In the competitive global market, the goal is to manufacture increasingly complex products of consistently high quality, at market-driven costs, often in customized versions. Smart factories, which autonomously adapt to changing production demands in accordance with Industry 4.0 principles, are essential to achieving this goal.
Increased communication demands:
Networked production systems must communicate not only with each other, but also with other systems within the company. This communication requirement encompasses everything from sensors and actuators in the field, through controllers and master computers, to local and central data centers, and the cloud. Each of these points serves as both a data source and a destination.
The ongoing miniaturization of microelectronics has broken down the rigid separation between control computers and peripheral devices. As sensors and actuators are increasingly equipped with their own processors, the number of smart network nodes in the field is growing rapidly. The architecture for data processing—centralized or distributed—depends on both technical and economic criteria, including the costs of data transmission over public networks such as 5G.
The traditional hierarchical model of information exchange is evolving toward a cross-structure data communication approach. This shift is driven by the need to improve productivity, process stability, product quality, and energy efficiency, all of which require high-quality information and, consequently, increase data transfer volumes.
Ethernet in Industrial Applications
In mainstream information technology (IT), the Ethernet network standard has become the benchmark for the rapid exchange of large amounts of data. As the world's leading standard for networking computers in office environments, Ethernet offers high transmission bandwidth. Furthermore, the TCP/IP protocol suite facilitates globally standardized data communication across the boundaries of individual local area networks (LANs).
Given the increasing volume of data in industrial machines and systems, it was clear that Ethernet also needed to be adopted for industrial operational technology (OT) applications. However, the precise synchronization of motion processes in industrial applications demands real-time capability in many areas. To achieve this, predictable timing is at least as crucial as having a sufficiently high data transmission rate.
Although Ethernet allows for the rapid transmission of large amounts of data, it lacks the deterministic timing required by some industrial applications. This necessitates improvements to meet the stringent requirements of industrial environments.
Real-time capabilities required for production:
The ability to achieve deterministic, real-time behavior is only possible with a common time base for all participants in the network. To achieve predictable real-time behavior with isochronous cycle times of less than one millisecond, automation system manufacturers have created a range of different proprietary real-time protocols under the umbrella of Industrial Ethernet.
Fieldbus systems based on these protocols facilitate the rapid transmission of large volumes of data and the transport of security-related data over the same lines using "black channel" technology. However, these systems often deviate considerably from the Ethernet standard and lack compatibility with each other and with surrounding networks.
Eliminating Proprietary Bus Systems:
The Institute of Electrical and Electronics Engineers (IEEE) has developed the Time-Sensitive Networking (TSN) Ethernet standard, an extension of Ethernet to include real-time capabilities. The IEEE 802.1 TSN standard regulates the behavior of data packet transmission by synchronizing time using a common time base and offers options for traffic scheduling and automated system configuration. These features are essential for the universal interconnection of all computer systems.
Another critical requirement is an open, real-time communication protocol to avoid the complexities and potential data loss associated with translation between systems from different manufacturers. This challenge was addressed in November 2018 with the introduction of OPC UA over TSN in SPS, a universal real-time communication platform that extends down to the sensor level.
Renamed OPC UA FX (Field eXchange), this standard resolves previous compatibility issues with a single, globally standardized protocol. Compatible with major hardware vendors, it serves as the foundation for all IIoT applications and is key to merging IT and OT into a single network.
Learn more about the technology behind TSN and the new global language OPC UA FX in this Kontron technical article.
A single standard for real-time communication,
TSN, is rapidly establishing itself as the definitive standard for real-time data communications. The redefinition of Ethernet has significantly improved performance, enabling networks with tens of thousands of nodes. These networks can communicate up to 18 times faster than any previous protocol and are also very easy to manage and configure. This advancement allows for the combination of digital image processing and real-time synchronized drive technology using cost-effective, on-site hardware.
Terminals without TSN capabilities can also function seamlessly on TSN networks, suggesting that Ethernet installations will eventually support TSN functionalities as a standard. This shift will eliminate the current high costs associated with overcoming compatibility issues, facilitating the integration of time-critical system components into the Internet of Things (IoT). Consequently, this will enable the realization of Industry 4.0 concepts. Furthermore, the deterministic timing behavior of data communication provides significant advantages in many applications beyond machines and production systems.
an early adopter of TSN
. As a pioneer in TSN, the company launched a Time-Aware Networking Starter Kit in April 2018. This comprehensive software environment supports programmers and users, addressing the significantly more complex network configuration required for TSN compared to standard Ethernet. The Starter Kit also includes suitable hardware with TSN-compatible interfaces for real-world testing, making it easier for system builders to adopt the technology.
One of Kontron's first TSN-compatible products was a PCIe plug-in board that provides up to four external TSN channels. These channels can be used individually, in redundant pairs, or in a ring configuration, enabling the creation of topology-independent TSN networks. Kontron has implemented fast communication logic using an FPGA (Field Programmable Gate Array), allowing for quick and easy response to standard changes by reloading with the latest versions.
The compact SMARC sAL28 module offers up to five Gigabit Ethernet ports and an integrated TSN switch, making it ideal for data concentration as an edge device.
-enabled products
as a standard feature in a growing number of its products, including its latest Box PCs, rackmount servers, workstations, and Panel PCs, as well as COM Express® modules, motherboards, and 3.5" SBCs. This is made possible by the incorporation of TSN functionality into semiconductors from various manufacturers, such as Intel® Core™ processors up to the current 14th generation. These processors support Intel's Time Coordinated Computing (TCC) technology, which enables TSN.
For example, the COMh-ccAS COM-HPC® (High Performance Computing) client module with 12th generation Intel® Core™ S processors delivers the power needed for versatile applications in networking, automation, measurement, and medical technology that require graphics-intensive and high-performance computing. The COMh-caRP industrial size A COM HPC/client module, equipped with 13th generation Intel® Core™ processors, up to 64 GB of DDR5 RAM, and up to 2.5 Gb Ethernet with TSN support, is also suitable for industrial applications.
Kontron's commitment to TSN extends beyond Intel processors. The OSM-S i.MX8M Plus solderable System-on-Module (SoM) integrates a powerful i.MX8M Plus Quad Arm® processor with a 1.6 GHz quad-core AI processor, 64 GB of eMMC storage, and 4 GB of LPDDR4 RAM. One of its dual GbE-LAN ports features TSN functionality, all within a compact 30 x 30 mm form factor.
From the smallest modules to embedded Box and Panel PCs, including the KISS V4 ADL family of rack-mount industrial systems and the KWS workstation, Kontron's portfolio of industrial computing hardware with extended temperature ranges and TSN capabilities meets a wide range of requirements. Furthermore, Kontron offers custom developments and variants, supporting customers in implementing specific automation projects through Kontron AIS.
Key component: Ethernet switches.
Deploying complex solutions in harsh industrial environments requires seamless interaction between hardware, software, and connectivity with production systems. This perfect integration is crucial for successfully implementing digital transformation in the manufacturing industry. Consequently, industrial switches are essential building blocks for effective Industry 4.0 and IIoT applications.
In addition to boards, modules, and industrial systems, Kontron's product portfolio also includes industrial Ethernet switches. The KSwitch D10 MMT is a robust and cost-effective eight-port managed TSN switch designed for high-speed and Gigabit networks. This industrial device features a high-quality metal housing that makes it resistant to environmental influences. It operates in a wide temperature range from -40 to +75 °C and supports an extended power supply range of 12 to 58 V DC. The KSwitch D10 MMT includes six Fast & Gigabit Ethernet ports with RJ45 connectors, along with two additional ports with RJ45 and SFP fiber interfaces supporting speeds up to 2.5 GbE/s. It comes equipped with a comprehensive set of TSN features and management capabilities in accordance with IEEE 802.1 TSN standards.
By fully integrating TSN into the hardware, including switches, Kontron simplifies the deployment of converged Ethernet-based networks. These networks allow deterministic, time-synchronized communications to run in parallel with regular IT traffic, facilitating true IIoT or Industry 4.0 environments based on common Ethernet protocol standards.
Reiner Grübmeyer, director of product management for systems and software at Kontron, states: "By fully integrating TSN into our hardware, including switches, we are making it easier for users to deploy converged Ethernet-based networks where deterministic, time-synchronized communications run in parallel with regular IT traffic."
Author: Reiner Grübmeyer, Director of Product Management for Systems and Software at Kontron
