Ethernet technology: connecting industrial and business platforms

The industrial landscape is rapidly evolving to address the challenging economic environment facing Australia today. Organisations need to become more efficient and flexible to maintain competitiveness and improve productivity.

This evolution has seen a significant increase in industrial ethernet technologies being applied to control systems and is being used to connect plant to business systems, helping industry achieve operational improvements.

Industrial ethernet is based on existing commercial technology; however, the components used are typically optimised for use in harsh industrial environments, where temperature extremes, humidity and vibration exceed the ranges found in controlled commercial environments.

Ethernet adoption across a plant or factory provides for easier information sharing and reduces network complexity. A single ethernet network can be used for standard control, as well as safety, motion, process, visualisation and asset management. This allows a reduction in the costs and time associated with the traditional approach using multiple fieldbuses.

By providing a scalable platform that can accommodate multiple applications, ethernet-based automation systems can help increase flexibility and accelerate deployment of new applications, providing companies with a future-proof network that can help them achieve their productivity goals.

Additionally, major improvements in wireless ethernet’s speed and reliability now bring a new realm of capabilities to controlling plants. Wireless obviously eliminates the need to run network cables across obstacles, further reducing the cost and complexity of installing traditional networks. This allows for great flexibility in an installation, where a combination of wireless and wired solutions may be used where conditions dictate.

Ethernet networks also allow for easy access to critically important, real-time data. A well-designed, robust, secure ethernet network can now allow real-time data to be accessed securely from anywhere in the world. Operational dashboards and reports provide increased visibility into current plant operations.

But exposing process networks to a wider audience raises valid security concerns. Due to their isolation, traditional fieldbuses inherently brought some level of security; although accessing data on these networks can be difficult. As industry moves towards a converged ethernet network, security becomes a prime concern. However, commercial providers of networks based on ethernet have, for the past two decades, been working on mitigating risks associated with viruses, unauthorised access, remote access and external attacks. Leading control system vendors are increasingly collaborating with traditional IT companies to design reference industrial ethernet architectures utilising current best practices.

This has led to a cultural change where IT and engineering are becoming closely aligned. In the past, industrial applications were maintained solely by engineers, but now the line between traditionally separate IT and engineering departments is becoming less defined. Engineers are becoming more familiar with IT technologies, and conversely, IT is fast learning the intricacies of industrial ethernet.

Researchers are predicting an explosion of end devices connected to ethernet, and as power over ethernet becomes accepted within industry, more and more devices are expected to be shipped ‘ethernet ready’. Manufacturers and automation vendors will continue to take advantage of investment and innovation in compatible commercial ethernet technologies and adapt these innovations to the industrial environment.

Robert Hicks has been involved with the process automation industry for more than 22 years, 10 years of which was spent commissioning process plants internationally. More recently, as Product Manager for Controllers and Networks at Rockwell Automation, he advises customers on product selection and best practices.