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I(oT) in Process Networks

Bogdan Doinea – IoT Systems Engineer


bdoinea@cisco.com

14 October 2016
What is IoT?

50B
Devices Connected
by 2020

Source: Cisco Consulting Services © 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 2
IoT World Forum – Reference Model for IoT
Levels

7 Collaboration & Processes


(Involving People & Business Processes)
Center
6 Application
(Reporting, Analytics, Control)

5 Data Abstraction
(Virtualization, Federation, Caching)

4 Data Accumulation
(Storage)

3 Edge Computing
(Data Element Analytics & Transformation)

2 Connectivity + Fog Computing


(Communication & Processing Units)

1 Physical Devices & Controllers Edge


(The “Things” in IoT) Sensors, Devices, Machines,
Intelligent Edge Nodes of all
© 2015 Cisco types
and/or its affiliates. All rights reserved. Cisco Confidential 3
A New Industrial Revolution
Digitizing Manufacturing to Capture the Value of the Internet of Everything

Technology Smart
Progress Devices

18th Century 20th Century 70’s Today


Steam Mass Production Robots Digitization

Digital Manufacturing Priority Investments #1 Analytics | #2 Connectivity | #3 Automation | #4 Mobility


© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 4
Source: SCM World/Cisco “Smart Manufacturing & the Internet of Things 2015” survey of 400 Manufacturing Business Line Executives and Plant Managers across 17 vertical industries.
Connected Machines Deliver Business Outcomes

Reduced Reduction in New Product OEE Improved Reduction in


Downtime Defects Introduction Improvement Inventory Energy Use

48% 49% 23% 16% 35% 18%


Unplanned Defect rate New product Average OEE Inventory Annual energy
downtime down down from introduction cycle improved turns increased cost down from
from 11% 4.9% time reduced from from from $8.4M
to 5.8% to 2.5% 15 to 11 74% to 86% 14 to 19 to $6.9M

The Real Economic Value is Immense

Source: SCM World/Cisco “Smart Manufacturing & the Internet of Things 2015” survey of 400 © 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 5

Manufacturing Business Line Executives and Plant Managers across 17 vertical industries.
Industry 3.0 to Industry 4.0
§ Step 1: Connect the plant floor
§ Step 2: Figure out how to gather the data from machines (protocol)
§ Step 3: Figure out how to model the data (syntax)
§ Step 4: Figure out how to use the data (semantics, analytics)
§ Step 5: Have a very simple way to integrate (REST API)

© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 6
Cisco IE Switches Product Overview
Aggregation

Access

2014 Interop 2014 Control


Best in Class
Tokyo Engineering Cisco IE 4000 Series Cisco IE 5000 Series
IoT Award Award
Cisco IE 3000 Cisco IE 3010
Cisco® IE Cisco IE 2000U Series Series Cisco
2000 Series Series CGS-2520
Features

§ Layer 2 or 3 § Layer 2 or 3 § Designed for all § Up to 8 PoE/PoE+ § Designed for all § Up to 12 PoE/PoE+
§ Layer 2 § Layer 2 and 3 (IP services) (IP services) industries § Dying Gasp industries § Dying Gasp
§ Small Form Factor (IP services) § Modular § 1RU § Layer 2 or 3 § TrustSec ® SGT § Layer 2 or 3 § TrustSec ® SGT HW
§ IP30 and IP67 § Small Form Factor § Up to 24 ports § 2 GE combo uplinks (IP services) HW ready (IP services) ready
§ CC* § PRP § IEEE 1588 PTP § 8 PoE and 16 SFP or § 4-port GE uplinks § MACsec § 4-port 10GE or § MACsec HW ready
§ DLR (only Stratix) § IEEE 1588 PTP § PoE/PoE+ 24 copper § Up to 20 ports GE § FNF HW ready GE uplinks § FNF hardware ready
§ Profinet MRP & Power Profile § Power profile § IEEE 1588 PTP & § Time Sensitive § 24 ports GE § Time Sensitive
§ Layer 2 NAT § PoE/PoE+ (CGS2520) power profile Network (TSN) HW § IEEE 1588 PTP & Network (TSN) HW
§ IEEE 1588 PTP § PoE/PoE+ § Layer 2 NAT ready power profile ready
§ Layer 2 NAT § CC*
§ PoE/PoE+

10 Gbps
1 Gbps
10/100 Mbps

© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 7
‘*’ –Selected Models
Introducing the new IE1000 Target FCS Q4FY16

SKU IE1K-copper IE1K-PoE EFT Q3FY16


4 10/100M RJ45 4 10/100M RJ45 (w/POE)
Downlinks
6 10/100M RJ45 8 10/100M RJ45 (w/POE)
(5port) 1 FE Copper
Uplinks 2 GigE Fiber
(8port) 2 FE copper
PoE N PoE/PoE+
Total Ports 5 or 8 8 or 10

Power Input 24 VDC nominal (9 – 36) 48/54 VDC nominal (44 – 57)

(5port) W3.81 x H12.7 x


Size (cm) D11.5 W4.5 x H12.7 x D13.3
(8port) W4.5 x H12.7 x D11.5

Console port None

Alarm input/output No Yes

Temperature range -20-60C -40-70C

Ingress Protection IP30 © 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 8

8
IE Switching Cauvery 15.2(4)EA Release
Industry Leading
Redundancy
• Media Redundancy Protocol
(MRP) support on IE-2000 series
One Combined Release
• IE-4000 combined with IE- Usability Features
2000, IE-2000U IE-3000,
IE3010, CGS2520 • NTP to PTP flywheel
• Identify/ Locate switch LED
Certifications • MODBUS TCP Server
• Express Setup enhancements
• PROFINET MRP from PI
(Profinet International)
IE2000 Additional features
• Profinet Stack V2.31 • PTP – PDV filtering
• FIPS & CC compliance • PTP – feedforward boundary clock
• MIB: LLDP-EXT-PNO-MIB
© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 9

• MACSEC: IE-4000
Cisco 809 Industrial Integrated Services Routers
Dimensions:
Cellular MAIN GPS Cellular AUX
• 5”x 6.25”x1.25” (DxWxH)

Temperature: -40C to +60C

Accelerometer and Gyroscope IEC61850-3 and IEEE1613


(not supported at FCS)
compliant

One USB Type B Port

One RJ-45 RS232 Serial Port


One RJ-45 RS232/RS485 Serial Port 9-60 VDC Power Input
Digital Alarm Ports (not supported at FCS)
CPU: Intel Atom C2308 Dual-Core Two 10/100/1000Base-T
Rangeley @ 1.25 GHz One USB 2.0 Type A port
Memory: 2GB DDR3 (1GB for GuestOS) (not supported at FCS)
Storage: 8GB eMMC flash (2-3 GB for
GuestOS) © 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 10
Industry 3.0 to Industry 4.0
§ Step 1: Connect the plant floor
§ Step 2: Figure out how to gather the data from machines (protocol)
§ Step 3: Figure out how to model the data (syntax)
§ Step 4: Figure out how to use the data (semantics, analytics)
§ Step 5: Have a very simple way to integrate (REST API)

© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 11
Machine Anatomy – Mazak i-400ST
Identify machine components to collect data
General Motion Controller (GMC)
• GMC is considered as the brain of the machine
• Off the shelf motion controller from suppliers
• Usually perform single motion control at a time
• Typically consist of motion controller/drive amplifier/sensor
• A machine will only have GMC or CNC but not both
• 1 to 1 ratios between GMC/CNC and machine

Computer
ComputerNumerical
NumericalControl
Controller
(CNC)
(CNC)
• CNC is a special type of GMC – customized motion controller
• CNC are different from GMC that CNC also provide coordinated
motion control and meet the special requirements of machine
tool industry
• In a CNC based machine, the precision of motion control
determines the overall system performance
• Typically consist of controller/servo drivers/spindle drives/HMI

Programmable Logic Controller (PLC)


• PLC functionalities include logic/drives/process control
• Work with GMC and CNC
• Pass G code to GMC/CNC to execute
• Many to 1 ratio between PLC and machine

© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 12
Mazak SmartBox Use Case

Factory

Historian Machine / Cell Package

Tool Health

Memex Merlin

OEE & Analytics

Quality

IoT FOG Node


Cell
Maintenance MTConnect
© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 13
© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 14
Industry 3.0 to Industry 4.0
§ Step 1: Connect the plant floor
§ Step 2: Figure out how to gather the data from machines (protocol)
§ Step 3: Figure out how to model the data (syntax)
§ Step 4: Figure out how to use the data (semantics, analytics)
§ Step 5: Have a very simple way to integrate (REST API)

© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 15
Why MTConnect ?
MTConnect Data Model is a Game Changer
Applications MANY IoT FoG Node ONE Machines & Assets

Historian Mazak Machine


w/ MTConnect adapter

Tool Health Cisco


IE-4000
Memex Merlin
Web service
Agent Adapter
HTTP://IP:5000/current TCP
5000 7878
Stateless Constant
OEE & Analytics (Request/Response)
Connection
Industrial Switch
Quality
Connect
Compute
Security
Maintenance
Analytics © 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 16
What is Goal of MTConnect ?
Translate Machines into Standard XML Semantics

© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 17
MTConnect Architecture
Read-Only Data from Machines

Adapter Agent Application

Machine Cell Zone IDC Compute


Compute
TCP 7878 MTConnect HTTP
OEE Software
CNC Agent

OS

Vendor Specific Covered By


Implementation MTConnect Merlin OEE on UCS
Standard
Raw Syntax Semantics
Device
a = 196.54 Linear X
01010011010 b = 12.43 Position 196.54 mm
10001010010 c = 87.22 Load 12.43%
Rotatory C
d=2 © 2015 Rotary
Cisco and/or its affiliates. Velocity:
All rights reserved. 87.22 RPM
Cisco Confidential 18
Industry 3.0 to Industry 4.0
§ Step 1: Connect the plant floor
§ Step 2: Figure out how to gather the data from machines (protocol)
§ Step 3: Figure out how to model the data (syntax)
§ Step 4: Figure out how to use the data (semantics, analytics)
§ Step 5: Have a very simple way to integrate (REST API)

© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 19
Anomaly Detect Use Case Cisco Parstream
• Sensor Inputs:
• Coolant Level
• Temperature
• PH
• Vibration
• Digital I/O Sensors look like
MTConnect Adapter.
• Feeds Data to MTConnect
Agent IoT Platform(ie-4000)
• Cisco Streaming Analytics can
be tuned to be process specific
Ø Pattern Matching
MTConnect Ø Predictive Analytics
Agent 5000
Ø Compound Signatures
Cisco CSA Cisco IE-4000 © 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 20
Streaming Analytics on Mazak’s Smart Box

IE4000 Switch
Cisco Streaming Analytics
Software Inside

© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 21
Industry 3.0 to Industry 4.0
§ Step 1: Connect the plant floor
§ Step 2: Figure out how to gather the data from machines (protocol)
§ Step 3: Figure out how to model the data (syntax)
§ Step 4: Figure out how to use the data (semantics, analytics)
§ Step 5: Have a very simple way to integrate (REST API)

© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 22
MTConnect Agent - Application Communication
Agent Application
IE 4000 HTTP Response IDC Compute
(XML)
MTC 1 MTC 2

IOS + IoX

OEE Software
HTTP GET

Merlin OEE on UCS

10ms 1s
• Application makes an HTTP request -> Agent responses
• Communication use REST (Representational State Transfer)
• Agent is a special purpose HTTP server (open source available)
• Response in XML
• Store and forward with publish / subscribe semantics
• Adapter collect machine data rapidly – in the range of 10ms
• Application collect data less frequently – in the range of 1s
• MTConnect agent need support data buffering © 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 23
Concluding?

© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 24
Core and Aggregation Industrial Data Center
Catalyst
4500X/6800

Catalyst
3850X/IE5000 MTConnect Application

IR 809/829 UCS E Series

Access & ICA 3000 CGR 1000


MTConnect Agent IE Switch Ring (Roadmap) (Roadmap)

Cell Level Compute Platform

Adapter CNC Adapter CNC


Controller
Controller
Data Abstraction
CNC CNC
c Data Processing
Controller Controller

Data Acquisition
Machine with Machine with
MTConnect Adapter MTConnect Adapter © 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 25
Big Stars
§ (For now) you just want to connect: IE2000 ->

§ You want your network to be Industry4.0 ready: IE4000 ->

§ You want to start gathering Machine Data NOW: IR829 ->

§ You want to start doing Analytics, fast, safe and at the edge -> Cisco CSA

© 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 26
Connected Machines Deliver Business Outcomes

Reduced Reduction in New Product OEE Improved Reduction in


Downtime Defects Introduction Improvement Inventory Energy Use

48% 49% 23% 16% 35% 18%


Unplanned Defect rate New product Average OEE Inventory Annual energy
downtime down down from introduction cycle improved turns increased cost down from
from 11% 4.9% time reduced from from from $8.4M
to 5.8% to 2.5% 15 to 11 74% to 86% 14 to 19 to $6.9M

The Outcome will be imense

Source: SCM World/Cisco “Smart Manufacturing & the Internet of Things 2015” survey of 400 © 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 27

Manufacturing Business Line Executives and Plant Managers across 17 vertical industries.