Field Level

In the field of industrial automation, the field level plays a crucial role as it comprises the foundational layer where physical work and monitoring occur. This level includes essential devices such as actuators and sensors, which are integral to controlling process parameters like flow, temperature, and pressure. These field devices are tasked with transferring data from machines and processes to higher levels for further monitoring and analysis.

The field level is considered the lowest hierarchy in industrial automation and is often referred to as the "arms and eyes" of an automated industrial process. It is at this level that real-time process parameters are converted into electrical signals by sensors, and actuators are employed to adjust these parameters accordingly.

The automation pyramid, also known as the ISA-95-Architecture or the Purdue Model of Control Hierarchy, is a conceptual representation of the different layers of automation within an industrial setting. The different levels are:

• Field Level (Level 0)

  This level forms the base of the pyramid and is where physical processes take place. It includes the actual process and instruments such as sensors, transducers, valves, and actuators that directly interact with the material being processed.

• Control Level (Level 1)

  At this level, you'll find systems that monitor and manage the physical processes, taking input from field level devices. It contains controller hardware and software solutions like PLCs and Distributed Control Systems (DCS), which implement control algorithms based on inputs from Level 1.

• Supervisory Level (Level 2)

  Supervisory Control and Data Acquisition (SCADA) systems typically operate at this level. This layer oversees the control level by providing centralized monitoring systems that collect data from different controllers, producing reports and insights.

• Planning level (Level 3)

  This level employs a computer management system called the Manufacturing Execution System (MES), which oversees the entire manufacturing process within a plant or factory, from the handling of raw materials to the delivery of finished products. MES acts as a bridge between plant floor operations and higher-level business systems, ensuring effective execution of manufacturing operations.

• Management Level (Level 4)

  At the pyramid's peak is the enterprise level, concerned with broader business processes of the manufacturing organization. Integral applications at this level are Enterprise Resource Planning (ERP), Customer Relationship Management (CRM), and Supply Chain Management (SCM).

Field Level communication is vital as it connects all the different components and machines of industrial production plants and supplies real-time data that can be used to diagnose problems immediately, allowing for faster decision-making based on the information provided. This data is also instrumental in predictive maintenance, helping to calculate when machinery will require attention to prevent equipment failure and costly downtime.

Industrial communication systems at the field level are part of a larger network that facilitates the exchange of data and information for controlling machines and plants, primarily in process and production automation. Often used protocols in these settings are for example Modbus, PROFIBUS or PROFINET which has been widely adopted due to its simplicity and ease of implementation.

Understanding the significance of field-level communication within industrial processes underscores the importance of interoperability among various devices and systems. Initiatives like the Field Level Communications (FLC) of the OPC Foundation aim to develop extensions to the OPC UA framework to enhance this interoperability.

The field level's relationship to industrial communication is foundational, providing the necessary data and control mechanisms that enable higher levels of automation to function effectively and efficiently.

Fieldbus technology 

Fieldbus technology can be broadly understood as a network system designed for real-time distributed control, commonly employed in industrial environments for connecting instruments, controllers, and other devices to computers. This kind of network is important for industrial automation because it enables machinery and equipment to communicate and coordinate actions in processes like manufacturing, processing, and other control application systems. Fieldbus systems operate on various protocols, each with a set of rules for data transfer. These protocols ensure that data is exchanged between devices in a predictable and reliable manner. Some of the well-known fieldbus protocols include PROFIBUS, Modbus and DeviceNet. Each has distinctive features, suited to various industrial needs.

Industrial Ethernet 

Industrial Ethernet refers to the use of Ethernet-based communication protocols in the industrial sector, particularly for automation and control systems. Unlike traditional Ethernet used in office or home environments, Industrial Ethernet is designed to withstand harsh industrial conditions, including exposure to extreme temperatures, vibrations, and electromagnetic interference. It supports real-time processing and reliability, meeting the rigorous demands of industrial operations for data exchange. Industrial Ethernet enables integration with various industrial devices and machinery within a robust and scalable network infrastructure. This resilience is essential for maintaining the integrity of communication in environments such as manufacturing plants, where it enables real-time interaction between programmable logic controllers (PLCs), human-machine interfaces (HMIs), and other devices, thereby improving production efficiency and reducing downtime.

IO-Link

IO-Link is a standardized technology (IEC 61131-9) that aims at providing a digital communication system for sensors and actuators in the field of industrial automation. It is essentially a point-to-point serial communication protocol used to connect a single sensor or actuator to an IO-Link Master. This is an Interface that connects IO-Link devices to the control system, capable of communicating with various fieldbuses like PROFINET, EtherCAT, or Ethernet/IP. IO-Link Devices are Sensors and actuators equipped with an IO-Link interface, connected to the Controller using standardized and typically unshielded cables. The benefits of IO-Link include detailed data transfer that goes beyond basic control signals, facilitating device parameters exchange and diagnostic information. This supports better operational efficiency and enables features such as remote configuration, monitoring of devices, and easy replacement, which contributes to improved uptime and productivity. IO-Link complements the move towards smart manufacturing and Industry 4.0 by allowing the integration of simple field devices into industrial networks and the IoT ecosystem, thus contributing to highly automated and intelligent industrial environments.

In the evolving landscape of industrial communication at the field level, current trends are leaning towards real-time communications with a significant shift in preference for Single Pair Ethernet (SPE)-enabled devices among automation engineers and installers. SPE is particularly advantageous as it enables IP connectivity for various applications, supporting the collection of field data in real-time. This trend is part of a broader movement towards digitalization, where seamless Ethernet communications from field devices to higher levels of the communication ecosystem are becoming increasingly important.

Looking towards the future, wireless technologies are expected to play a more prominent role in industrial communications. The integration of Time-Sensitive Networking (TSN) functionalities into wireless solutions will likely reduce the reliance on cables, further streamlining the communication process. Additionally, innovations such as Time-Sensitive Networking are among the most promising network technologies that could shape the future of industrial communications.

Hilscher has established itself as a pivotal entity in the realm of industrial communication, particularly at the field level where machines and devices require seamless and secure interaction. The company's expertise is evident through its comprehensive range of solutions that facilitate communication between machines, ensuring operational efficiency and reliability.

Hilscher's offerings include multiprotocol communication SoCs, PC cards and embedded modules, which are integral for highly integrated solutions, enabling a diverse array of field devices to connect effortlessly regardless of the network standard. The solutions are not only multiprotocol capable but also flexible and reliable, reflecting Hilscher's deep understanding of automation technology. This adaptability is crucial for the dynamic environment of industrial communication, where legacy fieldbuses coexist with Real-Time Ethernet and cloud connectivity.

With the netFIELD technology, Hilscher offers a broad ecosystem for the Industrial Internet of Things. From communication interfaces in the field devices and edge gateways to cloud portals and containerized applications, companies receive all the tools they need to obtain and process comprehensive process data from their systems and draw conclusions for optimized production processes.