Using Foundation Fieldbus Linking Devices in Industry 4.0

Summary

The evolution of industrial automation has spurred significant advances in communication protocols, efficiency and connectivity. At the heart of this transformation is Industry 4.0, which emphasizes smart manufacturing, data-driven decision making and real-time process optimization. While modern industrial instrumentation is transitioning to industrial Ethernet, previous capital outlay for older technologies such as Foundation Fieldbus and Profibus PA should not be wasted. To maximize their substantial investment in instrumentation, organizations must find effective ways to integrate legacy systems into newer digital infrastructures, such as modern distributed control systems (DCS) and programmable logic controller (PLC)-based control systems.

In addition to measuring primary process values, these digital devices can perform additional functions. They provide a wealth of status information that can inform the operator that the measured value might be compromised. Lord Kelvin’s assertion that “to measure is to know” is meaningless if the measured information is not shared with the rest of the control system.
 

The role of Foundation Fieldbus in Industry 4.0

Foundation Fieldbus—a well-established digital communication protocol for process automation—has been widely adopted across industries including oil and gas, chemical and power generation. Unlike traditional 4-20 mA analog systems, Foundation Fieldbus enables multivariable communication, device status and diagnostics and distributed control functionality. However, as Industry 4.0 initiatives gain momentum, there is a growing need to integrate these existing networks with industrial Ethernet and cloud-based platforms for seamless automation, asset monitoring and historical data storage systems.

This is where Foundation Fieldbus linking devices come into play. These devices act as intelligent gateways that facilitate communication between Foundation Fieldbus field devices and higher-level control architectures such as PLCs, DCS and supervisory control and data acquisition (SCADA) systems. By providing a robust connection between legacy process control systems and Industry 4.0-enabled infrastructures, linking devices help industries maximize the value of their existing investments while embracing the digital future.
 

The importance of ease of integration, redundancy and diagnostics

Foundation Fieldbus linking devices offer a range of features designed to support data-driven decision-making:

1. Seamless data exchange: Linking devices facilitate the smooth and efficient data exchange between Foundation Fieldbus H1 networks and industrial Ethernet protocols such as EtherNet/IP and Modbus TCP, which ensures compatibility with current automation systems. This data is often repackaged or reformatted to suit the host control system. Once the data is in the DCS or PLC in its native format, it can be easily propagated through the rest of the system including human-machine interfaces (HMIs), SCADAs and historians.
2. Advanced process diagnostics: A key advantage of Foundation Fieldbus linking devices is their ability to provide in-depth diagnostics of the field instrumentation. This functionality provides a window into the usually hidden behavior of the process instrument’s functionality by warning of a potential inaccurate reading or perhaps impending maintenance requirement. For example, a Magflow instrument could warn of a buildup of scale or sludge in the pipe, and although the instrument is still providing accurate readings, this information could be used to schedule specific maintenance in the near future. This approach of using all the information provided by the field device can have marked financial benefits, not only by decreasing production downtime, but also by guaranteeing quality of the final product.
3. Continuous system health monitoring: The ability to continuously monitor the status and health of the system, including the linking device, bus power conditioner, the fieldbus network and all connected instruments, is necessary for rapid fault identification and remediation. By providing real-time communication data for each field device, as well as bus parameters such as current draw and bus voltage, diagnosing communications problems happens faster and improving system reliability by initiating corrective active actions before operations are affected. This data, previously limited to specialized asset management systems, is now accessible to all downstream systems—from the operator in the control room to advanced maintenance planning systems. When a field device replacement is required, the linking device can facilitate rapid and efficient deployment by downloading the previous configuration to the replacement device, with remote options if necessary. It also includes onboard tools, such as packet capture analysis, to help identify and resolve any commissioning hiccups.
4. Redundancy for increased reliability: Modern linking devices include redundancy capabilities to ensure uninterrupted operation in both simplex and redundant control systems. Redundant configurations help prevent single points of failure, which provides higher system availability and reduces the risk of unexpected downtime. Both linking device and networking cabling redundancy strategies can be accommodated.
5. Secure and scalable connectivity: As cybersecurity becomes a growing concern in industrial automation, linking devices incorporate advanced security features. Secure authentication, encrypted communication and firewall capabilities help protect industrial networks from cyber threats while ensuring reliable data transmission.
6. Cloud and edge computing integration: With the increasing adoption of cloud-based analytics and edge computing, linking devices provide connectivity to cloud platforms and edge gateways. This can be particularly relevant for remote applications by allowing real-time data processing, AI-driven insights and remote monitoring, which further drives the Industry 4.0 vision.
7. Asset management and FDT/DTM data provider: The linking device needs to provide a communication tunnel to pass asset management communications as specified by the field device tool (FDT)/device type manager (DTM) framework to the instruments in the network, in addition to providing a DTM for its own management and monitoring. DTMs provide a visual interface to devices and are specific to each instrument manufacturer and type.

Industry 4.0 benefits of Foundation Fieldbus linking devices

The integration of Foundation Fieldbus linking devices into Industry 4.0 architectures offers numerous advantages to industrial operations.

1. Improved operational efficiency. By providing real-time access to process data, linking devices enable faster and more informed decision-making. Operators can optimize process variables, reduce energy consumption and enhance overall system performance. Detailed diagnostics of the network and the connected instruments enable timely troubleshooting and fault resolution.
2. Extended equipment lifespan. Measured system status data and advanced diagnostics help identify potential equipment failures before they occur. This not only minimizes unplanned downtime but also extends the lifespan of critical assets, thereby reducing capital expenditure.
3. Interoperability with modern control systems. Foundation Fieldbus linking devices ensure compatibility with Industry 4.0-ready control systems through Ethernet connectivity. A migration from older DCS can be accomplished without the disruption and additional investment in instrumentation.
4. Enhanced data utilization. With seamless integration into cloud and edge computing platforms, linking devices facilitate advanced data analytics, machine learning applications and remote monitoring. This enhances process optimization and drives continuous improvement initiatives.
5. Increased system reliability through redundancy. Redundancy in linking devices and their Ethernet media ensures uninterrupted communication between field instruments and control systems, which reduces downtime risks and improves overall process stability.

Wrapping up

As Industry 4.0 continues to reshape industrial automation, the role of Foundation Fieldbus linking devices becomes increasingly vital. By investing in Foundation Fieldbus linking devices with redundancy and advanced diagnostic capabilities, industries can unlock the full potential of their automation systems, enhance operational efficiency and future-proof their operations for the digital era.

With a commitment to innovation and reliability, Foundation Fieldbus linking devices empower industries to navigate the complexities of Industry 4.0 with confidence, which ensures a smarter, more connected future for industrial automation.

_{This feature originally appeared in the August/September issue of Automation.com Monthly.}