely understand the new complexity. They look at their installation as it was still an isolated island. Seeing the green lights of the modules and the PLCs and are happy to see everything running.

To be able to face all this and to make our systems safe we need:

?? Standardization.

?? Education.

?? Tools to monitor the network performance and health.

?? Tools to keep your network safe for hacker and other attacks.

?? Tools to help you to make sure that your network is up to date.

?? Components like switches smart enough to make right prioritizations

?? Knowledge about EMC and tools to analyze essential equipotential bonding systems.

And the most important thing, remember to set up local regulations, think before do. Do not just connect all things, use common sense. Make sure to have the tools and competence needed to monitor and understand your network, a green light on a network module does not mean that your system is performing good. Be sure to find the problems before they find you.

Be one step ahead and don’t forget your local network, then you can sleep good at night.

//Mattias Lindh.

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