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OPC UA Inside Out Part 6 - Brownfield and Greenfield Webinar
- 1. © Utthunga Technologies Pvt. Ltd. 2020 OPC UA Inside Out Part 6 – OPC in Brownfield and Greenfield Presented by: Utthunga OPC Services Division Utthunga for OPC
- 2. © Utthunga Technologies Pvt. Ltd. 2020 Company Overview Germany 500+ Professionals USA Japan 13 HQ & Development Centre Bangalore India © Utthunga Technologies Pvt. Ltd. 2020 SERVICES SOLUTIONSFOCUS Embedded Software & Hardware Product Engineering Digital Services Application Software Engineering Quality Engineering Process & Factory Power & Utilities IIoT, Cloud & Big Data Analytics Solutions Data Connectivity & Integration Solutions Custom Solutions Utthunga for OPC
- 3. © Utthunga Technologies Pvt. Ltd. 2020 Industry Associations Part of various Special Interest Groups (Technical Specifications, Architecture, Test & Certification and Marketing) Involved in reference Application Architecture, Design and Development Technology Outsourcing Partner PROFIBUS and PROFINET Competency Center FDT Test & Certification Center Part of Global Expert/Certified Community https://opcfoundation.org/about/opc-foundation/experts/ https://www.profibus.com/pi-organization/certified-people/ Utthunga for OPC
- 4. © Utthunga Technologies Pvt. Ltd. 2020 Speakers for Today About Speaker Smitha is an OPC expert specializing in OPC UA and device integration technologies She has over 15 years of experience in engineering and software development with proficiency in OPC, FDT, FDI, and EtherNet/IP Smitha is also the co-founder of Utthunga and guides internal product and business roadmaps She represents Utthunga is various industrial consortiums like FDT OPC UA Specification Working Group, FDI Specification, PA-DIM, EtherNet/IP FDI Annex specification etc Utthunga for OPC Smitha Rao
- 5. © Utthunga Technologies Pvt. Ltd. 2020 Speakers for Today Utthunga for OPC Rushendra Babu Guntur About Speaker Rushendra Babu is the CTO of Utthunga and is responsible for end-to-end new product and solutions development He leads the company’s R&D initiatives as well Rushendra has 20+ years of experience in life sciences, power, automotive and industrial automation Rushendra is passionate about building teams to deliver world-class solutions and products
- 6. © Utthunga Technologies Pvt. Ltd. 2020 1. Brownfield Perspective 3. OPC Foundation Roadmap 2. Greenfield Perspective Agenda Utthunga for OPC 4. Utthunga for OPC
- 7. © Utthunga Technologies Pvt. Ltd. 2020 Sample Assets PLC 1. Mitsubishi FX series 2. Siemens S7 3. Delta PLC Robots 4. ABB Robot 5.Panasonic Robot Injection Moulding Injection molding machines Paint Shop Siemens S7 series Edge Device ED : Edge device supporting Modbus RTU/TCP-IP, CC-Link, OPC UA Real world use case : Brown Field Project - Automobile Plant Utthunga for OPC Assembly Robots Injection Moulding 1 2 2 1 3 1 1 3 1 4 5 4 2 2 1 3 1 2 1 1 2 1 3 3 3 1 3rd Party IIoT solution ERP SystemIIoT Platform 3 3 1 Paint Shop
- 8. © Utthunga Technologies Pvt. Ltd. 2020 Project Goal Utthunga for OPC Goal #1 : Vertical Integration • Connect all the assembly lines, Robots, Injection molding machines, Paint shop, utilities to a common IIoT platform • This provides OEE, Production, Rejection count + reasons, Downtime + reasons etc Goal #2 : Data Harmonization • Collected Data to be harmonized even from 3rd party IIoT solution present at the injection molding area. • Collected data to be presented in the Dashboard (Role Based) and later, fed to the ERP system Goal #3 : Efficient Data Transmission • Improve the data quality • Maximize the transmission efficiency Goal #4 : Security • No compromise on the security • Seamless integration over firewall
- 9. © Utthunga Technologies Pvt. Ltd. 2020 Goal #1 : Vertical Integration Assembly Robots Injection Molding 1 2 2 1 3 1 1 3 1 4 5 4 2 2 1 3 1 2 1 1 2 1 3 3 3 1 3rd Party IIoT solution Data acquisition from various PLCs Data acquisition from Robots, injection molding machines Data acquisition from 3rd party IIoT platform Sync Data with ERP systems Efficient Asset Replacement Utthunga for OPC ERP SystemIIoT Platform Paint Shop
- 10. © Utthunga Technologies Pvt. Ltd. 2020 Goal #1 : Vertical Integration : OPC in Edge Device OPC UA Server Edge Device OPC DA Server (Classic) Vendor Specific OPC UA, Pub/Sub, MQTT, AMQP, Rest API OPC UA OPC UA Server OPC DA Client Protocol Integration OPC UA Aggregator OPC DA Edge Device with OPC UA support at Downlink/Uplink layer OPC UA Aggregator reduces the firewall port exposure, improving the security Edge Device can be in IPC, virtual machines or dedicated edge gateway built for specific requirement OPC UA enabled edge device simplifies the vertical integration Utthunga for OPC
- 11. © Utthunga Technologies Pvt. Ltd. 2020 Goal #1: Vertical Integration Utthunga for OPC OPC UA • Field Device Level • Edge Gateway Level (Uplink/Downlink OPC) • IIoT Platform Level Decision Factors • Technical requirement - network configuration/setup • Availability of these devices in the market
- 12. © Utthunga Technologies Pvt. Ltd. 2020 Goal #2: Data Harmonization - OPC UA Information Model Not just data - Semantic Information about the data Motor Axis Position Identification ….. OPC UA Information Model for Robotics OPC UA Server (OPC UA – Robotics IM) For ex: OPC Robotics describes the semantic self-description Utthunga for OPC Motor Axis Position
- 13. © Utthunga Technologies Pvt. Ltd. 2020 Goal #2: Data Harmonization - OPC UA Information Model OPC UA Information Access (Base Model and Services) Companion Information Model with other Industry standard Vendor Specific Information Model Companion Specification Document : Joint collaboration between OPC Foundation and other standard organization Represent Different Domains Domain Specific Companion Specification : Commercial Kitchen Equipment, Process Automation – Device Information Model, Machine Vision System, Plastics and Rubber Machinery, Tobacco Machines, Weighing Technology Industry Protocol companion specification : PROFINET, CIP, MTConnect, IO-Link etc. Device Integration Companion Specification : FDT, FDI etc. 25 Companion specification standard available…. Base Information Model of OPC UA Server Vendor Specific Extension of the Information Model Utthunga for OPC
- 14. © Utthunga Technologies Pvt. Ltd. 2020 Goal #2: Data Harmonization - OPC UA Information Model OPC UA Server OPC UA Server Motor Axis Position Motor Axis Position Fault Recovery ModeVendor A Vendor B Fault Recovery Mode OPC UA Client Robotics Companion Information Model Vendor B specific Information ModelComparing Information Model from Vendor A & B Generic Robotics aware Vendor B specific Utthunga for OPC
- 15. © Utthunga Technologies Pvt. Ltd. 2020 Goal #3: Efficient Data Transmission Data Information DecisionMakingCapability Utthunga for OPC DataVolume High Low Assembly Robots Injection Molding 1 2 2 1 3 1 1 3 1 4 5 4 2 2 1 3 1 2 1 1 2 1 3 3 3 1 3rd Party IIoT solution ERP SystemIIoT Platform Paint Shop Improves the data quality for decision making
- 16. © Utthunga Technologies Pvt. Ltd. 2020 Goal #3: Efficient Data Transmission OPC UA Client (Edge Gateway, HMI, Operator Station, 3rd Party IIoT Solution) OPC Client Session - A OPC Client Session - B OPC Client Session - Z OPC Client/Server OPC UA Server - A Publisher OPC UA Server - B Publisher OPC UA Server - C Publisher Middleware - Broker Subscriber Subscriber OPC Pub/Sub Push mechanism Scalable Easily Upgradable Pull Mechanism Resource Intensive Non-scalable Utthunga for OPC OPC UA Server - A OPC UA Server - B OPC UA Server - Z https://utthunga.com/wp-content/uploads/2019/10/Asset-Health-Monitoring-using-FITS-and-OPC-PubSub.pdf OPC Pub/Sub maximizes the transmission efficiency
- 17. © Utthunga Technologies Pvt. Ltd. 2020 Goal #4 : OPC UA Security Courtesy: https://opcfoundation.org/wp-content/uploads/2017/11/OPC-UA-Security-Advise-EN.pdf Edge Server OPC UA Server - A OPC UA Server - Z GDS (Discovery, Global Services and Management Client) IoT HubManagement Dashboard OPC Twin Micro service GDS Vault Micro service Key Vault OT Network IT Network Firewall Certificate Management using GDS and Azure Cloud
- 18. © Utthunga Technologies Pvt. Ltd. 2020 1. Brownfield Perspective 3. OPC Foundation Roadmap 2. Greenfield Perspective Agenda Utthunga for OPC 4. Utthunga for OPC
- 19. © Utthunga Technologies Pvt. Ltd. 2020 Aspirations and Goals Future proof Utthunga for OPC Optimized Capex and Opex Quick Commissioning Goal 1: Secure Goal 2: Modular Goal 3: Interoperable
- 20. © Utthunga Technologies Pvt. Ltd. 2020 Goal 1 : Security Control Production MES ERP Historian Optimizers Utthunga for OPC Zone 1 Zone 2 Zone 3 Controllers Controllers Optimizers Controllers Operations Zone 4 Zone 5 Field ISP CPE, Field, Partners etc Employees Field Exposed Services Cloud Services
- 21. © Utthunga Technologies Pvt. Ltd. 2020 Goal 1 : Security with OPC Control Production MES ERP Historian Optimizers Utthunga for OPC Zone 1 Zone 2 Zone 3 Controllers Controllers Optimizers Controllers Operations Zone 4 Zone 5 Field ISP CPE, Field, Partners etc Employees Field Exposed Services Cloud Services OPC UA OPC UA OPC UA OPC UA
- 22. © Utthunga Technologies Pvt. Ltd. 2020 Security Summary Utthunga for OPC Efficient Secure Design Optimized Threat Management Unified understanding of Security
- 23. © Utthunga Technologies Pvt. Ltd. 2020 Goal 2 : Modularity Utthunga for OPC Data Exchange Platform Companion Specifications HMI (OEM 2) Path Planning (OEM 4) Radar Inspector (OEM) Controller (OEM) Alarm Management (OEM 3) OPC based Data Exchange Platform
- 24. © Utthunga Technologies Pvt. Ltd. 2020 Ability to utilization specialty Systems Modularity Summary Utthunga for OPC Running Parallel Inspection and Advisory Systems Increased ability to Optimize and Innovate
- 25. © Utthunga Technologies Pvt. Ltd. 2020 Goal 3 : Interoperability Utthunga for OPC Data Exchange Platform OEM 1 OEM 1 Open standards based Information modelling OEM 2 Controller (OEM) Path Optimizer (OEM) MES OPC based Data Exchange Platform
- 26. © Utthunga Technologies Pvt. Ltd. 2020 Interoperability Summary Moving from Integration to Interoperability Utthunga for OPC True ownership of Data Vendor Independence Near Drop-in Replacements
- 27. © Utthunga Technologies Pvt. Ltd. 2020 Smart Factory Utthunga for OPC Connected Transparent Optimized Agile Enables Performance
- 28. © Utthunga Technologies Pvt. Ltd. 2020 OPC Adoption Devices & Manipulators Control Production Operations MES ERP, Historian PLC, Scada, DCS Devices Utthunga for OPC More Availability Upcoming Availability
- 29. © Utthunga Technologies Pvt. Ltd. 2020 1. Brownfield Perspective 3. OPC Foundation Roadmap 2. Greenfield Perspective Agenda Utthunga for OPC 4. Utthunga for OPC
- 30. © Utthunga Technologies Pvt. Ltd. 2020 OPC RoadMap Source : https://opcfoundation.org/about/opc-technologies/opc-ua/opcua-roadmap/ Deterministic UA: Field-Level Communication (FLC) Alias names Harmonization of companion Standards Provisioning Services Security MQTT v5 Semantic Validation Relate with established semantic models Interfaces and AddIns PubSub JSON Web Token, OAuth2 Reverse Connectivity SessionLess Services Security Transactions MetaData in the Cloud Cloud-Relay Deterministic communication using 5G Utthunga for OPC
- 31. © Utthunga Technologies Pvt. Ltd. 2020 1. Brownfield Perspective 3. OPC Foundation Roadmap 2. Greenfield Perspective Agenda Utthunga for OPC 4. Utthunga for OPC
- 32. © Utthunga Technologies Pvt. Ltd. 2020 Utthunga for OPC - Service Offerings Utthunga for OPC OPC Technology Implementation Partner Embedded OPC Development Service OPC Application Development OPC Cloud Service Integration OPC Consultation and Advisory Service OPC Connectivity Custom Solutions OPC Certification Support OPC Pub/Sub Integration OPC CoE Partner Service Technical + Domain Expertise Strong Customer Portfolio uOPC Suite - Connectivity framework
- 33. © Utthunga Technologies Pvt. Ltd. 2020© Utthunga Technologies Pvt. Ltd. 2020 Time for Audience Q&A
- 34. © Utthunga Technologies Pvt. Ltd. 2020 OPC UA Inside Out Webinar Series 5. OPC UA Inside Out Part 5 - Cloud Connectivity – 25th June, 2020 4. OPC UA Inside Out Part 4 - Tunneller – 11th June, 2020 3. OPC UA Inside Out Part 3 - Edge Gateway – 28th May, 2020 2. OPC UA Inside Out Part 2 - Embedded & constrained devices – 14th May, 2020 6. OPC UA Inside Out Part 6 - Green Field and Brown Field – 09th July, 2020 1. OPC UA Inside Out Part 1 - Introduction and Playing Field – 30th April, 2020 Utthunga for OPC www.youtube.com/c/Utthunga
- 35. © Utthunga Technologies Pvt. Ltd. 2020 Utthunga Technologies Pvt. Ltd. No. 8, 27th Cross, 2nd Stage, Banashankari, Bangalore – 560 070 Phone: +91-80-68151900 Mail: contact@utthunga.com
Notes de l'éditeur
- Good Evening Everyone, We welcome you to the webinar and we are glad that everyone could make it. Myself Anand from Utthunga Technologies, I’m your moderator for the day. Today we all will be a part of webinar on OPC UA Inside Out To maintain the flow of the webinar Q & A will be addressed in the last Giveaway – Presentation , link of recorded video Moving on to the next slide
- Change the ED icon to uConnect icon (depiction image) – ED2 should depict similar icon… Paint Shop should be changed with (Robot image with spray…) Remove the blue empty boxes ERP System => Make it look good…(aesthetic aspect is not taken care…)
- This needs to be improvised Task Data acquisition from various PLCs Without OPC in plant integration Have to upgrade the PLC or use industrial protocol converter to bring all the PLCs into one standard protocol like Modbus RS485/TCP Task Data acquisition from Robots, Taiwanese injection molding machines Without OPC in plant integration Surely general edge devices cannot have the native protocol, option is to develop a driver to understand the protocol which does not make sense With OPC in plant integration Forget about injection molding, Robots will surely have OPC option to publish the data At Edge Layer => At L1 Layer => For Injection Moulding => https://nbplastics.com/blog/how-the-iot-is-used-in-plastic-injection-molding/ http://www2.advantech.eu/EDM/eu/201704_Integrated_Automation_Systems/Case_Studies/5_Monitoring_Injection_Molding_Product_Quality.pdf
- Robots Axis – (Joints..) => 3 fundamental inform For every joint -> Position When moving => Moving Speed for each joint…. When 4 different joints move, Diagnostics Information, Error Information… Fault Recovery Mode for Robots () Speed at which is extremely fast….(TSN …, Beckhoff….??) Robots describing themselves The OPC UA Companion Specification for Robotics (in short OPC UA Robotics) provides a standardized information model which is capable of presenting all robot related data regardless of manufacturer or location in a uniform manner. Part 1 released today as draft version permits asset management, condition monitoring, preventive maintenance and vertical integration – at any time, anywhere in the world and independent of the robot brand or type. It provides the ideal basis for data analytics and for boosting OEE (Overall Equipment Effectiveness). The OPC Robotics specification describes an information model, which aims to cover all current and future robotic systems such as: – Industrial robots – Mobile robots – Several control units – Peripheral devices, which do not have their own OPC UA server Part 1 provides information for asset management and condition monitoring. In future parts, the information model will be extended to cover more use cases. The following functionalities are covered: – Provision of asset configuration and runtime data of a running motion device system and its components e.g. manipulators, axes, motors, controllers and software Following functions are not included and might be covered in future parts: – A messaging mechanism covered by events and alarms to provide conditions MTConnect => Cant write the data back to robots….. You can only read the data…
- system in a smart manufacturing tells simple value change in a fully digital network and created new business models. To have an uniform structure and common communication, German Platform industrie 4.0 such as ZVEI, VDMA, and BITKOM proposes the Reference Architecture model (RAMI 4.0) in a 3 dimension model. Axis 1 defines on Hiearchy levels products, Machines, Field Devices, control devices, station and so on. Axis 2 defines on the Life Cycle & Value streams, both “types” and “instances” can be represented in the OPC UA Information Model. Axis 3 defines the Layers such as asserts, integration, communication where communication layer comes in to the picture to provide access to the information. The OPC UA plays a major role in this communication layer to have an standard information model and exchanging the information a secure manner.
- system in a smart manufacturing tells simple value change in a fully digital network and created new business models. To have an uniform structure and common communication, German Platform industrie 4.0 such as ZVEI, VDMA, and BITKOM proposes the Reference Architecture model (RAMI 4.0) in a 3 dimension model. Axis 1 defines on Hiearchy levels products, Machines, Field Devices, control devices, station and so on. Axis 2 defines on the Life Cycle & Value streams, both “types” and “instances” can be represented in the OPC UA Information Model. Axis 3 defines the Layers such as asserts, integration, communication where communication layer comes in to the picture to provide access to the information. The OPC UA plays a major role in this communication layer to have an standard information model and exchanging the information a secure manner.
- Doing a best Job in the most optimized manner
- system in a smart manufacturing tells simple value change in a fully digital network and created new business models. To have an uniform structure and common communication, German Platform industrie 4.0 such as ZVEI, VDMA, and BITKOM proposes the Reference Architecture model (RAMI 4.0) in a 3 dimension model. Axis 1 defines on Hiearchy levels products, Machines, Field Devices, control devices, station and so on. Axis 2 defines on the Life Cycle & Value streams, both “types” and “instances” can be represented in the OPC UA Information Model. Axis 3 defines the Layers such as asserts, integration, communication where communication layer comes in to the picture to provide access to the information. The OPC UA plays a major role in this communication layer to have an standard information model and exchanging the information a secure manner.
- system in a smart manufacturing tells simple value change in a fully digital network and created new business models. To have an uniform structure and common communication, German Platform industrie 4.0 such as ZVEI, VDMA, and BITKOM proposes the Reference Architecture model (RAMI 4.0) in a 3 dimension model. Axis 1 defines on Hiearchy levels products, Machines, Field Devices, control devices, station and so on. Axis 2 defines on the Life Cycle & Value streams, both “types” and “instances” can be represented in the OPC UA Information Model. Axis 3 defines the Layers such as asserts, integration, communication where communication layer comes in to the picture to provide access to the information. The OPC UA plays a major role in this communication layer to have an standard information model and exchanging the information a secure manner.
- system in a smart manufacturing tells simple value change in a fully digital network and created new business models. To have an uniform structure and common communication, German Platform industrie 4.0 such as ZVEI, VDMA, and BITKOM proposes the Reference Architecture model (RAMI 4.0) in a 3 dimension model. Axis 1 defines on Hiearchy levels products, Machines, Field Devices, control devices, station and so on. Axis 2 defines on the Life Cycle & Value streams, both “types” and “instances” can be represented in the OPC UA Information Model. Axis 3 defines the Layers such as asserts, integration, communication where communication layer comes in to the picture to provide access to the information. The OPC UA plays a major role in this communication layer to have an standard information model and exchanging the information a secure manner.
- Utthunga is active contributor to OPC Foundation and some of the related companion standards. This has helped us to serve our customer much better way. We work with device manufacturer, Chip Manufacturer and system supliers in emabling their system OPC compliant. We have pool of OPC and Domain Expert and scalable pool of OPC engineers to develop these applications like embedded device development etc. We also work with some of these consortiums like ODVA, FieldComm group, FDT Group on OPC related activities. With our deep root in this subject, we will be your trusted OPC Technology implementation partner…. Kindly contact us for any support needed in OPC UA…. Now, lets move to the Q&A sessions… over to you Zishan.