At the Automation Fair, Rockwell engineers said that manufacturers and machine builders are increasingly migrating toward Ethernet. They described beverage and tire manufacturers, along with an major aluminum manufacturer and an auto company that have recently adopted EtherNet/IP. Today, approximately 60% of the automation equipment sold by Rockwell is Ethernet-based, they said.
"EtherNet/IP is the most popular protocol in the industrial sector right now," Kann told us.
Part of that popularity stems from an a partnership with networking giant Cisco Systems, Inc. Starting in 2006, the two companies worked together on the development of an Ethernet-based protocol, with Cisco doing the networking part of the development and Rockwell doing the controls.
At the Automation Fair, Rockwell rolled out the Stratix 5700 Managed Switch, created in partnership with Cisco. The small form factor Ethernet switch is targeted at machine builders -- a user community that has also started moving toward the Ethernet world. Rockwell also introduced an Ethernet adapter, Ethernet cables and an Ethernet/IP encoder.
Migration toward Ethernet also appears to be opening up opportunities for Cisco, which says that its industrial business is now growing at 50 percent annually. "It's been a change for us, in terms of understanding the applications and understanding what's needed," noted Chet Namboodri, global director of solutions and marketing for Cisco Industrial Intelligence. "But it's also becoming a significant business for Cisco."
To be sure, Rockwell and Cisco aren't the only ones pushing migration to Ethernet. There are now multiple strains of Ethernet on the factory floor, including Profinet, Ethernet Powerlink, EtherCAT, SERCOS III, and others. Moreover, many engineers still prefer the fieldbuses, largely because they know the technology and want to leave well-enough alone.
"There are still some corners of industry where the fieldbuses are hanging around," Kann said. "But that's slowly changing."
Engineers at the show said the biggest draw for major manufacturers is the ability to tie their Ethernet-based IT systems to the shop floor. Doing so gives them remote access to the factory that didn't always exist in the past.
"It's irreversible in our opinion," Kann said. "The future bodes well that it will continue."
I see a parallel here, sort of, between control and machine vision. In control there's been a gulf separating the functionality and usability of Ethernet/IP versus the control-specific protocols like EtherCAT and Ethernet Powerlink. In machine vision, there's been a parallel guilf, perhaps not so large, between various open-sourced protocols like USB or GigE and their vision-specific versions like the very new USB3 Vision, and the not so new GigE Vision. And the gulfs all about that pesky determinism issue.
Ann, you have hit the nail on the head by mentioning protocols like EtherCAT. There are applications where standard Ethernet/IP can be used, but to replace the more specific bus standards like Fieldbus, you need a deterministic protocol. These have now been developed. In the IP realm, the increase in speed to gigabit and beyond helps mitigate some of the determinism issues.
The gets into the whole remote monitoring issue -- the fact that improved data links throughout the factory are enabling sensors to send data back to a central monitoring station. This, in turn, is enabling both tighter control of processes and also a reduction in outages, because failure points can be fixed right away.
That sounds like a good solution, Jack -- much more like the former process of sending reports. The real-time network, however, could send the data on a near-continuous stream. Not quite the same as letting other areas of the enterprise peek into the process to ascertain performance and results, but it would solve some of the security issues.
Rob - One possible solution to that particular problem is creating a one-way or read-only link. The data can be sent out to the IT systems, but nothing can come in that way. Yes, that adds a layer of complexity regarding updates, but it also makes sure that both the IT and Controls people sign off on the update schedules and implementations.
I hadn't heard that about safety, Rob, but unfortunately, it makes sense. Sounds like the same principle operating in both cases, of security and safety procedures. At least in the case of security, both employee training and more robust safeguards in mobile equipment were required.
Yes, I've heard that personal smartphones have entered the workplace big-time, and it's causing problems for IT departments. But it's understandable. Employees are accustomed to their Androids and iPhones, and by comparison, their work BlackBerrys are not as advanced.
Part of what's fueling the security issue is the whole trend around the consumerization of IT. More and more employees, including plant managers and operators, are bringing their own smart phones to work and want to use those devices as part of their work tasks as opposed to maintaining two devices. That makes it hard for IT or the controls group to uphold proper security standards. Also, as Ann notes, the device can get lost or the kids can log on to download some Apps and presto, you have a breach or potential security problem on your hands.
Data security is a major issue, but then it can be tackled effectively to a great extent. This initiave will definitely reduce cost implications byt enhancing remore accessing of test suites and sites
Turning off security because it gets in the way of operating the machines! That's a good one. I've seen that with safety as well, I've seen employees and managers bypass or circumvent safety in order to speed up the line.
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