Wireless in Process Manufacturing: Making Progress, with More on the Way
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Wireless technologies are increasingly being used in process manufacturing. While no single wireless solution meets all application needs, technologies are improving to find the right balance between radio technology, power supply, and industrial requirements. Recent trends focus on extending battery life through lower power operation and energy harvesting. Wireless field sensing has been commercialized since 2003 and provides benefits like longer device life, more reliable communication, and better security. Standards like IEEE 802.15.4 and WirelessHART are helping wireless adoption by addressing interoperability. Going forward, wireless solutions could fully automate data capture and analysis to remotely monitor more plant assets with lower installation costs.
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Wireless in Process Manufacturing: Making Progress, with More on the Way
- 1. Wireless in Process Manufacturing: Wi l i P M f t i Making Progress, with More on the Way Harry Forbes Senior Analyst ARC Advisory Group y p HForbes@ARCweb.com
- 2. Agenda 2007 ARC Best Practices Research Why Multiple Technologies? Current trends, leading applications 2 © ARC Advisory Group
- 3. Industrial Wireless Products Must Find a âSweet Spotâ Radio Technology and End User interference Requirements rejection ISM RF Application Band vs. Requirements licensed li d (data (d t rate, latency, t l t range, etc.) Device Power Supply Network N t k Long U f l L Useful Protocols Life Network Industrial Topology Environment No single wireless technology solution meets all requirements of all applications! 10 © ARC Advisory Group
- 4. Industrial Wireless Solutions Require Many Design Decisions Radio Variables Signaling Range PAN LAN MAN WAN (meters) 1-30m 10-100m 100-5,000m 5,000-20,000m Data Rate (kbps) 102 103 104 105 106 Power Supply Self-contained or Rechargeable Mains power replaceable battery (high power) battery (low power) (low power) Radio Spectrum Unlicensed Unlicensed Licensed Sub-1GHz 2.4Ghz Modulation Analog Digital Spread Spread Spectrum Spectrum FHSS DSSS Application Variables Industrial Protected Higher IP ratings Hazardous locations (moisture, dust) location certification Data Sampling 1 Hz 10 Hz 100 Hz 1000 Hz Rates (Hz) Synchronization 1 sec 1 mSec 1 ”Sec Required 12 © ARC Advisory Group
- 5. Industrial Wireless Solutions Design Decisions -- Field Transmitters Radio Variables Signaling Range PAN LAN MAN WAN (meters) 1-30m 10-100m 100-5,000m 5,000-20,000m Data Rate (kbps) 102 103 104 105 106 Power Supply Self-contained or Rechargeable Mains power replaceable battery (high power) battery (low power) (low power) Radio Spectrum Unlicensed Unlicensed Licensed Sub-1GHz 2.4Ghz Modulation Analog Digital Spread Spread Spectrum Spectrum FHSS DSSS Application Variables Industrial Protected Higher IP ratings Hazardous locations (moisture, dust) location certification Data Sampling 1 Hz 10 Hz 100 Hz 1000 Hz Rates (Hz) Synchronization 1 sec 1 mSec 1 ”Sec Required 14 © ARC Advisory Group
- 6. Trend: Focus on extreme low-power operation New wireless sensor semiconductor ventures focused on low power operation p p ⹠2007 GreenPeak Technologies ⹠IEEE 802.15.4 (ZigBee) chips, modules ⹠Optimized for low power ⹠2006 Gainspan Corporation ⹠IEEE 802.11 (Wi-Fi) chips ⹠Optimized for low power ⹠Existing SoC products reduce power ⹠Dust Networks ⹠Ember ⹠TI 19 © ARC Advisory Group
- 7. Less Power Needed by New Radio Modules 20 © ARC Advisory Group
- 8. Trend: Self-Powered Wireless Sensor Nodes Super-capacitor Radio Power Micro- Conditioning controller PMG Vibration Energy Sensors Micro-generator g Commercialized 10/2007 (Bently Nevada wSIM) Power supplies are ATEX certified 21 © ARC Advisory Group
- 9. Wireless Field Sensing Commercial products since 2003 Longer life More reliable communication Better security Soon standards-based ⹠IEEE 802.15.4 ⹠HART V.7 (WirelessHART) ⹠ISA SP100 24 © ARC Advisory Group
- 10. Wireless Condition Monitoring - Future Sensors include energy harvesting Low i t ll ti L installation cost t Data capture can be fully automated Data analysis can be fully automated Will extend monitoring to important p p plant assets Can be installed on existing plant assets Requires network infrastructure 27 © ARC Advisory Group
- 11. Summary: Things To Remember Wireless can yield huge value, but not without effort Process plants will always use many different forms of wireless Wireless product introductions will continue to accelerate 31 © ARC Advisory Group
- 12. Thank You. For more information, contact the author at HForbes@ARCweb.com or visit www.arcweb.com www arcweb com 32 © ARC Advisory Group