Latency and engineering issues in using protocol converters
Protocol Converters are generally used for transforming data and commands from one device or application to another. This necessarily involves transformation of data, commands, their representation, encoding and framing to achieve the conversion.
There are simple and complex types of conversions depending on the application and domain in which this is being used. The simplest and most commonly used conversion is protocol conversion between Modbus RTU and Modbus TCP. In this conversion, there is no change in the overall framing. Hence it is easy to take the Serial Modbus RTU frame and encapsulate it in a TCP/UDP socket and send it over Ethernet. Since both the protocol framings are the same, except for the actual physical layer transmission, both the application layers will interpret data similarly as long as the communication interfaces are made transparent.
However, there do exist very complex conversions, for example: where the data is formatted, the data types supported, the object models, etc. They are so different that the conversion engine needs to make modifications not only in framing, but in mapping information for each type of data, command, and in some cases, the object models. Also, there might be user configurations required in defining the mapping of supported and non-supported data types
These transformations, however, bring about conversion advantages, communication delay, processing latency, and an overall end to end processing time which is finite and needs to be considered in all solution designs.
The latency of end-to-end communication depends on the processing delay of the hardware and/or software being used, the protocol & conversion complexity, and the solution architecture. These latencies can vary for typical industrial and energy automation applications from 10 to 20 milliseconds to as high as 1 second. Solution architectures using protocol converters need to consider this latency and how it will impact the project for which converters are being considered.
Also, the majority of such architectures would involve configuration and mapping which both require considerable engineering effort and engineering time. These need to be considered while defining project schedules.
A programmable logic controller (PLC) or programmable controller is an industrial computer that has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, machines, robotic devices, or any activity that requires high reliability, ease of programming, and process fault diagnosis.
SCADA is a control system architecture comprising computers, networked data communications and graphical user interfaces for high-level supervision of machines and processes. It also covers sensors and other devices, such as programmable logic controllers, which interface with process plant or machinery.
A remote terminal unit (RTU) is a microprocessor-controlled electronic device that interfaces objects in the physical world to a distributed control system or SCADA system by transmitting telemetry data to a master system, and by using messages from the master supervisory system to control connected objects. Other terms that may be used for RTU are remote telemetry unit and remote telecontrol unit.
Modbus or MODBUS is a client/server data communications protocol in the application layer of the OSI model. It was originally published by Modicon in 1979 for use with its programmable logic controllers (PLCs). Modbus has become a de facto standard communication protocol for communication between industrial electronic devices in a wide range of buses and network.
A fieldbus is a member of a family of industrial digital communication networks used for real-time distributed control. Fieldbus profiles are standardized by the International Electrotechnical Commission (IEC) as IEC 61784/61158.
A terminal server connects devices with a serial port to a local area network (LAN). Products marketed as terminal servers can be very simple devices that do not offer any security functionality, such as data encryption and user authentication. The primary application scenario is to enable serial devices to access network server applications, or vice versa, where security of the data on the LAN is not generally an issue. There are also many terminal servers on the market that have highly advanced security functionality to ensure that only qualified personnel can access various servers and that any data that is transmitted across the LAN, or over the Internet, is encrypted. Usually, companies that need a terminal server with these advanced functions want to remotely control, monitor, diagnose and troubleshoot equipment over a telecommunications network.
Industrial Ethernet (IE) is the use of Ethernet in an industrial environment with protocols that provide determinism and real-time control. Protocols for industrial Ethernet include EtherCAT, EtherNet/IP, PROFINET, POWERLINK, SERCOS III, CC-Link IE, and Modbus TCP. Many industrial Ethernet protocols use a modified media access control (MAC) layer to provide low latency and determinism. Some microprocessors provide industrial Ethernet support.
IEC 61850 is an international standard defining communication protocols for intelligent electronic devices at electrical substations. It is a part of the International Electrotechnical Commission's (IEC) Technical Committee 57 reference architecture for electric power systems. The abstract data models defined in IEC 61850 can be mapped to a number of protocols. Current mappings in the standard are to Manufacturing Message Specification (MMS), GOOSE [see section 3, Terms and definitions, term 3.65 on page 14], SV or SMV, and soon to web services. In the previous version of the standard, GOOSE stood for "Generic Object Oriented Substation Event", but this old definition is still very common in IEC 61850 documentation. These protocols can run over TCP/IP networks or substation LANs using high speed switched Ethernet to obtain the necessary response times below four milliseconds for protective relaying.
Distributed Network Protocol 3 (DNP3) is a set of communications protocols used between components in process automation systems. Its main use is in utilities such as electric and water companies. Usage in other industries is not common. It was developed for communications between various types of data acquisition and control equipment. It plays a crucial role in SCADA systems, where it is used by SCADA Master Stations, Remote Terminal Units (RTUs), and Intelligent Electronic Devices (IEDs). It is primarily used for communications between a master station and RTUs or IEDs. ICCP, the Inter-Control Center Communications Protocol, is used for inter-master station communications. Competing standards include the older Modbus protocol and the newer IEC 61850 protocol.
Profinet is an industry technical standard for data communication over Industrial Ethernet, designed for collecting data from, and controlling equipment in industrial systems, with a particular strength in delivering data under tight time constraints. The standard is maintained and supported by Profibus and Profinet International, an umbrella organization headquartered in Karlsruhe, Germany.
EtherCAT is an Ethernet-based fieldbus system developed by Beckhoff Automation. The protocol is standardized in IEC 61158 and is suitable for both hard and soft real-time computing requirements in automation technology.
Sercos III is the third generation of the Sercos interface, a standardized open digital interface for the communication between industrial controls, motion devices, input/output devices (I/O), and Ethernet nodes, such as PCs. Sercos III applies the hard real-time features of the Sercos interface to Ethernet. It is based upon and conforms to the Ethernet standard. Work began on Sercos III in 2003, with vendors releasing first products supporting it in 2005.
A storage area network (SAN) or storage network is a computer network which provides access to consolidated, block-level data storage. SANs are primarily used to access data storage devices, such as disk arrays and tape libraries from servers so that the devices appear to the operating system as direct-attached storage. A SAN typically is a dedicated network of storage devices not accessible through the local area network (LAN).
openSAFETY is a communications protocol used to transmit information that is crucial for the safe operation of machinery in manufacturing lines, process plants, or similar industrial environments. Such information may be e.g. an alert signal triggered when someone or something has breached a light curtain on a factory floor. While traditional safety solutions rely on dedicated communication lines connecting machinery and control systems via special relays, openSAFETY does not need any extra cables reserved for safety-related information. It is a bus-based protocol that allows for passing on safety data over existing Industrial Ethernet connections between end devices and higher-level automation systems – connections principally established and used for regular monitoring and control purposes. Unlike other bus-based safety protocols that are suitable for use only with a single or a few specific Industrial Ethernet implementations and are incompatible with other systems, openSAFETY works with a wide range of different Industrial Ethernet variants.
An enterprise appliance transaction module (EATM) is a device, typically used in the manufacturing automation marketplace, for the transfer of plant floor equipment and product status to manufacturing execution systems (MES), enterprise resource planning (ERP) systems and the like.
A universal gateway is a device that transacts data between two or more data sources using communication protocols specific to each. Sometimes called a universal protocol gateway, this class of product is designed as a computer appliance, and is used to connect data from one automation system to another.
IEC 60870 part 5 is one of the IEC 60870 set of standards which define systems used for telecontrol in electrical engineering and power system automation applications. Part 5 provides a communication profile for sending basic telecontrol messages between two systems, which uses permanent directly connected data circuits between the systems. The IEC Technical Committee 57 have developed a protocol standard for telecontrol, teleprotection, and associated telecommunications for electric power systems. The result of this work is IEC 60870-5. Five documents specify the base IEC 60870-5:
RDMA over Converged Ethernet (RoCE) or InfiniBand over Ethernet (IBoE) is a network protocol which allows remote direct memory access (RDMA) over an Ethernet network. It does this by encapsulating an InfiniBand (IB) transport packet over Ethernet. There are multiple RoCE versions. RoCE v1 is an Ethernet link layer protocol and hence allows communication between any two hosts in the same Ethernet broadcast domain. RoCE v2 is an internet layer protocol which means that RoCE v2 packets can be routed. Although the RoCE protocol benefits from the characteristics of a converged Ethernet network, the protocol can also be used on a traditional or non-converged Ethernet network.
Cyphal is a lightweight protocol designed for reliable intra-vehicle communications using various communications transports, originally destined for CAN bus, but targeting various network types in subsequent revisions. OpenCyphal is an open-source project that aims to provide MIT-licensed implementations of the Cyphal protocol. The project was known as UAVCAN prior to rebranding in March 2022.
