Manufacturing Automation for Assembly and Inspection MM453

Manufacturing Automation for Assembly and

Inspection
MM453

Dr. Nigel Kent

Rm S366
[email protected]

Dublin City University

Sem 1 2022

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9

Lecture 9

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Supervisory Control And Data Acquisition (SCADA)

ANSI/ISA-95, or ISA-95 as it is more commonly referred, is an

international standard from the International Society of
Automation for developing an automated interface between
enterprise and control systems.

ENTERPRISE RESOURCE PLANNING.

BUSINESS AND LOGISTICS
ERP

MANUFACTURING ENTERPRISE SYSTEM.

OPERATIONS AND MANAGEMENT MES

SUPERVISORY CONTROL (SCADA),

HMI’S, EMBEDDED SYSTEMS MONITORING AND SUPERVISORY

PLC’S, MICROCONTROLLERS,
SENSING AND MANIPULATION
MICROPROCESSORS

SENSORS AND ACTUATORS PROCESS/SYSTEM

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Supervisory Control And Data Acquisition (SCADA)

ANSI/ISA-95, or ISA-95 as it is more commonly referred, is an

international standard from the International Society of
Automation for developing an automated interface between
enterprise and control systems.

ENTERPRISE RESOURCE PLANNING.

BUSINESS AND LOGISTICS
ERP

MANUFACTURING ENTERPRISE SYSTEM.

OPERATIONS AND MANAGEMENT MES

SUPERVISORY CONTROL (SCADA),

HMI’S, EMBEDDED SYSTEMS MONITORING AND SUPERVISORY

PLC’S, MICROCONTROLLERS,
SENSING AND MANIPULATION
MICROPROCESSORS

SENSORS AND ACTUATORS PROCESS/SYSTEM

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Supervisory Control And Data Acquisition (SCADA)

ANSI/ISA-95, or ISA-95 as it is more commonly referred, is an

international standard from the International Society of
Automation for developing an automated interface between
enterprise and control systems.

ENTERPRISE RESOURCE PLANNING.

BUSINESS AND LOGISTICS
ERP

MANUFACTURING ENTERPRISE SYSTEM.

OPERATIONS AND MANAGEMENT MES

SUPERVISORY CONTROL (SCADA),

HMI’S, EMBEDDED SYSTEMS MONITORING AND SUPERVISORY

PLC’S, MICROCONTROLLERS,
SENSING AND MANIPULATION
MICROPROCESSORS

SENSORS AND ACTUATORS PROCESS/SYSTEM

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Supervisory Control And Data Acquisition (SCADA)

The bottom two layers of the ISA95 model can be called an

information loop i.e. the sensor feeds data to the PLC. Depending
on how the PLC is programmed is can effect change on the
actuator. This in turn changed the technical process, changing the
sensor value - and the loop continues.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Supervisory Control And Data Acquisition (SCADA)

Overall management of an automated enterprise requires some

means of collecting and sending information between several
information loops or processes.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Supervisory Control And Data Acquisition (SCADA)

Essential components of the collection and sending communication

across a local area network (LAN) include:
1 Topology - How the network is constructed
2 Transmission medium - Physical means of data
communication
3 Network access protocol - How the communications are
decoded

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network Topology

• Point-to-point connection:The simplest connection

is a point-to-point connection between two devices.
One key disadvantage here is that if a device has to
communicate with several other devices, a separate
connection has to be established in each case.
• Line topology: Connecting devices in series to form
a line topology is also referred to as a bus topology.
The devices are all connected to one transmission
medium. Classic fieldbus systems such as PROFIBUS
feature this type of topology.
• Bus Topology All stations share a trunk line with
termination points. Information accessed
simultaneously - accepted by the relevant unit. Bus
topology adopted into IEEE 802.3 (Ethernet), IEEE
802.4 Manufacturing Protocol (MAP) standards.

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Lecture 9
Network Topology

• Ring topology:Every device can essentially

communicate with every other device via two
channels (clockwise , counter-clockwise). And
this is the main advantage of this structure:
device communication is preserved if one section
of the network is interrupted.
• Star Topology A computer/server acts as a
central hub. It is relatively easy to keep track of
data flow and prioritise communications. Whole
system goes down when the central computer
crashes, typically redundancies are built in.
• Tree Topology: A tree has several distribution
components, depending on its size, and can
therefore be regarded as an “expanded” star. One
example of this is the common type of Ethernet
office network using switches as a distribution
component.
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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Transmission Medium

Twisted pair cable is made by intertwining two or more separate

insulated wires together and running them parallel to each other.
For each pair, one line is ground and the other line is a data line.
The twisted wires have interference cancelling properties. Thus, it
is suitable for data transmission over short distances as the cable
reduces the effect of electromagnetic interference on electronic
signals. It is also more pliable and easier to install than coaxial
cable (next slide).

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Transmission Medium

Coaxial cable has an inner conductor that is surrounded by an

insulating layer, which has conductive shielding around it. For some
applications, even the outer jacket of the cable may be insulated.
The center conductor carries the electrical signal. The shielded
design of the cable allows for transmission of data rapidly through
its copper core without interference from environmental factors.

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Lecture 9
Transmission Medium

Fibre optic cable is differentiated from coaxial and twisted pair

cabling in several ways. Its core consists of optic fibre rather than
copper. As such data is transmitted by light rather than an
electrical or electronic signal. Transmissions can travel at a greater
distance at a much faster pulse 26,000 times faster than twisted
pair.

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Lecture 9
Transmission Medium

Characteristics Twisted pairCoaxial Fibre

Data rate Low data rate.
Moderately Very high data
high data rate. rate.
Noise immunity Low noise im- Higher noise Highest noise
munity. immunity. immunity.
Installation Easy installa- Fairy easy in- Difficult to in-
tion. stallation. stall
Cost Cheap Relatively Relatively ex-
cheap pensive
Attenuation High attenua- Low attenua- Very low atten-
tion tion uation
The most prominent feature that distinguishes these cables is their data
transmission rate. Twisted pair cables have a data transfer rate of a
maximum of 10 Mbps, whereas coaxial cables can be 80 times faster than
a twisted pair. Optical fiber cables are used for high-speed data transfer.
The transfer speed is approximately 69% of the speed of light.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network Components

Before we look at network access protocols it is work looking at

some networking components. The fundamental purpose of a
network is to send data between two devices (hosts).
Over long distances these there can be losses on data lines a
repeater can be used to amplify these attenuated signals.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network Components

In order to connect multiple hosts on a single network we can use a

Hub. A hub is effectively a multi port repeater.

The disadvantages of a Hub are that it send the same signal to all
hosts resulting in high bandwidth consumption and low security.

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Lecture 9
Network Components

A bridge can be used to connect two hub connected hosts. The

bridge serves to limit the data transmission to its respective hub
network.

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Lecture 9
Network Components

Switches are a combination of hubs and bridges

• Multiple Ports like a hub
• Learns which hosts are on each port like a bridge

Switches facilitate communication within a network

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Lecture 9
Network Components

Routers learn which network they are attached to and the route to
those networks are stored in a routing table

Routers facilitate communication between Networks

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network Components

A gateway acts as a connection point between two network types.

It can act as the link between the Information Technology (IT)
component of a facility and the operations technology of the
facility (OT). Linking layers 1-3 and 4-5 of the ISA 95 model.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

Open System Interconnect (OSI)

• In an effort to encourage some standardisation in the design
of communication networks, the International Standards
Organization (ISO) has established a reference model, which
is a description of how networks should be designed in terms
of layers of responsibility.
• The purpose of the reference model is to divide the
communication problem into a series/stack of sub-problems,
or layers.
• Each layer only deals with the layer above or below it.
• Outgoing/sent messages move down a stack, while
incoming/received move up.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

Open System Interconnect (OSI)

Application  To allow access to network resources

Upper Layers
Software/

Presentation  To translate, encrypt and compress data

 To establish, manage and terminate a session

Session
 API, Sockets, WinSock

 To provide reliable processes to process message delivery

Heart of OSI Transport
and error delivery

Network  To move packets from source to destination

Lower Levels
Hardware/

Data Link  To organise bits into frames

 To transmit bits over a medium

Physical
 To provide mechanical and electrical specifications

Sent Data To/From

Next Node
Received Data
Transmission Medium (Fibre/Coaxial etc.)

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

• Physical Layer. This defines voltage levels, baud rate, hardware

used at nodes and transmission medium. Transmission can
occur separately from reception in which case it is termed half
duplex or simultaneously when it is termed full duplex.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

• Data Link Layer. This layer interacts with the wire / wireless
signals i.e. the physical layer through network access cards. It
also finds the physical address on the network known as MAC
addresses. MAC addresses are 48 bit addressees (12 hex
digits) specific to a hardware component. The Data Link
Layer ensures valid messages only are passed up to the next
layer. This layer also establishes if the message is for that
node. The integrity of information can also ensured by
checking the data. Switches are layer 2 or Data link layer
devices.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

• Network layer. The network layer finds the shortest path to the
destination on the network. This usually means the shortest
time. It is used to add information to the packet if two or
more LANs are connected using a router. The addressing
scheme is called IP addresses and is as 32 bit number
represented as 4 octets (0-255). Routers and hosts are
considered Layer 3 or network layer technologies. The
Network layer is concerned with end to end delivery whereas
leyer 2 is hop to hop or device to device delivery.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

• Transport Layer. Service to service delivery. The transport layer

guarantees end to end transmission of data. It checks to see
does the destination address exist, did the recipient receive
the data, is incoming data ok or has it been corrupted. This is
used again where there is more than one LAN. This layer
divides the data up into packets and coordinates the
transmission and reception of packets. It also sets the correct
transmission rate if dealing with a slower recipient.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

• Transport Layer. The addressing scheme is known as ports.

0-65535 for both TCP and UDP. Servers listen for request on
predefined ports. Clients select random port for each
connection.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol
• Session Layer. This layer looks after specific user needs such as
passwords etc. It defines what rights the user has and
therefore gives permissions to the user (what software
functionality is available). It also groups information in a
manner appropriate to the user.
• Presentation layer. In this layer a protocol is used to convert
data between computers using different forms of encoding in
the Application layer. Before transmission over the network
the data often generated in ASCII format has to be converted
to binary. Encryption is also provided here. Also data can be
compressed here for more efficient transmission over the
network.
• Application layer. This layer contains user specific data,
application software which uses the network to function.
Examples would be email, web browsers, file sharing services,
print servers, network drives, social media (Linkedin, Facebook
etc.)
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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

Not all layers are necessary, e.g. if all stations are on one LAN and
use the same application protocols we can dispense with the
network, transport, session and presentation layers.

Open system interconnect is just a model, the most prevalent

manifestation of this is the Transfer Control Protocol/Internet
Protocol (TCP/IP).
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Lecture 9
Network access protocol

For the application layer that will

depend on the application running.
Web browsing might use hyper text
transfer protocol (http) or hyper text
transfer protocol secure (https).

If with http we had to login to a server

we would be using the equivalent of a
session layer as well. If the data was
encrypted as is the case with https we
would effectively be including a
presentation layer.

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Lecture 9
Network access protocol

At the transport layer we can use:

• Transmission Control Protocol
(TCP) TCP guarantees end to end
transmission of data
• User Datagram Protocol (UDP). In
the case of UDP there are no checks.
The data sent and any error checking
is left to upper levels.

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

At the internet layer some examples

of the protocols are:
• Internet Protocol (IP)
• Internet Control Message
Protocol (ICMP)

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Lecture 9
Network access protocol

At the network access layer we

include the data link layer and the
physical layer so we are concerned with
protocols such as ethernet, fieldbus and
then aspects of the physical medium
such as cabling, connectors etc

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Lecture 9
Network access protocol

R1 R2
M1 M2

Data Application

9056 80 Data Transport

Segment

Text
M1(IP) M2(IP) 9056 80 Data Internet

Packet
Text

M1(MAC) R1(MAC) M1(IP) M2(IP) 9056 80 Data Network Access

Frame
Text

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

R1 R2
M1 M2

Data Application

9056 80 Data Transport

Segment

Text
M1(IP) M2(IP) 9056 80 Data Internet

Packet
Text

R1(MAC) R2(MAC) M1(IP) M2(IP) 9056 80 Data Network Access

Frame
Text

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

R1 R2
M1 M2

Data Application

9056 80 Data Transport

Segment

Text
M1(IP) M2(IP) 9056 80 Data Internet

Packet
Text

R2(MAC) M2(MAC) M1(IP) M2(IP) 9056 80 Data Network Access

Frame
Text

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

R1 R2
M1 M2

Data Application

9056 80 Data Transport

Segment

Text
M1(IP) M2(IP) 9056 80 Data Internet

Packet
Text

R2(MAC) M2(MAC) M1(IP) M2(IP) 9056 80 Data Network Access

Frame
Text

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

R1 R2
M1 M2

Data Application

9056 80 Data Transport

Segment

Text
M1(IP) M2(IP) 9056 80 Data Internet

Packet
Text

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

R1 R2
M1 M2

Data Application

9056 80 Data Transport

Segment

Text

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

R1 R2
M1 M2

Data Application

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

Sending Machine Receiving Machine

Application Data Application

TCP or UDP
Segment
Transport Data Transport
Header

Segment
IP or ICMP
Packet Segment
Internet Data Internet
Header Header

Packet
Ethernet, WiFI, ISDN
Packet Segment Frame
Frame Header Data
Header Header Trailer
Network Network
Access Frame Access
10010100110100010100101001000101 - Bits

Data sent over twisted pair, coxial etc.

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Lecture 9
Network access protocol

Transport Protocol (Segment) Header Format

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Lecture 9
Network access protocol

Internet (Packet) Header and Network Access (Frame)

Format

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Manufacturing Automation for Assembly and Inspection MM453
Lecture 9
Network access protocol

Integrity of data is ensured at different levels.

Transport and Internet layers use a checksum on the contents of
their respective headers only.
Original Data
10011001 11100010 00100100 10000100
1 2 3 4

Sender Reciever
1 10011001 110011001
2 11100010 211100010
101111011 101111011
1 1
01111100 01111100
3 00100100 3 00100100
10100000 10100000
4 10000100 4 10000100
100100100 100100100
1 1
Sum 00100101 00100101
Checksum 11011010 Checksum 11011010
Sum 11111111
Complement 00000000

Conclusion ⇒ Accept Data

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Lecture 9
Network access protocol

Integrity of data is ensured at different levels.

Network access layer uses a Cyclic Redundancy Check (CRC) on
the entire frame
Original Data 1010000
Generator Polynomial = x3 + 1
CRC Generator = 1x3 + 0x2 + 0x1 + 1x0 = 1001
For a CRC generator of n bits append the end of the original message by n − 1 zeros
XOR the CRC generator with the appended Original Data

Sender Reciever

1010000 000 1010000011

XOR 1001 XOR 1001
0011000000 0011000011
XOR 1001 XOR 1001
01010000 01010011
XOR 1001 XOR 1001
0011000 0011000
XOR 1001 XOR 1001
01010 01001
XOR 1001 XOR 1001
0011 0000

1010000 000 Conclusion ⇒ Accept Data

011
1010000011 ⇒ Transmitted Data

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