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Profibus DP permanent network monitor with features for industry 4.0

Grant number: 17/00877-0
Support type:Research Grants - Innovative Research in Small Business - PIPE
Duration: November 01, 2017 - July 31, 2018
Field of knowledge:Engineering - Electrical Engineering
Principal Investigator:Guilherme Serpa Sestito
Grantee:Guilherme Serpa Sestito
Company:Toledo & Souza Engenharia Ltda
City: São Carlos
Assoc. researchers: Danilo Barbosa Porto ; Gustavo Nicolau Gonçalves ; Lucas Lancellotti Sanches

Abstract

This research project aims to develop a functional prototype of a permanent monitor of Profibus DP protocol for industrial networks, one of the most widespread and consolidated communication protocols in the Brazilian industrial park. Permanent network monitors are devices installed in the field and permanently connected to networks. These devices also passively capture the digital signals of communication and interpret them for the extraction of indices and indicatives about the operation and quality of the network. From the perspective of "Industry 4.0", which provides automation paradigms and systems closer to Information Technology and with intense connectivity, generation and analysis of data from machines and equipment and cloud computing (IIoT - Industrial Internet of Things , Big Data and Cloud Computing), it is considered that permanent monitors of industrial networks are fully compatible with this trend. The Profibus DP network monitor equipment that is being proposed for development has the desired technical characteristics that place it in a competitive advantage with the imported competitors, and it has no national similar. Also, it incorporates strategic technologies from IIoT and Industry 4.0, unlike competitors. The scientific and technical challenges that present themselves, if they are overcome, will give the product the condition to be the only Profibus DP network monitor ready to connect to Industrial Internet of Things, Big Data and Cloud Computing systems through modern standards Open communications such as OPC-UA and MQTT, and support M2M (Machine-to-Machine) interoperability through Web Services and also to have the capability of monitors installed on the same local network discover and share their statuses with each other. The development stages of the project concentrate activities to develop a network monitor based on hardware modules with good processing power, Linux operating system, suitable for real-time processing of events that occur in periods of less than 1ms, with power at 24Vdc and a case for industrial panels with DIN rail mounting, serial connection for Profibus DP via isolated RS-485 transceiver for rates of 9.6Kbps up to 12Mbps and connection to Ethernet network 100 Mbps or 100/1000 Mbps per RJ-45 connector. On this platform, the project provides the development of a responsive web server with graphic visualization of innovative monitoring data for the market with the possibility of customizing the webpage uploaded to the monitor in order to enable new business models not served By the competition, from the OPC server embedded on the server, from the client and broker MQTT embedded for auto-recognition of monitors in the local network and possibility of external monitoring by other information systems, with the premise of not having to install computer programs for configuration or operation of the system. These technologies are aimed at integrating the proposed monitor into big data analytical systems in the cloud. Regarding the commercial prospects of the proposed monitor, it is projected to sell 40 to 50 units in the first year of commercialization, with progressive increases in the following years. In addition to the incremental increase in company revenues valued at R $ 260,000.00 from the first year of commercialization, there are complementary benefits for the company as the possibility of using the proposed project as the basis for the development of other medium-term network monitors - Profibus PA monitor, Fieldbus Foundation monitor and Profinet monitor and expanding the company's ability to access new customers, distributors and markets. (AU)