In the context of WinCC communication quality, we have previously discussed various optimization methods for WinCC configuration projects, such as the number of process variables in archives, access speed, and script simplification. Now, I will analyze the communication quality from common industrial communication methods like Industrial Ethernet, PROFIBUS, MPI, and PROFINET, as well as the selection of transmission media such as twisted pair, fiber optic, and coaxial cables.
Once the communication method and transmission medium are determined, a large portion of the communication quality is already set. However, it can still be affected by several factors. Here’s a detailed breakdown:
1. **Industrial Ethernet with Twisted Pair Cables** – This is one of the most commonly used and cost-effective methods for WinCC communication. It uses the widely adopted TCP/IP protocol, which is similar to internet communication. However, this method employs a shared network where devices compete for bandwidth, leading to potential collisions and unpredictable data transfer rates. The real-time performance is therefore limited.
Due to the use of twisted pair cables, the network has limited bandwidth and poor resistance to interference. To maintain stability, it's recommended not to connect to unrelated computers or the internet, as this reduces the risk of virus attacks and unnecessary traffic. In WinCC projects, minimizing dynamic loops (such as excessive screen objects or variable connections) helps reduce the interaction between WinCC and PLC, thereby lowering the communication load.
When the system is running normally, the network traffic can be very high, often causing the TXD indicator on the CP443-1 module to flicker constantly. This indicates multiple WinCC servers communicating with a single PLC, or multiple PLCs communicating with each other. To address this, using fiber optic cables can increase bandwidth and improve signal integrity. Alternatively, adding a WinCC Central Archive Server can reduce the number of WinCC servers, significantly decreasing the communication burden on the PLC.
2. **PROFIBUS with PROFIBUS Cables** – This is the standard communication method for Siemens industrial control systems, especially in older installations. PROFIBUS is divided into three types: DP, FMS, and PA. DP is the most commonly used. For WinCC monitoring stations, a CP5611 or CP5613 network card is required, allowing the station to act as a DP slave.
If the WinCC station fails or the network card needs maintenance, it can disrupt communication with other DP slaves, affecting production. To avoid this, connecting the system in a ring topology is highly recommended.
For applications requiring high reliability, the FMS protocol should be used instead. This requires a Profibus communication module like CP443-5 or CP342-5 on the PLC side. This setup separates the communication path between WinCC and DP slaves, improving safety and reducing the PLC’s workload. However, this comes at an increased hardware cost.
The PA protocol is suitable for field-level smart devices such as transmitters and sensors. Since PROFIBUS uses a token ring mechanism, it offers better real-time performance than Industrial Ethernet, with more stable communication intervals and improved network security.
3. **MPI Protocol** – This is a point-to-point communication method with a low speed of 187.5 Kbps, similar to serial communication. WinCC can only communicate with one PLC at a time, making it suitable for small-scale or local control systems. It lacks scalability and is not ideal for larger or more complex setups.
4. **PROFINET Protocol** – Based on both PROFIBUS-DP and Industrial Ethernet, PROFINET combines the advantages of both. It supports real-time communication and can connect field-level devices to the management level. It also uses the standard TCP/IP protocol, making it compatible with broader networks.
While PROFINET offers superior performance, the modules that support it are more expensive and less commonly used in the market. Unless there is a specific need for real-time monitoring of field devices from the office, it may not be necessary. Instead, controlling and managing field equipment through operators and engineers can enhance operational safety and hierarchical efficiency.
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