Challenges

We are now entering the fourth industrial revolution, whose main paradigm is that information and deeper integration between machines, operators and management is the key driver of productivity growth. In order to realize this idea, each machine, facility and process in one production must be bound together and the whole data stream should flow into a unified management system where it becomes useful information that helps to optimize the production process.

This deeper integration and interdependence also requires a high degree of reliability of the newly built cyber-physical system and raises the critical need for a secure and reliable connection to the server which manages the production processes. A collision in data traffic can cause huge damage to the production process. For this reason, the modern idea of a “smart” factory would not be possible without a reliable and fast industrial communications network.

For this reason, the network switches in the main communication network ring have to meet a number of challenges caused by the heavy manufacturing process such as vibrations, electrical shocks, high-temperature amplitude, high frequency and electromagnetic disturbances, etc. In addition, the industrial network has to cover a large area with high speed and reliability.

In such systems, client devices are introduced with a variety of protocols and data exchange methods. Therefore, the network switch must be able to handle industrial protocols of different manufacturers.

With the entry of different devices into a communications network, the requirements for its security and stability are also rising. This should allow logical separation of individual users.

Last but not least, network switches must allow for easy installation and replacement without interrupting the communication.

Project with network switches Wago 852-1305

As part of a project to build a complex industrial control system that integrates SCADA, MES and EMS systems into a wire and cable manufacturing plant, Siviko OOD has built the first industrial communications network in Bulgaria based on the Industrial-Managed-Switch Wago 852-1305. The topology of the network makes a ring and is compliant with the requirements of IEC 62439-3: 2016: Industrial communication networks – High availability automation networks – Part 3: Parallel Redundancy Protocol (PRP) and High-availability Seamless Redundancy (HSR). Its total length is approximately 1000m, it has 11 network switches and serves as the backbone of the entire industrial control system. The Wago 852-1305 provide innovative Xpress Ring Reservation (less than 50 ms recovery) and JET Ring (less than 350 ms recovery). This increases the probability of failure-free operation of the network ring to 99.9%.

Why Wago 852-1305 Network Switches?

First of all, the Wago 852-1305 Industrial-Managed-Switch responds to the challenges presented – reliability, security, flexibility and ease of service. They fully meet the requirements of IEC 62439-3: 2016. The system achieves 99.99% reliability with the Xpress Ring technology, which connects all switches. One of the devices is configured as a connection arbiter. When the ring is in good condition, the arbitrator separates it logically and ensures the correct operation of the logical communication layers. In case the ring is discontinued physically in a given location, in less than 50 ms the arbitrator restores the logical interruption and the data flow is recovered. In addition, the network switches can be supplied with electricity from two different locations. Other integrated features of the switch such as Auto-negotiation, Rate limitation, Port isolation, etc. optimize your network performance and provide a secure network, offering a cost-effective solution in a small but powerful package.

Second, the architecture of the industrial communications network allows users with different roles to be separated and logically connected according to preliminary criteria – local segmentation. This increases the level of security and reduces the exchange of redundant information, which increases the free network capacity.

Third, the basic setup and maintenance of an industrial communications system is easy and reliable. It is implemented with hardware and software from WAGO Kontakttechnik GmbH & Co. KG. All Industrial-Managed-Switches provide data under the MODBUS TCP protocol. All current events are transmitted to an Ignition SCADA system from which real-time key parameters are monitored for the communications network. Each event is backed up in a database, allowing detailed analyses to be made after emergencies in communications devices.

Conclusion:

Siviko has chosen Wago 852-1305 because it meets all the requirements and challenges in building an industrial communications network – flexibility, reliability, performance, good integration with industrial control systems and easy and convenient configuration through various interfaces at an affordable price.