Time-sensitive networking syncs flexible communication between data and control

Time-sensitive networking (TSN) is a set of standards developed by the Institute of Electrical and Electronics Engineers (IEEE) 802.1 working group to enable deterministic real-time communication over Ethernet networks. The TSN update was released in 2016 and enhances standard Ethernet by introducing features that guarantee the timely and reliable delivery of data, which is crucial for applications that require synchronized and precise communication.

TSN introduces features like precise time synchronization across network devices, traffic scheduling and resource reservation to ensure that time-critical data is transmitted reliably and within strict latency boundaries. This is achieved through protocols such as IEEE 802.1AS for clock synchronization, which aligns the timing of all devices on the network. Traffic scheduling mechanisms like the time-aware shaper (IEEE 802.1Qbv) allow the network to prioritize critical data streams by controlling the timing of packet transmissions.

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Without TSN, industrial networks must be carefully planned and are rigid in their architectures. In the climate of digital transformation and smart manufacturing, it’s increasingly important for manufacturers to have machines that communicate flexibly across an industrial network, comingling control and data communications. This leads to the most cost effective and flexible solutions, not to mention giving equipment OEMs a new and technical competitive advantage.

More industrial control network traffic

Examples of other TCP/IP traffic that would be beneficial to superimpose on an industrial control network include monitoring and diagnostics data, such as that generated by simple network management protocol (SNMP), which helps in overseeing network devices and ensuring optimal performance.

Machines that integrate human-machine interface (HMI) data allow operators to interact with control systems in real-time, enhancing the ability to monitor processes and respond promptly to any issues. Data logging and historian services can collect and archive process data over time. This is valuable to OEMs and their customers, providing valuable insights for analysis, optimization and regulatory compliance.

Incorporating enterprise resource planning (ERP) integration enables seamless communication between the production floor and business management systems, improving coordination and efficiency across the organization. Remote access traffic facilitates maintenance and troubleshooting from off-site locations, reducing downtime and operational costs. Including security monitoring traffic, such as data from intrusion detection systems, helps protect the network against unauthorized access and cyber threats. Additionally, transmitting predictive maintenance data gathered from sensors allows for the anticipation of equipment failures and scheduling of proactive maintenance, thereby enhancing equipment reliability and lifespan. Video surveillance traffic can also be advantageous for monitoring production areas to ensure safety protocols are followed and to assist in incident investigations. By superimposing these types of TCP/IP traffic onto an industrial control network, OEMs can create a more integrated, efficient and secure operational environment for manufacturers.

Combining TSN and Gigabit Ethernet

The CC-Link Partner Association (CLPA) is an international organization dedicated to the advancement of industrial automation network technologies. One of its key initiatives is promoting Ethernet with TSN through its development of CC-Link IE TSN. This technology is an open industrial Ethernet solution that combines Gigabit Ethernet bandwidth with TSN capabilities, enabling high-speed, deterministic communication essential for modern industrial applications.

The concept is to help companies adopt Ethernet with TSN by providing comprehensive technical specifications, development support and certification processes. It facilitates collaboration among device manufacturers, system integrators and end users to ensure interoperability and compatibility of products utilizing CC-Link IE TSN.

By aligning CC-Link IE TSN with international standards, this ensures that the technology can be seamlessly integrated into existing systems worldwide. This alignment simplifies the adoption process for companies and promotes a wider acceptance of Ethernet with TSN in various industries.

The partnership encompasses a global network of partner companies that develop and supply products compatible with CC-Link technologies. A comprehensive directory of companies and their products suitable for industrial designs is available to system designers, engineers and end users seeking compatible and interoperable automation. These partners range from device manufacturers and software providers to system integrators, all contributing to a diverse ecosystem of solutions. Maintaining this extensive list ensures that users have access to a broad selection of products that meet international standards and can be seamlessly integrated into various industrial applications.

Within the directory, each company profile includes detailed information about their offerings, such as controllers, I/O modules, network switches, motion control devices and software tools that support CC-Link IE TSN. Product listings often provide technical specifications, certifications and compatibility details, enabling designers to make informed decisions when selecting components for their systems.

9 ways TSN benefits machines and processes

The deterministic nature of TSN ensures that data is transmitted promptly and predictably, which is crucial for real-time control and monitoring. This improved data flow not only optimizes machines but also supports strategic decision-making through insights gained from detailed analysis. As a result, OEMs help manufacturers achieve higher productivity, reduce downtime and maintain a competitive edge in their industries.

1. Timely reliable data transmission

Complex machines—such as industrial robots, automated manufacturing systems and advanced machinery—can benefit from better access to sensor data and control elements through the use of Ethernet with TSN. Ethernet with TSN provides a high-bandwidth, deterministic communication network that ensures timely and reliable data transmission. This enhanced data flow enables sophisticated analysis, leading to improvements in machine performance, maintenance and overall operational efficiency.

2. Real-time machine monitoring

Better access to sensor and control data allows for precise real-time monitoring of machine operations. Ethernet with TSN ensures that critical data is transmitted with minimal latency and jitter, which is essential for synchronized control tasks. For example, in a manufacturing assembly line, real-time data from sensors can be used to adjust robotic movements instantaneously, reducing errors and increasing productivity. This level of control enables machines to respond dynamically to changing conditions, enhancing flexibility and efficiency.

3. Improved remote machine access

Improved data access facilitates remote machine monitoring and control. Ethernet with TSN supports secure and reliable data transmission necessary for remote operations. OEMs and other experts can analyze machine performance, diagnose issues and implement solutions from different locations, reducing the need for on-site interventions. This capability is particularly beneficial for multinational companies or facilities located in remote areas.

4. Predictive maintenance strategies

Access to detailed sensor data facilitates predictive maintenance strategies. Machines that continuously monitor component condition—such as temperature, vibration and pressure—can use data analytics to identify patterns that indicate wear or potential failure. Ethernet with TSN supports the high data throughput required for such detailed monitoring. Predictive maintenance minimizes unplanned downtime by scheduling repairs before failures occur, extending machine life and optimizing maintenance resources.

5. Machine optimization and efficiency

Analyzing the rich data collected from sensors and control elements allows for the optimization of machine operations. Advanced analytics and machine learning algorithms can process this data to identify inefficiencies and recommend adjustments. Ethernet with TSN's reliable and timely data transmission ensures that the analysis is based on accurate information. For instance, adjusting process parameters in response to real-time data can enhance energy efficiency, reduce waste and improve product quality in manufacturing processes.

6. Immediate safety detection and response

Real-time access to data enhances safety systems by enabling immediate detection and response to hazardous conditions. Ethernet with TSN's deterministic communication is critical for safety protocols that require guaranteed response times. For example, if a sensor detects an abnormal temperature rise, the system can automatically initiate cooling procedures or shut down equipment to prevent accidents. Additionally, comprehensive data logs assist in compliance with industry regulations by providing transparent operational histories and facilitating audits.

7. Scalable network performance

Ethernet with TSN allows for the seamless integration of additional sensors and control elements without degrading network performance. This scalability supports the evolution of complex machines as new technologies emerge. Furthermore, TSN enables the convergence of operational technology (OT) and information technology (IT) networks, allowing for unified communication across different system levels. This integration simplifies network architecture and improves collaboration between different departments, such as production and enterprise management.

8. Simplified network infrastructure

By consolidating multiple communication protocols onto a single Ethernet with TSN network, manufacturers can reduce the complexity of their networking infrastructure. This simplification leads to cost savings in installation, maintenance and training, as there is less need for specialized equipment and expertise. A unified network also enhances reliability by reducing potential points of failure associated with having multiple disparate systems.

9. Synchronized data exchange for complex control schemes

Reliable, high-speed communication provided by Ethernet with TSN enables the implementation of advanced control strategies, such as distributed control systems and coordinated multi-axis control. Synchronized data exchange is crucial for applications like robotics, where precise timing between multiple components determines overall performance. TSN ensures that control commands and feedback signals are delivered in a timely and predictable manner, enhancing the effectiveness of these complex control schemes.