OpenPnP: a Plug-and-Produce Architecture for the Industrial Internet of Things
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Industrial control systems are complex, software-intensive systems that manage mission-critical production processes. Commissioning such systems requires installing, configuring, and integrating thousands of sensors, actuators, and controllers and is still a largely manual and costly process. Therefore, practitioners and researchers have been working on ``plug and produce'' approaches that automate commissioning for more than 15 years, but have often focused on network discovery and proprietary technologies. We introduce the vendor-neutral OpenPnP reference architecture, which can largely automate the configuration and integration tasks for commissioning. Using an example implementation, we demonstrate that OpenPnP can reduce the configuration and integration effort up to 90 percent and scales up to tens of thousands of communicated signals per second for large Industrial Internet-of-Things (IIoT) systems. OpenPnP can serve as a template for practitioners implementing IIoT applications throughout the automation industry and streamline commissioning processes in many thousands of control system installations.
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OpenPnP: a Plug-and-Produce Architecture for the Industrial Internet of Things
- 1. —ABB CORPORATE RESEARCH CENTER, LADENBURG, GERMANY OpenPnP: a Plug-and-Produce Architecture for the Industrial Internet of Things Heiko Koziolek, Andreas Burger, Marie Platenius-Mohr, Julius Rückert, Gösta Stomberg PUBLIC
- 2. — May 29, 2019 Slide 2
- 3. —
- 4. — Commissioning 1) Place, connect sensor („plug“) 2) Set fieldbus address 3) Retrieve sensor type 4) Select device package, download 5) Enter configuration parameters 6) Get addresses to logic engineering 7) Map program variables 8) Compile and download control logic Repeat for all devices (go to 1) … Production start („produce“) 60 – 90 minutes per device!
- 5. — 60 – 90 minutes per device! Commissioning 1) Place, connect sensor („plug“) Production start („produce“) 60 – 90 minutes per device!Target: <10 sec per device!
- 6. — May 29, 2019 Slide 6 Industrial Boiler Laser Level Transmitter Pneumatic Valve Automation Controller Typical Control Loop Example
- 7. — May 29, 2019 Slide 7 Industrial Boiler Laser Level Transmitter Pneumatic Valve Automation Controller Requirement 4: Real-time Communication Requirement 3: Automated Signal Matching Requirement 2: Standardized Device Descriptions Requirement 1: Automated Network Discovery Requirement 5: Device Replacement Plug & Produce
- 8. — May 29, 2019 Slide 8 Industrial Boiler Laser Level Transmitter Pneumatic Valve Automation Controller Open PnP Architecture
- 9. — May 29, 2019 Slide 9 Industrial Boiler Laser Level Transmitter Pneumatic Valve Automation Controller SERVER CLIENT & SERVER SERVER Open PnP Architecture
- 10. — May 29, 2019 Slide 10 Industrial Boiler Laser Level Transmitter Pneumatic Valve Automation Controller Plug & Produce Software Service SERVER CLIENT & SERVER SERVER CLIENT Open PnP Architecture
- 11. — May 29, 2019 Slide 11 Industrial Boiler Laser Level Transmitter Pneumatic Valve Automation Controller Plug & Produce Software Service SERVER CLIENT & SERVER SERVER CLIENT Open PnP Architecture Our Main Contribution
- 12. — Open Platform Communications Unified Architecture (OPC UA), IEC 62541 http://industrial.embedded-computing.com/articles/iic-connectivity-framework-defines-iiot-network-architecture-for-scalable-interoperability/Slide 12May 29, 2019
- 13. — Controller IEC 61131 Runtime Controller OPC UA Server OPC UA LDS Field Device (Sensor / Actuator) Device OPC UA Server <<informat ion model>> PLCOpen OPC UA LDS <<informat ion model>> OPC UA for Devices, NAMUR NE131, IEC 61987 PLCOpen Comm. Channel Operations Server Ethernet Supervision Plug-and- Produce Service Engineering Server Engineering Repository Device Management Internet Public Driver Repository retrieve signal conf ig, arbitrat e 61131Runt im e t ransfer configs, browse signals, enable subscr. upload control logic monit or process OPC UA LDS UDP Sub. UDP Pub. UDP Sub. UDP Pub. mult icast probe & announce exchange signal values OPC UA OPC UA OPC UA download device driver, device paramet ers retrieve device driver HTTP HTTP OPC UA LDS cyclic signal exchange retrieve engineering data exchange signal values cyclic signal exchange Reference Architecture Plug & Produce May 29, 2019 Slide 13
- 14. — Controller IEC 61131 Runtime Controller OPC UA Server OPC UA LDS Field Device (Sensor / Actuator) Device OPC UA Server <<informat ion model>> PLCOpen OPC UA LDS <<informat ion model>> OPC UA for Devices, NAMUR NE131, IEC 61987 PLCOpen Comm. Channel Operations Server Ethernet Supervision Plug-and- Produce Service Engineering Server Engineering Repository Device Management Internet Public Driver Repository retrieve signal conf ig, arbitrat e 61131Runt im e t ransfer configs, browse signals, enable subscr. upload control logic monit or process OPC UA LDS UDP Sub. UDP Pub. UDP Sub. UDP Pub. mult icast probe & announce exchange signal values OPC UA OPC UA OPC UA download device driver, device paramet ers retrieve device driver HTTP HTTP OPC UA LDS cyclic signal exchange retrieve engineering data exchange signal values cyclic signal exchange Reference Architecture Plug & Produce May 29, 2019 Slide 14
- 15. — Controller IEC 61131 Runtime Controller OPC UA Server OPC UA LDS Field Device (Sensor / Actuator) Device OPC UA Server <<informat ion model>> PLCOpen OPC UA LDS <<informat ion model>> OPC UA for Devices, NAMUR NE131, IEC 61987 PLCOpen Comm. Channel Operations Server Ethernet Supervision Plug-and- Produce Service Engineering Server Engineering Repository Device Management Internet Public Driver Repository retrieve signal conf ig, arbitrat e 61131Runt im e t ransfer configs, browse signals, enable subscr. upload control logic monit or process OPC UA LDS UDP Sub. UDP Pub. UDP Sub. UDP Pub. mult icast probe & announce exchange signal values OPC UA OPC UA OPC UA download device driver, device paramet ers retrieve device driver HTTP HTTP OPC UA LDS cyclic signal exchange retrieve engineering data exchange signal values cyclic signal exchange Reference Architecture Plug & Produce May 29, 2019 Slide 15
- 16. — Controller IEC 61131 Runtime Controller OPC UA Server OPC UA LDS Field Device (Sensor / Actuator) Device OPC UA Server <<informat ion model>> PLCOpen OPC UA LDS <<informat ion model>> OPC UA for Devices, NAMUR NE131, IEC 61987 PLCOpen Comm. Channel Operations Server Ethernet Supervision Plug-and- Produce Service Engineering Server Engineering Repository Device Management Internet Public Driver Repository retrieve signal conf ig, arbitrat e 61131Runt im e t ransfer configs, browse signals, enable subscr. upload control logic monit or process OPC UA LDS UDP Sub. UDP Pub. UDP Sub. UDP Pub. mult icast probe & announce exchange signal values OPC UA OPC UA OPC UA download device driver, device paramet ers retrieve device driver HTTP HTTP OPC UA LDS cyclic signal exchange retrieve engineering data exchange signal values cyclic signal exchange Reference Architecture Plug & Produce May 29, 2019 Slide 16
- 17. — Controller IEC 61131 Runtime Controller OPC UA Server OPC UA LDS Field Device (Sensor / Actuator) Device OPC UA Server <<informat ion model>> PLCOpen OPC UA LDS <<informat ion model>> OPC UA for Devices, NAMUR NE131, IEC 61987 PLCOpen Comm. Channel Operations Server Ethernet Supervision Plug-and- Produce Service Engineering Server Engineering Repository Device Management Internet Public Driver Repository retrieve signal conf ig, arbitrat e 61131Runt im e t ransfer configs, browse signals, enable subscr. upload control logic monit or process OPC UA LDS UDP Sub. UDP Pub. UDP Sub. UDP Pub. mult icast probe & announce exchange signal values OPC UA OPC UA OPC UA download device driver, device paramet ers retrieve device driver HTTP HTTP OPC UA LDS cyclic signal exchange retrieve engineering data exchange signal values cyclic signal exchange Reference Architecture Plug & Produce May 29, 2019 Slide 17 Requirement 1: Automated Network Discovery Requirement 2: Standardized Device Descriptions Requirement 3: Automated Signal Matching Requirement 4: Real-time Communication Requirement 5: Device Replacement
- 18. — Reference Architecture Plug & Produce May 29, 2019 Slide 18 newState = suspended Plug-and- Produce Service Cont roller OPC UA Server Device OPC UA Server Device UA Server X get subscribed devices from pub/ sub config in router approve replacement get device configuration device configuration store device configuration stop device change to simulat ion modeloop newState = simulated get signal configuration matched Signals for all subscribing devices announce new device via mDNS upload stored configuration change to running modeloop newState = running remat ch signals acknowledge resume controller change to suspend mode 1 2 3 4
- 19. — Implementation Plug & Produce May 29, 2019 Slide 19 Level Sensor Temperature Sensor Commu- nication Boards Power Supply Ethernet Connection
- 20. — 60 – 90 minutes per device! Commissioning 1) Place, connect sensor („plug“) Production start („produce“) Target: <10 sec per device!
- 21. — Time for Typical Commissioning Effort Comparison May 29, 2019 Slide 21 # Phases Classic Approach HART comm. + PC Tool Steps L M H OpenPnP Approach OPC UA comm. + PnP Service Steps L M H 1 Prepare replacing Store config via HART, unmount device 05:30 13:00 22:00 Store config via OPC UA, unmount device 03:11 07:32 14:05 2 Mount the device physically Prepare, use accessories, fix the device 05:00 20:00 40:00 Prepare, use accessories, fix the device 05:00 20:00 40:00 3 Connect the cabling Run cabling to device, attach to device 05:30 09:00 21:00 Run cabling to device, attach to device 05:30 09:00 21:00 4 Establish basic comm. Power on, connect, download device package 00:43 01:18 03:38 Power on, network discovery, connect via OPC UA 00:11 00:21 00:46 5 Calibrate the device Manually use calibration tool 00:00 03:00 04:30 Manually use calibration tool 00:00 03:00 04:30 6 Set basic parameters Manually set basic parameters via laptop 01:00 01:20 02:50 Automatically transfer parameters 00:02 00:02 00:02 7 Set adv. parameters Manually set advanced parameter via laptop 00:00 00:55 02:10 Manual set + automatic transfer of parameters 00:00 00:12 00:42 8 Conduct loop check Set simulation value, check loop back 00:20 00:40 01:10 Perform automatic connection check 00:01 00:01 00:01 9 Integrate device into DCS Map logic variables to IO channels, download logic 02:00 04:30 12:00 Discover controller, set up, match signals, set up communication 00:03 00:08 00:11 (Phase 1-9) 20:03 53:43 01:49:18 13:58 40:16 01:21:17 (Phase 1-3) 15:30 41:00 01:21:00 13:40 36:30 01:15:00 (Phase 4, 6-9) 04:33 09:43 00:23:48 00:18 00:46 00:01:47 Total sum Installation time Config time
- 22. — Time for Typical Commissioning Effort Comparison May 29, 2019 Slide 22 # Phases Classic Approach HART comm. + PC Tool Steps L M H OpenPnP Approach OPC UA comm. + PnP Service Steps L M H 1 Prepare replacing Store config via HART, unmount device 05:30 13:00 22:00 Store config via OPC UA, unmount device 03:11 07:32 14:05 2 Mount the device physically Prepare, use accessories, fix the device 05:00 20:00 40:00 Prepare, use accessories, fix the device 05:00 20:00 40:00 3 Connect the cabling Run cabling to device, attach to device 05:30 09:00 21:00 Run cabling to device, attach to device 05:30 09:00 21:00 4 Establish basic comm. Power on, connect, download device package 00:43 01:18 03:38 Power on, network discovery, connect via OPC UA 00:11 00:21 00:46 5 Calibrate the device Manually use calibration tool 00:00 03:00 04:30 Manually use calibration tool 00:00 03:00 04:30 6 Set basic parameters Manually set basic parameters via laptop 01:00 01:20 02:50 Automatically transfer parameters 00:02 00:02 00:02 7 Set adv. parameters Manually set advanced parameter via laptop 00:00 00:55 02:10 Manual set + automatic transfer of parameters 00:00 00:12 00:42 8 Conduct loop check Set simulation value, check loop back 00:20 00:40 01:10 Perform automatic connection check 00:01 00:01 00:01 9 Integrate device into DCS Map logic variables to IO channels, download logic 02:00 04:30 12:00 Discover controller, set up, match signals, set up communication 00:03 00:08 00:11 (Phase 1-9) 20:03 53:43 01:49:18 13:58 40:16 01:21:17 (Phase 1-3) 15:30 41:00 01:21:00 13:40 36:30 01:15:00 (Phase 4, 6-9) 04:33 09:43 00:23:48 00:18 00:46 00:01:47 Total sum Installation time Config time
- 23. — Time for Typical Commissioning Effort Comparison May 29, 2019 Slide 23 # Phases Classic Approach HART comm. + PC Tool Steps L M H OpenPnP Approach OPC UA comm. + PnP Service Steps L M H 1 Prepare replacing Store config via HART, unmount device 05:30 13:00 22:00 Store config via OPC UA, unmount device 03:11 07:32 14:05 2 Mount the device physically Prepare, use accessories, fix the device 05:00 20:00 40:00 Prepare, use accessories, fix the device 05:00 20:00 40:00 3 Connect the cabling Run cabling to device, attach to device 05:30 09:00 21:00 Run cabling to device, attach to device 05:30 09:00 21:00 4 Establish basic comm. Power on, connect, download device package 00:43 01:18 03:38 Power on, network discovery, connect via OPC UA 00:11 00:21 00:46 5 Calibrate the device Manually use calibration tool 00:00 03:00 04:30 Manually use calibration tool 00:00 03:00 04:30 6 Set basic parameters Manually set basic parameters via laptop 01:00 01:20 02:50 Automatically transfer parameters 00:02 00:02 00:02 7 Set adv. parameters Manually set advanced parameter via laptop 00:00 00:55 02:10 Manual set + automatic transfer of parameters 00:00 00:12 00:42 8 Conduct loop check Set simulation value, check loop back 00:20 00:40 01:10 Perform automatic connection check 00:01 00:01 00:01 9 Integrate device into DCS Map logic variables to IO channels, download logic 02:00 04:30 12:00 Discover controller, set up, match signals, set up communication 00:03 00:08 00:11 (Phase 1-9) 20:03 53:43 01:49:18 13:58 40:16 01:21:17 (Phase 1-3) 15:30 41:00 01:21:00 13:40 36:30 01:15:00 (Phase 4, 6-9) 04:33 09:43 00:23:48 00:18 00:46 00:01:47 Total sum Installation time Config time
- 24. — Up to 90% reduced efforts for config • Automated transfer of parameters • Automated identification of devices • Automated signal matching of devices • Faster Ethernet communication For a plant with 10,000 devices, this can accumulate to 1500h time saving (≈ 1 person year). Time for Typical Commissioning Effort Comparison May 29, 2019 Slide 24 # Phases Classic Approach HART comm. + PC Tool Steps L M H OpenPnP Approach OPC UA comm. + PnP Service Steps L M H 1 Prepare replacing Store config via HART, unmount device 05:30 13:00 22:00 Store config via OPC UA, unmount device 03:11 07:32 14:05 2 Mount the device physically Prepare, use accessories, fix the device 05:00 20:00 40:00 Prepare, use accessories, fix the device 05:00 20:00 40:00 3 Connect the cabling Run cabling to device, attach to device 05:30 09:00 21:00 Run cabling to device, attach to device 05:30 09:00 21:00 4 Establish basic comm. Power on, connect, download device package 00:43 01:18 03:38 Power on, network discovery, connect via OPC UA 00:11 00:21 00:46 5 Calibrate the device Manually use calibration tool 00:00 03:00 04:30 Manually use calibration tool 00:00 03:00 04:30 6 Set basic parameters Manually set basic parameters via laptop 01:00 01:20 02:50 Automatically transfer parameters 00:02 00:02 00:02 7 Set adv. parameters Manually set advanced parameter via laptop 00:00 00:55 02:10 Manual set + automatic transfer of parameters 00:00 00:12 00:42 8 Conduct loop check Set simulation value, check loop back 00:20 00:40 01:10 Perform automatic connection check 00:01 00:01 00:01 9 Integrate device into DCS Map logic variables to IO channels, download logic 02:00 04:30 12:00 Discover controller, set up, match signals, set up communication 00:03 00:08 00:11 (Phase 1-9) 20:03 53:43 01:49:18 13:58 40:16 01:21:17 (Phase 1-3) 15:30 41:00 01:21:00 13:40 36:30 01:15:00 (Phase 4, 6-9) 04:33 09:43 00:23:48 00:18 00:46 00:01:47 Total sum Installation time Config time
- 25. — Performance Measurements Slide 25 CPU Utilization Pub/sub: 40,000 signals/s Client/server (1 client): 25,000 signals/s Client/server (30 clients): 10,000 signals/sExemplary control use case – 6,000 I/O points with 100ms updates (= 60,000 signals/s) – 2 controllers share 8 field communication interfaces (FCIs) Industrial controllers Sensors & actuators Field comm. interfaces … … ……… … … May 29, 2019 CPU is bottleneck. But good scalability even on small devices. Clients/Subscribers: Raspberry Pi 3, Model B, Quad Core 1.2GHz 64bit CPU, 1GB RAM, RTLinux Server/Publisher: Raspberry Pi Zero, 1GHz single-core CPU, 512MB RAM, RTLinux
- 26. — Summary May 29, 2019 Slide 26 OpenPnP: a Plug-and-Produce Architecture for the Industrial Internet of Things Reference architecture that can be implemented with many libraries in many applications Based on OPC UA technology for the Internet-of-Things Good effort reduction for commissioning and good scalability Future work - Handling data integrity - Self-calibration - Virtual commissioning
Editor's Notes
- Recorded measurements from the first twenty seconds of each experiment are discarded to limit the analysis to the stable phase and ignore transient effects. All experiments were repeated at least five times to rule out random effects caused by the testbed setup and, e.g., operating system processes. We report results in the form of average values over the individual measurement repetitions. Configuration: 100ms target publishing rate C/S: More than 30 client sessions led to error messages issued by the server, therefore, these measurements could not be finalized