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A new record for distributed control (sidebar)

Profibus network explained

In deploying 126 micro PLCs on Valley's line, a method was needed to permit PLCs to communicate with one another, as well as with the master PC. That's the function of a control network. A network literally consists of a common cable that connects the PLCs to one another and to the PC. Each "member" on the network is called a node. But a network is far more than just wire. All the nodes need to agree to communicate using the same "language," or network protocol.

There are many types of network protocols (sometimes also called device networks or field buses). Since Dorner designed the labeling/sortation/collating line and specified the PLCs, it also selected the network protocol. For Valley's application, Dorner suggested Profibus.

Profibus was originally developed by Siemens but is now published as an "open" IEEE standard. Any company can manufacture Profibus-compliant components by incorporating microchips inside those controls components that "understand" the Profibus protocol.

Not being locked into a single vendor's components was important to Valley and Dorner. While the system uses Siemens PLCs and Siemens-distributed I/O components, Dorner suggested a communications card from SST (Waterloo, Ontario, Canada) inside the PC.

"What Siemens did that really helped us," says Jim Lysaught, director of systems engineering at Dorner, "is they put Profibus on their entire product line, even on these low-end micro PLCs."

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