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industrial automation (5)

Industrial automation and controls modernization can be a daunting task. Is it time to upgrade? What will this cost me? Are we ready? How will we even do this? There is a lot to consider with all those questions, and probably more, running through your head. A good starting point for developing a plan is to start by organizing the information that needs to be gathered to scope the project(s). From there, you can start talking to integrators and vendors to get pricing, budgets, timelines, and equipment lists. To develop a thorough spec, follow these steps.
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What is OPC?

The acronym “OPC” stands for “OLE (Object Linking and Embedding) for Process Control”. OLE is based on the Windows COM (Component Object Model) standard.

OPC standard is implemented in server/client pairs. The OPC server is a program that translates the hardware communication protocol used by a PLC into the OPC protocol. The OPC client software is a program that connects to the hardware, such as an HMI. The OPC client communicates with the OPC server to receive data or send commands to the hardware.

 

How does OPC work?

OPC specification describes the interface between clients and servers, servers and servers, including access to real-time data, monitoring of alarms and events, access to historical data and other applications.

The classic OPC connection scenario is a single server-client connection on a single computer, but there are more options which include:

  • Connecting an OPC client to several OPC servers. This is called OPC aggregation.
  • Connecting an OPC client to an OPC server over a network. This can be done with OPC tunneling
  • Connecting an OPC server to another OPC server to share data. This is known as OPC bridging

 

Technical Benefits of OPC

In addition to improving OPC server and client connections, the OPC DataHub can connect any OPC server or client to other applications as well, including Excel, a web browser, or any other database. And, it can be used to import OPC data into Linux or QNX.
Usage

Following OPC specifications are used in industries:

  • OPC-DA (Data Access): Provides access to real-time data. We can query most recent

values of temperature, pressure, density, acceleration, and other types of process control data from OPC-DA server.

  • OPC-HDA (Historical Data Access): This is used to retrieve historical process data for analysis. This data is typically stored in files, databases or remote telemetry systems.
  • OPC-AE (Alarms & Events): OPC AE servers are used to accept and exchange

process alarms and events.

  • OPC-DX (Data eXchange): It defines the way OPC server data is exchanged with other OPC servers.
  • OPC-XML (XML Data Access): It defines schema and data representation formats based upon XML standard. This makes it possible to share & manipulate process control data across all operating systems – Windows, UNIX, Solaris, etc.


Benefits of using OPC standard are:

  • Reduced load on the hardware device.
  • Increased scalability of the system.
  • Because of OPC server, client applications need not know anything about hardware protocol details.
  • Though device need not serve multiple clients, So Increased life for the device.
  • Interoperability (Unix/Linux and Windows – both platforms are supported by OPC)
  • Standardization

eInfochips – OPC implementation

At eInfochips, we have provided embedded solutions for OPC’s industrial automation product line for our clients in embedded solutions. This includes detailed work on:

  • BIS systems: Building Integration System , or BIS, is a software package that brings building automation, access control, video surveillance, intrusion, fire alarms and voice evacuation onto one convenient management suite. The classic OPC Server had implemented specific protocol over TCP/IP protocol to monitor and control different types of building integration system panels, which is able to interface with OPC client of the BIS system software.
  • System alerts: In OPC Server, we had implemented OPC-DA (Data Access), OPC-HDA (Historical Data Access) and OPC-AE (Alarms & Events) specifications. For controlling and monitoring panels, OPC client fires different commands to the panels by using OPC server e.g. unlock door, lock door, arm area etc.

OPC server developed by eInfochips contains the following modules, functionalities and activities, listed below.

To know more about the IoT services and solutions

  • Design, Development and Testing of OPC Classic server for different panels used in a building integration system with specific Automation protocol
  • Implementation of following group commands on OPC Server,
    • System
    • Panel
    • Door
    • Area
    • Output
    • Point
  • OPC server communication stacks integration (TCP)
  • OPC server security – Command Authentication AES 256
  • Client and status command implementation

We have also developed OPC Clients for our customers, running on Linux OS to communicate with OPC server over Ethernet. This further communicates with OPC server for Reading and Writing data/parameters. In OPC Client, we had implemented OPC-DA (Data Access), OPC-HDA (Historical Data Access) and OPC-AE (Alarms & Events) specifications. OPC Client will communicate with OPC Server for fetching data from the PLC. At the other end, it will send/receive historical and live data of temperature, pressure, density, acceleration etc. from the OPC server to the cloud for storage and analysis.

To know more about how we can help you with OPC implementation for your building automation needs, Learn more about our Industrial Automation Solutions or digital engineering services

 

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When you have the responsibility of ensuring a manufacturing plant is operating at its full potential at all times, talk of “Industry 4.0” and “industrial automation like never before” might be exciting but far-fetched. Industry 4.0 is just an empty phrase used by marketers who want to take your money, right?

Maybe in some cases, but the ideas behind the buzzy terms can actually give you an edge over competitors. Industry 4.0 is not a phase, but it’s also not an obligation that you need to “opt in to” 100% right away.  Industrial automation is a combined result of our greater digital capacities, smarter machines, and improved cross-channel communication that have accompanied the digital age.

In 2019, the technology is here: from decentralized cloud systemsto self-correcting and self-directing machines. However, it’s not everywhere yet, and most plants are simply taking baby steps towards preparing their lines to be as compatible as possible to these new technologies so that they can gradually work their way in. Industry is slowly moving towards a more optimized, efficient, automated structure, but this transition will be happening in the industrial world over the next few decades.

What do those “baby steps” look like? Where should begin to optimize lines in the most cost-effective, long-term ROI benefits?  We have compiled a list of 5 relatively simple ways you can take this year to set your plant up for new “Industry 4.0” industrial automation technologies:

1. Integrate a Single Virtual Server

Managing the IT aspect of your plant is difficult when you need to find cost-effective storage and data processing solutions for your company that also comply with all of the regulations and contingencies of your industry. However, upgrading a server to a virtual option is probably the most important upgrade you can do to get started on the road to future industrial automation applications that use a truly decentralized communication with virtual operating system.

If your plant currently runs exclusively on physical servers, you don’t need to go virtually all at once. The wonderful thing about industry 4.0 is that much of the software integrations available will integrate with your existing hardware. You can invest in one virtual server, and then layer software integrations on to it over time.

By starting with a single server, you can cut costs, maintain a realistic learning/adaptation curve, and try out a virtual server option without committing 100% to a change. There are numerous virtual server options available, so talk to a process automation expert about what server will work best for your plant, and which server to upgrade first.

2. Get Basic Industrial Automation Security – Two-Factor Authentication

With increased adaptability and communication on virtual servers comes increased cyber threats, and unfortunately, there is no way around this. One of the easiest and fastest upgrades you can do for your company is to implement two-factor authentication (2FA) for all employees. A simple password is no longer anywhere near secure enough to protect your employees and your data.

Luckily, everything from Twitter to Cloud servers now offer 2FA options, it’s usually just a question of getting the settings implemented correctly and creating a protocol that requires every employee to use 2FA at all times. It may seem tedious or frustrating at first, but this is a small habit that can make a huge difference in your cyber security and overall functioning of your plant.

3. Make Your Next Machine Purchase a Smart Machine

You probably aren’t yet at the point of having a completely automated assembly line of smart machines that create highly customized orders while communicating with and correcting each other (like the assembly line in this German plant.) However, smart machines do exist, and if you are getting ready to purchase a new machine, finding one that has automation, optimization, and decentralized communication abilities will be a great investment in your plant’s future.

Customizable “smart machines” are virtually independent of a human operator. The ability of these machines to adapt to the demands of individualized production requirements allows for scalable, lean production processes. In other words, with these new machines, you can produce a larger variety of products faster than ever before.

If your current machines are working fine, there is no need to replace them with smart machines right away. But from this point forward, it is a good idea to consider buying a smart machine for your next upgrade. Don’t be afraid to use an automation integrator to advise you on the appropriate machine, technology, and compatibility with existing plant automation systems.

4. Implement Technology Upgrades that Overlay or Automatically Integrate Existing Plant Industrial Automation

Be choosy about the automation products you decide to implement into your current systems moving forward. You want applications that both set your systems up for future technology integrations and help move you away from expiring legacy applications.

This shouldn’t mean replacing all your old applications, programming, and platforms all at once other. Most Industry 4.0 automation tools are created in an “overlay” style, meaning they are created to be able to function on top of your existing processes and are not supposed to disrupt everything you have already built.

Embracing a new software or system should never mean that you have to throw away your existing processes and start from scratch. If this is how you feel when you are getting ready to purchase a new software, machine, or server then it probably isn’t the right product for your company.

Talking to an expert about what products will work best with your current setup is a good idea before making any changes to your industrial automation. At my company, EPIC systems, we've seen the difference that selecting the right product solutions has made for hundreds of process automation projects — it's a key step for any manufacturing plant. No matter who you work with, you don't want to bypass this step.

5. Optimize One of Your Plant’s Processes

Divide and conquer, as they say. Just as it is best to upgrade one server at a time, it is helpful to focus specifically on one plant process at a time when you are looking to optimize and automate your plant.

This could mean focusing on optimizing your shipping procedure or optimizing one assembly process. The important thing to remember is that as you do this “experimental optimization” you are not just looking for an impressive return on investment, you are also looking to get your entire team comfortable with the automation and ready to embrace even more. This is why the “how” is just as important (if not more important) than the “what” when it comes to choosing a process to optimize. Go slow, be transparent, and include everyone in the process so that it is a success all around.

Industry 4.0 is creating a world where employees can delegate mundane tasks to smart machines and rely on highly communicative, agile systems in order to work faster and more effectively than ever before. There is no reason for any manufacturing plant to be left behind in this industrial evolution, with numerous products and services available to help walk you through the industrial automation process gradually and intelligently.

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What are common features of IIoT and SCADA/HMI and differences between them? And what advantages do Internet of Things Platforms have over SCADA systems? Find out answers in our new presentation.

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Tibbo announced the release 5.4 of AggreGate IoT Integration Platform.

We've achieved great results in optimizing AggreGate server performance, especially event and value update storage performance. From now on, a single server can process and persistently store up to a hundred thousand events/updates per second, which is almost equal to 10 billion events per day. Such performance figures don't even require any high-end server hardware.

A new chapter has been opened by this release, presenting AggreGate's graphical and textual programming languages inspired by IEC 61131-3 standard, also known as "SoftPLC". Millions of engineers are now able to use AggreGate as a process control logic development environment.

One innovative feature of AggreGate's automation languages is tight integration of runtime with the Tibbo Project System hardware. Your programmed logic can access and control all Tibbit modules of a Linux-based TPS board/box. Currently available languages are: Function Block Diagram (graphical), Structured Text (graphical), Sequential Function Chart (textual).

Widget capabilities are no longer limited by the standard set of components. Now it can be easily extended. New Widget Component SDK allows to implement custom visual components in Java and use them in AggreGate widgets. Extend AggreGate's wide component palette with UI controls best suited to your needs!

We continue making our UI interface clearer and more user-friendly. The next step is lightweight icons. We redesigned them to be up-to-date with modern flat paradigm. New color coding assists users to navigate over various available toolbar actions.

Other major improvements include:

  • Built-in timestamps and quality for data tables.
  • Component connectors that allow to visually link UI components with each other.
  • Secure and reliable Agent communications. Agent-Server communications now can be SSL-protected. When transferred data amount is critical, data compression can be enabled in parallel to encryption.
  • Granulation, a brand-new highly customizable data aggregation and consolidation tool. The granulation engine allows to combine datasets into compact representation that contains all important aspects of original information in virtually any form suitable for later processing. This allows to reduce memory and storage consumption along with boosting data processing performance.
  • Server remote upgrading. To reduce company's expenses, a remote AggreGate server upgrade operation is now supported. You can use our Unified Console application to connect to a remote server, upload a server upgrade bundle file and wait while the upgrade process is finished. That's it! All operations, including database backup, stopping server, upgrading and restarting will be performed at the server side automatically.

We are bringing our IT & Network Management solution (AggreGate Network Manager) to a new level by turning it into a full-fledged IT Service Management System. In this release, we introduce several essential instruments for that: Configuration Management Database (CMDB), metrics engine and topology-based root-cause analysis tools. Another ITSM functionality - IP address management module - is now available and you can use it out-of-the-box.

AggreGate 5.4 includes new device drivers: CoAP, MQTT, IEC 104, DLMS/COSEM, SMI-S.

You can get detailed information on the new 5.4 release, download and try the updated AggreGate IoT Platform on our website: http://aggregate.tibbo.com/news/release-54.html

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