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Chapter 1
Introduction to industrial communication networks
1.1. Specific features of contemporary production systems
Contemporary production, transportation and communication systems share
one common specific feature; they all incorporate complex, hierarchy-based
structure which is built on a set of interrelated and interacting subsystems. An
advanced approach to achieving high performance subsystems of enhanced
functionality requires the development of integrated systems for production
control. In turn each production system can be rendered as three level hierarchy
model. The lowest level of this hierarchy is occupied by the systems for real
time automatic control of production processes which take place in individual
machines, equipments and executive mechanisms. The second level ties together
the systems belonging to the first level based on territorial/production principle
for the purpose of executing tasks of operative/administrative character. Level
three is occupied by the systems for control of activities belonging to the realm
of economy and organizational practice.
1.2. Communication systems architecture
Characteristic properties of contemporary production systems structure af-
fect the architecture of communication systems. The latter are developed on the
basis of hierarchical heterogeneous computer network of three levels. (fig. 1.1):
Information level: main network;
Control level: networks for operative/dispatching control incorporating
monitoring computers and work stations;
Field level: communication networks with programmable logic control-
lers, sensors, actuators.
1.3. Characteristic features of contemporary communication systems
Contemporary communication networks utilize a number of communication
media such as cable connections, optical fibers, radio connections, infra-red
rays, etc. Recently a trend of reducing the cost of communication interfaces has
been observed along with the development of network architectures of various

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and mutually complementary functions. All these create favorable conditions for
developing heterogeneous hierarchical industrial systems featuring a global
scope of their control functions.



Fig. 1. 1.
1.4. Distributed control systems
Distributed control systems (DCS) for production control are a major type of
subsystems within the integrated systems for production control. There are two
basic types of DCS: vertically integrated and horizontally integrated.
1.4.1. Decentralized vertically integrated architectures of DCS type one
These are based on hierarchy and characterized by functional organization
and vertical information exchange between subsystems belonging to different
levels of hierarchy (fig. 1.2).


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PS PS PS PS
OPS OPS OPS
Legend: OPS - Oper at or st at i on PS - Pr ocess st at i on

Fig. 1. 2.
The subsystems (controllers, data collection subsystems, monitoring comput-
ers, operator stations) are in fact the independent components of DCS which in-
teract at intervals by exchanging information on the network. A major trend in
this type of DCS is the transition to an open system architecture based on stan-
dard networks and protocols such as Ethernet with TCP/IP and operating media
which support user-server interactions between the subsystems of DCS.
1.4.2. Decentralized vertically integrated architectures of DCS type two
This particular type of DCS feature high level of decentralization (fig. 1.3)
and utilize devices with specialized functions. DCS include a certain number of
simple controllers which are based on single chip microcomputers and a com-
puter designed for work station.

REG REG REG REG
OPS Legend:
OPS - Oper at or st at i on
REG - Regul at or

Fig. 1. 3.
1.4.3. Horizontally integrated architectures of DCS
Horizontally integrated architectures allow for both vertical and horizontal
interactions between the subsystems of DCS. Inherent to this class of architec-
tures are the systems with remote input and output in which microprocessor
controllers are reduced to intelligent input/output devices whereas control func-
tions are performed by computer whose role in this case is that of a work station

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(fig. 1.4). However, their dependence on the calculating capacity of the work
station is considered a disadvantage. This dependence is overcome by using
network client-server architectures.


Fig. 1. 4.
Horizontally integrated systems, which are made of field nets, have become
an object of ever increasing interest over the recent years.

Computer networks underlying the structure of network systems for control, which
include intelligent units such as regulators, programmable logic controllers, intelli-
gent sensors, actuators, etc., are referred to as field networks.

1.5. Automatic control systems with network communication
Automatic control systems with network communication (ACSNC) are sys-
tems in which control and terminal units (sensors, transducers, detectors, actua-
tors, control elements, automatic controllers, work stations, etc.) are connected
via network. Each of these units represents a node (station) within the particular
network and communicates with the other units by way of network medium.
1.6. Functional distribution of distribution systems with network
communication
From functional point of view, control systems which feature network com-
munication can be distributed into three levels:
1.6.1. Field level systems
They are built up by field networks for communication of programmable
logic controllers (PLC) with intelligent terminal units: sensors, measuring de-
vices, actuators, etc. These systems include network specifications such as
DeviceNet, CAN, Foundation Fieldbus, Profibus-DP etc. Field networks under-

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lie the hierarchy of control systems with network communication (fig. 1.5).
They are employed in controlling continuous production processes, control ele-
ments, controllers, sensors and other units used in the production process.
Field networks display a number of advantages as compared to conventional
structures:
They ensure higher data security by including control information;
Allow for higher accuracy in data transfer as they utilize entirely digital
communication;
Available multi-variant access feature in which detectors are used to read
various parameters of processes;
Allow for remote configuring and diagnostics of network units.
1.6.2. Control level systems
These are made up of PLC in local networks of deterministic character.
M-PLC
I/O
SCAN
IPC REG PLC
P T F
DU C
PLC
IPC
SCAN
M-PLC
T
Progr. Logic Controller
Industrial Computer
Scan device
Main PLC
Thermometer
P
F
C
I/O
DU
REG
Pressure guage
Flow indicator
Commuter
Input / Output devices
Drive unit
Regulator
Legend

Fig. 1. 5.

Systems of this level allow for real time control of processes as well as inte-
raction between various types of PLC, work stations, computers, program and
diagnostic units. Networks belonging to this level are in essence serial commu-
nication systems effecting the connection between units which exchange applied

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information in a determined and predefined way. Their purpose is to facilitate
exchange of technology programs as well as coordinating and control informa-
tion for the PLC. Networks should conform to the raised standard requirements
in terms of capacity, security and rate of data transmission, noise resistance and
determinacy for real time operation.
1.6.3. Information level systems
Information level systems are used for management and information ex-
change on a company level; their purpose being the solution of principal tasks in
company management. The common inherent problems with these systems are
related to the bulk and rate of transferred information, security and protection
from unauthorized access. Contemporary systems of this level make a wide use
of the specification known as Ethernet (fig. 1.6). Networks of this level feature
high traffic carrying capacity and are intended for exchange of large arrays of
information. Unlike most competitor technologies these possess a major advan-
tage in having their price reduced at regular periods.


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DeviceNet CAN DeviceNet
ControlNet
Ethernet
Ethernet
Information
Information
Control
PowerVault 2 0 0 5
1 1 1 0 9 8 3 2 1 0
PowerVault 2 0 0 5
1 1 1 0 9 8 3 2 1 0
Fieldbus

Fig. 1. 6.