ICPC25 – Logic And Distributed Control Systems

Jan 2025 Session – VI Sem. B.Tech (ICE)

Lecture-37: Communication in Industrial Control

Systems

08-April-2025
Dr. Sri Ram Shankar R.
Assistant Professor, Dept. of ICE,
Chamber No. 204-A, First Floor, Dept. Main Building
NIT-Tiruchirappalli.
E-mail: srir@nitt.edu, +91-431-250 3366
 Data Communications
Data communications refers to the different ways that PLC microprocessor-based
systems talk to each other and to other devices.
A point-to-point serial communications link:
• Serial communications is used with devices
such as printers, operator workstations,
motor drives, bar code readers, computers,
or another PLC.
• Serial communications interfaces are either
built into the processor module or come as
separate modules.
• A serial module installed in each controller
is normally all that is required for two PLCs
of the same manufacturer to establish a
point-to-point
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Local Area Network (LAN)
Local area network or LAN is a system that interconnects data communications
components within a limited geographical area, typically no more than one or
two miles.
Network communications supports communication among multiple PLCs and
other devices.

PLC networks allow:

• Sharing of information such as the current state of
status bits among PLCs that may determine the
action of one another.
• Monitoring of information from a central location.
• Programs to be uploaded or downloaded from a
central location.
• Several PLCs to operate in unison to accomplish a
common
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goal. Lecture-37: Communication in Industrial Control systems 3
Transmission Media
Transmission media are the cable through which data and control signals flow on a
network. The transmission media used in data communications systems include
coaxial cable, twisted pair, or fiber optics
Each cable has different electrical capabilities and may be more or less suitable to
a specific environment or network type. Not all networks transmit information
through cable.
Wireless Wi-Fi Ethernet
networks, such as the DF1
Radio Modem, communicate
through radio waves, which
are transmitted through the air.

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Application of LANs
Communication system for distributed control systems (DCS), that uses individual
controllers to control the subsystems of a machine or process.

Supervisory control and data acquisition (SCADA). A LAN allows data collection
and processing for a group of controllers to be accomplished using one host
computer as the central point for collecting data.

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 Levels of functionality of Industrial Networks
There are three general levels of functionality of industrial networks.

Device Level —The device level involves various sensor and actuator devices of
machines and processes. These may include devices such as sensors, switches,
drives, motors, and valves.

Control Level —The control level would be the networks industrial controllers are on.
This level may include controllers such as PLCs and robot controllers.
Communications on the control level includes sharing I/O and program data between
controllers.

Information Level —The information level is a plantwide network typically composed

of the company’s business networks and computers. This level may include
scheduling, sales, management, and corporatewide information.
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Each device connected on a network is known
as a node or station.

As signals travel along a network cable, they

degrade and become distorted in a process
that is called attenuation. If a cable is long
enough, the attenuation will finally make a
signal unrecognizable.

A repeater is a device that amplifies a signal to

its original strength in order to enable its
signals to travel further

Different network types will have different

specifications for cable length and type
without a repeater.
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 Methods of Data Transmission
(1) Parallel transmission and (2) Serial transmission.

In parallel data transmission, all bits of the binary data are transmitted
simultaneously.

• Eight transmission lines are required to transmit

the 8-bit binary number.
• Each bit requires its own separate data path and
all bits of a word are transmitted at the same time.
• Parallel data transmission is less common but
faster than serial transmission.
• A common example of parallel data Parallel data transmission
transmission is the connection between a
computer and a printer.
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 Methods of Data Transmission
(1) Parallel transmission and (2) Serial transmission.

In serial data transmission, all bits of the binary data are transmitted simultaneously.

• In serial transmission, bits are sent sequentially on the same channel (wire) which
reduces costs for wire but also slows the speed of transmission.

• Serial data can be transmitted effectively over

much greater distances than can parallel data.
• Each data word in the serial transmission must
be denoted with a known start bit sequence
followed by the data bits that contain the
intelligence of the data transmission and a stop
bit.
• An extra bit, termed a parity bit, may be used to
provide some error-detecting Lecture-37:
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Network Topologies
Network topology is the physical layout of devices on a network formed by the
network cables when nodes are attached.

Star Topology • A network controller switch or hub is connected to

several PLC network nodes.
• A switch performs the same basic function as a hub
but effectively increases the speed, size, and data
handling capacity of the network.
• The configuration allows for bidirectional
communication between switch/hub and each PLC.
• The network controller hub controls all
communication.
• All transmissions must be sent to the switch/hub,
08/04/2025 which then
Lecture-37: Communication sends
in Industrial them to the correct PLC.
Control systems 10
Star Topology …

• One problem with the star topology is that if the

Star Topology switch/hub goes down, the entire LAN is down.

• This type of system works best when information

is transmitted primarily between the main
controller and remote PLCs. However, if most
communication is to occur between PLCs, the
operation speed is affected.

• Also, the star system can use substantial

amounts of communication conductors to connect
all remote PLCs to one central location.
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 Bus Topology
Bus topology, is a network configuration in which all stations are connected in
parallel with the communication medium and all stations receive information from
every other station on the network.
• Uses a single bus trunk cable to which individual nodes are attached by a cable drop
that taps off the main cable.
• Each node is interfaced to the bus using a network interface module that is attached
using a drop cable or connector.
• Each end of the bus must be terminated with a terminating resistor.

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 Bus Topology …
• As the data move along the total bus, each PLC node is listening for its own node
identification address and accepts only information sent to that address.
• Because of the simple linear layout, bus networks require less cable than all
other topologies.
• No single station controls the network and stations can communicate freely to
one another.
• Bus networks are very useful in distributive control systems, because each
station or node has equal independent control capability and can exchange
information at any given time.
• Another advantage of the bus network is that you can add or remove stations
from the network with a minimum amount of system reconfiguration.

• This network’s main disadvantage is that all the nodes rely on a common bus
trunk line, and a break in that common line can affect many nodes.

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 Method of Access Control in Bus Topology …
3) Polling: (E.g.) Master-Slave network

A master controller controls all communications

originating from other controllers.
• The master controller sends data to the slave
controllers.
• When the master needs data from a slave, it will poll
(address) the slave and wait for a response.
• No communication takes place without the master
initiating it.
• Direct communication among slave devices is not
possible.
• Information to be transferred between slaves must be
sent first to the network master unit, which will, in turn,
retransmit the message to the designated slave device.

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 I/O Bus Networks
I/O bus networks can be divided into two categories:
(i) Device bus networks and (ii) Process bus networks.

Device bus networks

They interface with low-level information devices such as pushbuttons and limit
switches that primarily transmit data relating to the on/off state of the device and its
operational status.

- Device bus networks that interface only with discrete devices are called bit-wide
bus networks. (Transfers <= 8bits of information)
- Device bus networks that include discrete devices as well as small analog devices
are called byte-wide bus networks. (Transfers >50 bytes of information)

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 I/O Bus Networks …
Process bus networks

They are capable of communicating 100s of bytes of data per transmission.

They mostly use analog devices, high-level information devices such as smart
process valves and flowmeters.

- Slower because of large data packet size

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Network Protocol
A network protocol defines how data is arranged and coded for transmission on
a network.
Two devices in a network need to understand the protocols to successfully
communicate.

Proprietary systems
• Designed to a specific vendor’s Open network systems
standards; • Based on international
• Different communications standards developed
protocols, command sequences, through industry
error checking schemes, and associations.
communications media used by
each manufacturer.

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 Gateway
• Gateways enable communication between
different architectures and protocols.
• Gateways can change the format of a message
so that it will conform to the application
program at the receiving end of the transfer.

❖ Bridges: Perform function of Network Access

Translation only
❖ Gateways: Perform adjustment of data formats
and data transmission control, in addition to
Network Access Translation.

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 Method of Access Control in Bus Topology
Network access control ensures that data are transmitted in an organized manner preventing
the occurrence of more than one message on the network at a time.

1) Token Passing : (E.g.) Peer-to-peer networks

In a token passing network, a node can transmit data on the network only when it has
possession of a token. A token is simply a small packet that is passed from node to node. When
a node finishes transmitting messages, it sends a special message to the next node in the
sequence, granting it the token. The token passes sequentially from node to node, allowing
each an opportunity to transmit without interference. Tokens usually have a time limit to
prevent a single node from tying up the token for a long period of time.

2) Collision Detection: (E.g.) Ethernet

Nodes listen for activity on the network and transmit only if there are no other messages on the
network.
When a collision is detected, each node that wants to transmit a message will wait a random
amount of time and will resend its data if it does not detect any network activity.
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Methods of Access Control …

Token Passing

CSMA/CD
Carrier Sense Multiple Access –
Collision Detection
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 Method of Access Control in Bus Topology …
3) Polling: (E.g.) Master-Slave network

A master controller controls all communications

originating from other controllers.
• The master controller sends data to the slave
controllers.
• When the master needs data from a slave, it will poll
(address) the slave and wait for a response.
• No communication takes place without the master
initiating it.
• Direct communication among slave devices is not
possible.
• Information to be transferred between slaves must be
sent first to the network master unit, which will, in turn,
retransmit the message to the designated slave device.

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 Peer-to-Peer (P2P) Network
• Peer-to-peer networks use the token passing media
access method.
• Each device has the ability to request use of, and
then take control of, the network for the purpose of
transmitting information to or requesting informa-
tion from other network devices.
• Each device is identified by an address.
• When the network is operating, the token passes
from one device to the next sequentially.
• The device that is transmitting the token also knows
the address of the next station that will receive the
token.
• Each device receives the packet information and
uses it, if needed.
• Any additional information that the node has will be
sent in a new packet.

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 Thank you ! ☺
Ref:
Ch. 14 – PLCs by Petruzella

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