Next Generation Wireless Requirements for Automotive Manufacturing

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Next Generation Wireless Requirements for
Automotive Manufacturing

• Unique Requirements for Discrete Parts
  Manufacturing

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Presenter

• Mike Read
• Senior Technical Specialist IT - Ford Motor
  Company
• Former Controls Engineer and Instrumentation
  Engineer
• Controls/IT Liaison
• Focus area Programmable Device Interface and
  Networking
• Member USCAR Programmable Controls Committee

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• What is USCAR?
• The United States Council for Automotive
  Research (USCAR) is the umbrella organization for
  collaborative research among Chrysler LLC, Ford
  Motor Company and General Motors Corporation.
  Founded in 1992, the goal of USCAR is to further
  strengthen the technology base of the domestic
  auto industry through cooperative research and
  development.

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User Group Preferences
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• Why Wireless?
• Wireless I/O is desired for equipment where
  wiring is either high maintenance, not physically
  possible or cost prohibitive
• Wireless is NOT intended to be the replacement
  for all currently wired networks

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High Speed I/O

• High Speed I/O Typical examples
• Robot end effector
• Wiring is routed through the robot and is high
  maintenance due to continuous cable flex and
  tight radius joints.

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High Speed I/O
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High Speed I/O
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High Speed I/O
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High Speed I/O
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High Speed I/O
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High Speed I/O
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High Speed I/O
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High Speed I/O

• Additional High Speed I/O Typical examples
• Places where hard wiring is not an option and bus
  communications are high maintenance
• Carriers on electrified monorail systems
• Track mounted and rotary equipment
• Wireless Emergency Stop for wireless teach
  pendants

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High Speed I/O

• Performance Requirements
• Throughput time (PLC to device or Device to PLC)
  - 10ms
• Power-up time (Initial connection of DC power to
  full wireless device functionality) - 1.5 seconds
  or less
• 0 to 60 Degree (C) Operating Range
• Deterministic response time
• Very high reliability

Required for tool changing applications
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High Speed I/O

• Performance Requirements
• High density - approximately 50 instances of
  devices with 16 I/O points each within a 10M
  radius
• High EMF/RFI tolerance - Capable of operation in
  close proximity to welding and other RF devices
• Must not interfere with existing 802.11 b/g/a/n
  infrastructure

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High Speed I/O

• Form Factor
• Many unique switches placed in difficult
  locations
• Tightly clustered
• 8-16 I/O points per group
• Independently powered outputs

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High Speed I/O

• Device Connection
• Discrete Wired
• 8-16 I/O devices independently wired per RF
  device
• OR
• DeviceNet Wired
• 8-16 I/O DeviceNet devices per RF device

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High Speed I/O

• Power Supply
• 24 Volt DC power is locally available for field
  power in most applications
• Daily battery change is acceptable if required
  for wireless Emergency stop applications.

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High Speed I/O

• PLC Interface
• EtherNet/IP
• DeviceNet alternative
• Range
• Wireless I/O to PLC typically 10M or less

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Medium Speed I/O

• Secure Wireless Controls - Ethernet Applications
• Mobile PLC applications
• AGV systems
• Track mounted systems
• Rotary test stand applications

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Medium Speed I/O

• Secure Wireless Controls
• Ethernet Requirements
• Isolated, secure controls networks
• Connection to a secure wireless access point
• Access point must manage security, not the PLC

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Medium Speed I/O

• Performance Requirements
• 2Mbps data rate
• Must not interfere with existing 802.11 b/g/a/n
  infrastructure
• Low Power 802.11A UNI 1 and UNI 2 band preferred.
  Adjustable power required for distance limiting.

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Medium Speed I/O
Additional Requirements

• Form Factor
• Mount in metal control enclosure
• Antennas externally mountable
• Power Supply
• 24 Volt DC
• PLC Interface
• EtherNet/IP
• Distance
• Typical 30M to 60M
• For security reasons, extended range is not an
  advantage

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• Low Speed Applications
• Useful for applications that are cost prohibitive
  to wire back to a central location
• Remote temperature sensors and setpoints for
  energy management applications
• Machine mounted vibration signature devices
• Utility meters for power, gas, steam, compressed
  air, etc.

Low Speed I/O
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Low Speed I/O

• Performance
• Very low bandwidth,
• Communications from devices hourly, daily or on
  event
• Mesh or similar radio relay network required to
  extend range
• Must not interfere with existing 802.11 b/g/a/n
  infrastructure

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Low Speed I/O

• Form Factor
• Typical installations are in a metal control
  enclosure
• Externally mountable antenna

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Low Speed I/O

• Power Supply
• Battery power preferred, one year minimum life
• PLC Interface
• EtherNet/IP
• DeviceNet is an acceptable alternative

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• Interoperability and Standards
• Interoperability is critical
• Multiple devices, multiple suppliers Must be
  interoperable
• ISA SP100 Compliance
• Open standard compliance is the key to
  interoperability

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• Requirements for a safe and secure wireless
  controls network
• Prevent on-line programming from remote locations
• Prevent unauthorized access to programmable
  controls devices
• Prevent malicious tampering
• Prevent inadvertent tampering

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• Network Segmentation
• Isolated network segments serve several important
  functions
• Limit the group-to-group exposure
• Limit the ability to make remote changes from
  beyond safe working distance from the equipment

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Questions?
Mike Read Ford Motor Company mread_at_ford.com