T26 - Wireless Design Considerations for Industrial Applications
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PUBLIC - 5058-CO900H
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Agenda Technology Overview WLAN Architectures
Application Recommendations WLAN Recommendations
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Technology Overview Benefits of industrial wireless network Connection to hard-to-reach and restricted areas Lower installation and operational costs Cabling reduction Elimination of cable failures Equipment mobility New and more efficient applications Personnel mobility Higher productivity and less downtime PUBLIC
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Technology Overview Challenges of wireless communication Half-duplex shared medium: Only one device can transmit at any given time Higher latency, jitter and packet loss compared to wired Ethernet Reasons: media contention, collisions and interference Can be minimized but not completely eliminated PUBLIC
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Technology Overview Challenges of wireless communication Wireless coverage area cannot be precisely defined Site survey is required Spectrum sharing and security concerns Signal quality may change over time Interference sources and obstructions Wireless advantages > challenges IF • WLAN is designed and maintained properly • Used for appropriate applications PUBLIC
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Technology Overview Matching wireless technology with application Supervisory / HMI Peer-to-peer Control Distributed I/O Control Safety Control
IEEE 802.11a/g/n/ac
Highest performance Plant-wide coverage and roaming Enterprise WLAN convergence Advanced security 5 GHz spectrum – less interference PUBLIC
Long Range SCADA Remote site connectivity Outdoor mesh
Process Instrumentation Wireless Sensors
IEEE 802.11a/g/n Cellular 3G / 4G LTE / WiMAX Proprietary 900 MHz / 2.4 GHz Licensed bands
ISA-100.11a WirelessHART ZigBee / Bluetooth
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Technology Overview Wireless client types Embedded wireless adapter: • Limited antenna capabilities • Placement restrictions • Client density per AP • Modernization costs
AP
Bridge
External adapter (wireless bridge): • Single wired client (MAC address)
Work Group Bridge (WGB): • Multiple wired clients • Single wireless client WGB
WGB
Work Group Bridge is the main method of connecting industrial devices PUBLIC
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Technology Overview Wireless mobility types Static equipment
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Permanent location Wire replacement for hard-toreach places Examples: process control, condition monitoring, standalone OEM machines
AP WGB
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Technology Overview Wireless mobility types Nomadic equipment
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Stays in place while operating Moves to a new location in the shutdown state Examples: process skids, storage tanks, reactors, portable manufacturing equipment
AP
AP
WGB
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Technology Overview Wireless mobility types Mobile equipment (no roaming)
Changes position while operating Remains connected to the same AP Examples: rotary platforms, machines with tracks, overhead cranes with small spans
AP
WGB
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Technology Overview Wireless mobility types Mobile equipment (fast roaming)
Connects to multiple APs while operating Does not drop application connections Examples: AGVs, ASRS, overhead cranes, train cars
AP
WGB
Site survey and architecture selection are critical PUBLIC
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Agenda Technology Overview WLAN Architectures
Application Recommendations WLAN Recommendations
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Autonomous WLAN Architecture
Autonomous AP
WGB
Autonomous AP
SSID1 5 GHz
…
WGB
SSID2 5 GHz WGB
• Each autonomous AP is configured and managed independently • Standalone IACS applications • Small number of APs and clients • Typically non-roaming clients • WGB mode is configured on the autonomous AP only
WGB
…
Stratix 5100™ Wireless Access Point and Workgroup Bridge PUBLIC
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Autonomous WLAN Architecture FactoryTalk® Application Servers
Industrial Zone
Fixed controller to Wireless I/O Topology
Level 3 - Site Operations Cell/Area Zones Levels 0-2
Fixed Programma ble 1 Automation Controller 2
2
AP
1
WGB
Wireless I/O
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FTView ME
1
Standard I/O Safety I/O
2
HMI (FactoryTalk View)
Considerations: Large number of connections (rack-optimized, safety, analog) System size vs. RPIs
FTView SE
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Autonomous WLAN Architecture FactoryTalk® Application Servers
Fixed controller to Wireless controller Topology Considerations: Cell/Area Zones Levels 0-2 I/O or drives that are controlled by controller on a Standard and Safety 1 Produced/Consumed, mobile equipment MSG HMI (FactoryTalk View) Second Ethernet module 2 vs. switch Larger tag sizes, fewer connections Industrial Zone
Level 3 - Site Operations
Fixed controller 2
1 AP
1
2
Wireless controller
WGB
Local I/O or drives PUBLIC
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Autonomous WLAN Architecture Wireless controller to Wireless controller or I/O
Both source and destination behind WGBs – two wireless frames per single EtherNet/IP packet AP
WGB
Wireless controller
Wireless controller or I/O
Not recommended: x2 wireless bandwidth, higher latency PUBLIC
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Unified WLAN Architecture Identity Service Engine (ISE) Mobility Services Engine (MSE)
SSID3 2.4 GHz
WGB
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LWAP
SSID1 5 GHz
…
Lightweight APs (LWAPs) are configured and managed by a Wireless LAN Controller (WLC)
•
Plant-wide coverage and roaming
•
Plant-wide mobility and RF policies
•
Advanced security policies
•
Advanced spectrum analysis, Location Services, and wireless Intrusion Prevention
WLC
Cisco Prime Infrastructure
LWAP
•
WGB (Roaming)
LWAP
LWAP
SSID2 5 GHz WGB
…
WGB
Note: Stratix 5100™ in WGB mode can join a Unified WLAN as a client to an LWAP Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Unified WLAN Architecture
Fixed controller to Wireless controller or I/O Topology (No Roaming) FactoryTalk® Application Servers
Level 3 - Site Operations
Industrial Zone
Wireless LAN Controllers
Cell/Area Zones Levels 0-2
WGB LWAP (FlexConnect)
Fixed controller
Wireless controller LWAP (FlexConnect)
LWAP
LWAP
WGB WGB
Locally Switched Wireless Ethernet
Wireless I/O
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FTView ME
Wired Ethernet Wireless FTView SE I/O Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Unified WLAN Architecture Intra-Cell/Area Zone Fast Roaming FactoryTalk® Application Servers
Level 3 - Site Operations
Industrial Zone
Wireless LAN Controllers
Cell/Area Zones Levels 0-2
WGB Fixed controller LWAP (FlexConnect)
Wireless controller
LWAP
LWAP
LWAP (FlexConnect)
X
WGB
WGB
CAPWAP Tunnel Wireless Ethernet
Wireless I/O
FTView ME
Wired Ethernet Wireless controller
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Unified WLAN Architecture Plant-wide Fast Roaming
FactoryTalk® Application Servers Centralized controller
Level 3 - Site Operations
Industrial Zone
Wireless LAN Controllers
WGB LWAP
WGB
Wireless I/O
WGB
LWAP
X
Cell/Area Zone 1 Levels 0–2 CAPWAP Tunnel Wireless Ethernet Wired Ethernet
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Fixed controller
LWAP
Fixed controller LWAP
X
Roaming WGB
WGB
X
LWAP
Wireless I/O
Cell/Area Zone 2 Levels 0–2 Inter-Cell/Area Zone Roaming Equipment Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Unified WLAN Architecture Wireless User Access
ISE (Enterprise)
Enterprise WAN
Internet
Enterprise Zone: Levels 4–5
WLC (Guest) WLC (Enterprise) Industrial Demilitarized Zone (IDMZ) Remote Access Gateway
Industrial Zone: Levels 0-3 ISE
WLC (Industrial) Level 3 Site Operations
Deploying Identity Services within CPwE: ENET-TD008 ENET-WP037 (whitepaper) PUBLIC
Levels 0-2 Cell/Area Zone
Trusted Partner SSID3 LWAP Corporate User Plant Engineer SSID2 SSID1 Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Selecting the WLAN Architecture Unified WLAN
Autonomous WLAN
Large number of APs (>10)
Small number of APs (
