SUCCESS STORY
Trend-setting Network Solution for Machine Controls
On the wire with switches and firewalls: How the Elisental wire plant implements a forward-looking network solution for existing machine controls with Helmholz.
From tea bags to aircraft construction
Whether as stitching wire on tea bags, as architectural mesh in modern buildings or as a connecting element in aircraft construction, the aluminum products of Drahtwerk Elisental W. Erdmann GmbH & Co. can be found in many places around the world. Founded in Neuenrade near Iserlohn in 1919, the independent family-owned company focused on wires as its main product right from the start - and early on on aluminum, which was a young material at the time. By specializing in aluminum wires and rods, the Elisental wire plant, now run by the third and fourth generations of the family, has successfully positioned itself as a strong player in international competition with around 150 employees.
One pillar of the company's sustainable success is the continuous further development of the company and the production processes. The automation with Profibus and PROFINET, which has long since been completed, represented an important modernization boost.
With the prospect of the new possibilities of Industry 4.0 and IoT, it was then time for new, forward-looking paths in 2019. Or as Dirk Urbach, technical service employee, puts it, "We know we have a lot to tackle to stay ahead in the market - and we've already implemented a lot of it."
Previously, the higher-level company network could only record whether a machine was stopped or running, and in some cases at what speed. A key goal for Dirk Urbach and his colleagues was therefore initially to make better use of the data from the machines, for example for detailed monitoring or, in the future, for software-based automation of entire production processes.
This resulted in a clear task: "How do we get the data directly from the PLC into the software?" It quickly became apparent during initial networking attempts that this requirement was by no means so easy to fulfill. In particular, the network quality was not satisfactory at first. "For example, the broadcast protocols of the machines interfered with each other," explains Dirk Urbach. So what was needed was a really stable network with cleanly transmitted data.
„We have to tackle a lot to stay ahead in the market“
Dirk Urbach, Employee of the Technical Service
Overall concept from Helmholz
The solution was finally found in an overall concept from Helmholz. As a result, each machine is mapped in the higher-level network. Its data is thus available 1:1 in the server or for further use - currently by monitoring software - and can be output, for example, as a daily data table (in Excel or csv file format).
Managed PROFINET switches with four, eight and, where appropriate, 16 ports create the prerequisites for smooth data traffic between machine controllers and software by prioritizing PROFINET telegram traffic in the machine network. The managed switch can distinguish whether the telegram is a web request, an FTP file transfer, a media stream, or a PROFINET telegram. In the event of a high transmission load, the telegrams can thus be sorted according to their importance. This prevents telegram losses from occurring.
The switches also offer concrete advantages for the users: "I can assign individually on which place each system or participant sits," according to Dirk Urbach's experience. "In addition, the switches make the network more secure thanks to the clear assignment including labeling fields, because the electricians can no longer make mistakes. And last but not least, I can also track what's happening in the network at any time from outside via VPN access." With the integration of the machine network into a higher-level production network, however, the problem of cybersecurity arises.
The Industrial Ethernet Bridge and Firewall WALL IE from Helmholz therefore forms the second pillar of the overall concept for the Elisental wire plant. The machine network is regarded as a LAN (Local Area Network), the production or company network as a WAN (Wide Area Network). The WALL IE protects both networks by precisely regulating which subscriber may exchange data with which device. The specifications can be defined on a user-specific basis. The prerequisite for this is a packet filter functionality.
As an additional special feature, the WALL IE can be used both in NAT operating mode and as a bridge. In bridge mode, it acts as a layer 2 switch. However, unlike normal switches, packet filtering is also possible in this operating mode. The packet filter can be used to restrict access between the production network and the respective machine or line. For example, it can be configured that only certain nodes from the production network are allowed to exchange data with defined nodes from the automation cell. Otherwise, the data packet is rejected or discarded.
These Helmholz Products are in use at Drahtwerk Elisental
Initial practical experience and outlook
After the first few months of practical operation, Dirk Urbach is "super satisfied with the Helmholz devices" and adds: "Since commissioning, the network has been running consistently stable and completely trouble-free." Now that eight ultra-modern plants have been equipped with networking components, the next step will be to add further generations of controllers. The NETLink® gateways from Helmholz are ideal for integrating analog controls and automation devices, especially with Profibus - according to Dirk Urbach, "a nice bridge for integrating older plants into digital environments without detours." In the final expansion stage, the network solution successively implemented by Helmholz at the Elisental wire plant will then include a total of 40 to 50 integrated machines and plant components.
The leading European manufacturer of drawn aluminum wires has opened its location in Neuenrade, Germany
Elisental and Helmholz: on the way to Industry 4.0
The Helmholz company supports the Elisental wire plant in integrating the existing machine controls into a higher-level network. Fabian Slowakiewicz is a product manager at Helmholz. He talks to AUTlook about the challenges of the project and Helmholz's wide range of solutions.
What were the biggest challenges of the project from your point of view?
Fabian Slowakiewicz: Definitely: establishing a structured network between the machine and company networks. Initially, the machines were connected directly to the company network, which led to significant problems, such as complete machine downtime. The reasons for this were partly hidden network loops, broadcast domains that were too large, and unprioritized data traffic. The machines have different levels of technology, and some systems must first be upgraded to Ethernet with appropriate communication processors, such as the NETLink Pro Compact.
How long did it take from the first request to implementation?
For the first systems it took about 6-7 months. Others are currently still being upgraded or planned. At the beginning, the network problems first had to be successively identified and narrowed down.
What was the cooperation with the customer like for you?
The first contact was established by our partner and system integrator Elkomp Nord GmbH. Through the use of suitable Helmholz products and add-ons, initial concepts and future network topologies followed. During the first visits to the customer's site, a very good basis for discussion was quickly established. The luxury of working in an interdisciplinary team, consisting of customer, manufacturer and system integrator, has drastically simplified many processes and problems. Not least because of short decision-making paths.
This resulted in a very good interaction of all companies and responsibilities: from project planning, PLC programming and IT administration to sales and purchasing. As a medium-sized company, we attach great importance to going the whole way with the customer. As is so often the case, the last mile in IoT and network planning determines project success or failure. From my point of view, efficient and open communication was a decisive factor for success.
At the Drahtwerk Elisental, all machines and plant components will be integrated - is there a time horizon for this?
As things stand at the moment, it is planned to take about a year. However, in practice there are always new machines and conversions. Digitization, or production optimization, remains a continuous process and is difficult to pin down to a single project.
Higher-level network solutions for existing control systems: I assume such projects will become more frequent - with all the pitfalls that entails: What to avoid, what is the recipe for success?
1. define concrete goals - what added value is to be generated?
Our customers usually want to gain more data from the machines. But especially with regard to IoT services and cloud solutions, there are many opportunities to collect and evaluate data. Therefore, the specific goal must be clear in advance so that the endeavor does not only cost money, but also brings added value.
2. don't overestimate your networks
There are excellent switch and router manufacturers in the classic IT environment. However, these usually have no place inside a machine network. There are completely different requirements in a control cabinet. Not only because of the temperature and design, but also in terms of protocols and their prioritization. A PLC is by nature very talkative! This quickly creates broadcast domains that are too large and can cause problems throughout the company that are difficult to identify. MiniFirewalls, such as "WALL IE" and managed PROFINET switches can help here.
3. IT is not OT and OT is not IT
First priority is to form cross-functional teams and clearly define who is responsible for which network areas work together! An IT administrator is usually not the right person to manage the machine network, because often different tools are used in a machine network than in IT. Conversely, it is difficult for PLC programmers to assess what dangers a machine network can pose to the rest of the company. At Helmholz we help to reconcile both worlds.
4. Thorough preparation - ACTUAL analysis
For this purpose, we always ask ourselves the following questions in advance: Which controllers are used? Which fieldbus systems/interfaces are available? How busy is the PLC? Can a communication processor be upgraded to Ethernet or does the complete PLC have to be renewed? Is there a network topology/documentation of the plant networks? In which cycle should the data be collected? Good preparation also includes good advice. Feel free to contact us at an early stage with your thoughts, projects or goals.
5. A suitable overall package for the infrastructure
Helmholz specializes in fieldbus communication and network technology. Therefore, we can implement a comprehensive range of solutions and corresponding network topologies for your projects, from field-terminable network or PROFINET connectors to unmanaged switches, mini firewalls, managed PROFINET switches, remote maintenance routers and fieldbus couplers with MQTT.
Security is a special topic here: How big is this topic in discussions with customers?
Cyber security is increasingly coming into focus and products are being scrutinized more attentively and critically by our customers. Conversations about IEC 62443 or ISO 27001 are becoming more frequent. "Cyber-secure!" cannot be represented with a seal or certificate. Appropriate processes and known information paths must also be defined internally - both at manufacturers and at customers - on how to act in the event of a known security vulnerability.
„As a medium-sized company, we attach great importance to going the full distance with the customer.“
Fabian Slowakiewicz, Product Manager, Helmholz GmbH & Co. KG
