from device into the enterprise -...

September 6, 2011 [1]

From Device into the EnterpriseInformation Integration via OPC Unified Architecture

Uwe Steinkraussascolab GmbH OPC Certification Test Laboratory

September 6, 2011 [2]Copyright OPC Foundation 2011

Agenda• OPC Foundation

Organization, Activities, Events

• OPC Unified ArchitectureBasics, Security, Scalability

• OPC UA ApplicationsSuccess Stories: Embedded Devices up to Enterprise Integration


OPC Foundation

OPC FoundationScottsdale, Arizona

OPC EuropeVerl, Germany

OPC JapanMusashino-shi, Tokyo

OPC AsiaChina & India

• Vision of OPC is secure, reliable, multi-vendor, multi-platform interoperability

• Collaboration is key to incorporating multiple “open” standards into an unified platform architecture


World Membership Demographics

• International Industry Standard Organization • 430 Members (9/2011)

334 Corporate + 67 End User + 29 Research/Affiliate

3500 + Total Companies Build OPC Products = 22000 + Products

OPC Members by Region (9/2011)

Europe46%

North America37%

Japan7%

Rest of World10%

Europe North America Japan Rest of World


OPC Europe - Organization• Directors and Officers

• Dr. Reinhold Achatz (Siemens) is founding OPC member and board member since the beginning


OPC Europe Team• “OPC Europe Advisory Board”

• Group of influencers, research, technical and marketing experts• Experts with different expertise: PLC, SCADA, MES, ERP, vertical markets• Help on local activities: translations, presentations, technical info


• Trade Shows, Events, Workshops, Seminars, Presentations >>> soley focused on OPC UA <<<

OPC UA enters:• new Branches• new Markets• new Opportunities

OPC Europe 2011 – Events

April 4th – 8thHannover MesseHannover, Germany

May 25th“OPC Day at SAP”Walldorf, Germany

Sept 19th – 23th IOP Europe

Nuremberg, Germany

Nov 22rd – 24th SPS/IPC/Drives

Nuremberg, Germany

January 2011 December

Sept 10th OPC Day

Espoo, Finland

Oct 4th – 6thSmart Automation

Linz, Austria

Nov 17th OPC Day

Antwerp, Belgium

Sept 20th – 21st Intelligent Building Systems

Paris, France


SPS/IPC/Drives Nuremberg 2010• Impression: November 2010, joined booth with PLCopen• Message: From Controller into the Cloud• 14 Sponsors, Live Demo, 6 UA-enabled PLCs


Hannover Messe 2011• Impression: April 2011, 75qm OPC booth• Message: Interoperability – OPC UA• 12 Sponsors• SAP Live Demo• 10 UA Products


OPC-Day Europe 2011• OPC Day 2011 hosted by SAP

in their HQ in Germany

• Annual Eventsame period within yeardifferent locations, countries

• Information SourceLatest Tech UpdatesNew/Emerging ProductsNetworkingfor Members and Non-Members

• 15 Sponsors


IOP Nuremberg 2011• Siemens hosting European Interoperability Workshop (IOP) once

per year in their HQ in Nürnberg

• Goal: Testing OPC products against each other • to validate interoperability• meet and network with other developers• test matrix

• 2011: more UA than‘classic’ products registered


SPS/IPC/Drives 2011• Impression: Nov 22rd – 24th 2011, OPC booth hall 7-190• Message: From Controller into the Enterprise• 12 Sponsors (due to limited space)• Live Demo on Smart-Phone• New Products


OPC Technology

from COM to UA


The problem 15 years ago• PC based software products become part of Automation Systems• Devices are connected via different bus systems and protocols to the PC• Network interface cards have vendor specific programming interfaces• Large number of proprietary interfaces required high development and

maintenance costs for applications

• OPC (DA) was designed to solve this problem

Device

PCPC

Driver BDriver A Driver C

Driver D

Application

A B CD

Driv

er E

A B C

D

E

E

Field Bus

F

F

Application


The Solution

• OPC Foundation defines APIs to access different types of process data• Special OPC interfaces for current process data, for events and process alarms

and for historical data• OPC interfaces uses Microsoft Windows base technology COM / DCOM• Hardware vendors can provide OPC Servers as standard driver and software

vendors must implement only one driver as OPC Client to access process data

PCPC

Driver BDriver A Driver C

Application

OPC

Application

OPC OPC OPC

Basic Service of Microsoft OS

Field Bus

Device

OPC

OPC

DCOMCOM


The NEW Solution

• OPC Foundation defines high performance protocol (TCP Binary)• One fixed set of services to access all information (DA, AE, HDA)• Totally platform independent (Win, Linux, vxWorks, QNX, Solaris, …)• Security (Authentication, Encryption, Certificates)• Object Oriented Information Model

PC, Panel, Cluster, Mainframe(WinCE, XP, 7, Linux, Unix, …)

Smart-Phone, iPad, …

Application

OPC UA

App

Device

OPC UA

UA UA UA UA UA

OPC UA

4840

unsecured Network


The Problem today• COM based OPC is used in applications it was not designed for

• Embedded devices• Limitations on Windows CE e.g. no DCOM support• Requirements to implement a standard like OPC on other embedded OS

• MES and ERP systems• These system require combinations of complex data, methods and events• These information types are not adapted or not defined and cannot be

combined in one API

• Open issues in distributed systems• DCOM timeouts, DCOM configuration, limited security, reconnect• Missing features in APIs for robustness and reliability

• Features implemented by products but not standardized by OPC• Redundancy• Server chaining …


OPC UA

Basics, Scalability, Security


Requirements for OPC UA

Wide adoption of

OPC

OPC used as common system interface

Communication between distributed

systems

SecurityAccess control

InternetFirewalls

RobustnessFault tolerant

Platformindependent

Redundancy

Performance Scalability MESERP

Embeddeddevices

SCADA

Modeling Data

Common model for all

OPC data

Complex data

Method calls

Meta data

Base for otherstandard data

models

Type system


Unified Architecture

OPC-UA: New Generation OPC• Definition 2003 – 2006• Verification and Implementation 2006 – 2008• Final OPC Foundation Release 2009• IEC 62541 Release 2010 – 2011

• OPC UA = established OPC features+ Platform independence+ Standard internet and IP based protocols+ Built in security features+ Generic object model+ Extensible type system+ Scalability through profiles

+ Migration path from Classic OPC


MainframeMainframe

PortablesPortables

DesktopDesktopPCPC

ServerServer

ServerServerClusterCluster

EmbeddedEmbeddedSystemsSystems

devices portables desktops servers clusters mainframes

devices portables desktops servers clusters mainframes

ControllersControllers

OPC Scalability

‘classic’ OPC

OPC UAStack: C / C++ / C# / Java


OPC-UA Technical OverviewOS platform independent: Windows, WinCE, Linux, Euros, QNX, VX-Works…

• avoid DCOM, offers direct communication via TCP / HTTP• allows to integrate UA products directly into controllers

Protocols/Bindings• Binary: best performance, one single TCP port 4840• Web service (SOAP): firewall friendly (e.g. port 80/443)

OPC Deliverables• OPC Foundation providing UA stacks and sample code

C/C++ stack / .NET stack / JAVA stack

Security (mandatory implemented in UA stack, optional use)• Authentication via x509 certificate, SSL-encryption and data integrity

Technical Enhancements:• Support for redundancy• Heartbeat for connections in both directions• Buffering of data and acknowledgements of transmitted data

Lost connections don‘t lead to lost data


OPC-UA Base• Architecture

• Integration of DA, A&E, Commands, Complex Data, and Object Types

• Designed for Federation• abstract data/ information from the plant floor, through information

models, and up to enterprise systems

• Information Modeling• development and deployment of standard information models to address

industry domains specifics

• Complex Data• OPC Standard & Domain & vendor specific…


OPC-UA Base• Security

• Collaboration, Development & Reference

• Enterprise Integration• OPC UA standard messaging system

• Robustness / Reliability Designed & Built in….• NO Failures• Sequence numbers, keep-alives, resyncing, and support for

redundancy

• Commands• Call Methods, invoke State Machines

• Companion Standards • industry groups define content (“what”)

OPC Unified Architecture provides the transports (how”)


Elimination of OPC-Gateway-PC• Problem:

• OPC DA require Windows COM/DCOM• Non Windows-systems require a Win-Gateway-PC

The „OPC-PC“ to be connected remotely via OPC

• Solution:• Integration of UA into the controller

Production

OPC DA Server OPC UA Server

UA -TCP

Production level


OPC-UA Security• Implemented in UA-stack, optional use

• Authentification & Authorisation• via x509 Certificates• User Name / Password• Kerberos

• Integrity• Signing of messages

• Confidentiality• SSL encryption between endpoints

• Benefits• Allows secured communication

through unsecured environment

• From office through gatewaysinto production

IP 172.16.10.x

IP: 192.2.10.x


OPC UA

Information model


UA Base Information Model• Object Oriented Base Model• Types and References• Mashed Network• Inheritance

>> Everything that can bedescribed with an object oriented language, can alsobe modeled in UA and transferred over the networkand accessed via standardized services.


UA extended Information Model• Device Integration (DI)

• Initiative of EDDL Consortium, standardisation for field-devices• Released 2009

• Field Device Integration (FDI)• EDDL and FDT Consortium, Read and write of data• Released 2010

• PLCopen• Released 2010

• Upcomming UA-Informationmodels• Analyzer Device Integration (ADI)• MIMOSA• IEC61850 CIM• ProdML• ISA-95 and ISA-88


• PLCopen : www.plcopen.org• IEC6-1131-3 • Global standard for Industrial Control Programming• Languages: ST, IL, LD, FBD

PLCopen Overview


PLCopen and OPC: Team membersPLCopen & OPC UA: Interoperability On The Next Level• Enables OPC interfaces in embedded controller• PLC information model in a standardized format• Rapid engineering for HMI / MES / ERP• Moving information from shop floor to enterprise• Secure, remote “out-of-the-PLCopen-box” communication


UA-Clients: SCADA/MES/ERP

Presentation

• Standardized UA access• Identical namespace• Complete information model

Advantages:• Re-useable HMI Faceplates“• Rapidly engineering• Transparent PLC controller

PLCopen:

Content „WHAT“

OPC-UA-Server:

Communication „HOW“

All information about

IEC61131-3 project:

• FB‘s

• POU‘s

• Structures

• Tasks / Resources..

PLCopen & OPC: Results


PLCopen and OPC: Demo


Vision:• make use of OPC UA to define MES communication profiles

• international, standardized transport layer including authentification and security

• adapted by most important PLC controller vendors• enable communication with machines from different vendors• most important production KPI‘s should be structured and defined• cooperate with other groups to make use of their results

Next step: PLCopen & OPC go MES

Status:• internal draft paper available• planing for kick off


OPC UA Solutions


UA solutions: Device to Mainframe• Toolkits and SDKs (C / C++ / Java)• used by all large automation vendors• all platforms, all architectures

(x86, ARM, PPC, x64, Mips, … <> WinCE, vxWorks, Linux, QNX,…)• UaModeler - Code Generator• OEM solutions for legacy OPC connectivity

Solutions:• PC, IPC, Panel• Embedded Device• Smart-Phone


UA solutions: UA Server Device• ARM 9 rack mount UA Server Gateway• Embedded Linux• S7, Modbus, CAN, …• Ring Buffer Data Storage• Configured through UA

OPC UA goes Mobile: Android and also Apple (iPhone and iPad)• ARM Cortex A8• Android 2.2• UA Client• UA Security


SAP product „SAP Plant Connectivity“ provides OPC-UA

SAP support UA: The Perfect PlantHarmonizes Complex Manufacturing Network Interdependencies


SAP support UA demo: Architecture

RemoteRemoteWindowsWindowsTerminalTerminal

„OPC UA allows a platform independent, easy and secure connection between SAP business systems with distributed shop floor data even on smallest embedded devices” Dr. Arne Manthey, Product Manager, SAP AG


• Areva Multibrid 5000 wind turbine offshore (Alpha Ventus)• Connectivity to IT: OPC-UA

• PLC: Beckhoff CX1020 embedded PLC with integrated UA Server

• C# Client based on Unified Automation

UA solutions: Wind Turbines


• Automation Controller series with PLC, Motion and GUI

• OPC-UA Server integrated:• DA: Data Access• HA: Historical Access• AC: Alarm & Condition

• OPC-UA client integrated• UA client functionality as

FUNCTIONSBLOCKS out of the IEC61131-3 PLC

UA solutions: PLC controller


• Custom board with 400MHz ARM CPU • Connectivity:

• OPC-UA Server for 20 GPIO’s• OPC-UA client as UI-Silverlight application

UA solutions: Embedded Controller


Company: Arburgworldwide leading vendor of injection molding machines

Application: VxWorks based PLC

OPC UA: Embedded OPC UA Server

• Visualization• Configuration• Diagnostics• Vertical integration

HMI/SCADAMES

Pre-installedPre-configured

Data consistence

UA solutions: @ Arburg


UA solutions: @ MieleConnection between-HMI Siemens WinCC V7.0-PLC BECKHOFF TwinCAT

Ethernet

TCP/IP

30 Test stations with OPC-UA Server

OPC-UA

Company Allmendinger„ OPC UA Client for WinCC“

„Because of the use of OPC-UA we got a stabil and high-performance system, which meets our requirements.“

Frank Mestekemper, Miele


UA solutions: @ Fraunhofer IPA


Your benefitConsistency of Totally Integrated Automation+Openness of

OPC

Enterprise Resource Planning

Management Level

Operations Level

Control Level

Field Level

SIMATIC Net OPC, SIMATIC WinAC RTX, SIMATIC HMI Panels, SINUMERIK, SIMATIC S7, SIMOTION, …

SIMATIC Net OPC, S7 OPC Redundancy, SINEMA Server, SIPLUS CMS, SIMATIC WinCC, SIMATIC PCS 7, …

SIMATIC IT, SIPLUS CMS

More to come…

MES

DCS SCADA

OPC UA will be available for further relevant Siemens products in a timely manner

Penetration at all automation levels

UA solutions: @ Siemens


OPC UA resources


OPC UA Resourceswww.opcfoundation.org


Deliverables of the OPC Foundationwww.opcfoundation.org


Sample Code• OPC UA Stack

• In different languages ANSI C, .NET C#, Java

• Sample Code• .NET C# Server / Client


Test Tools

• Compliance Test Tool (UA CTT)• UA Server• UA Client• Script Based• Debugging


Certification Laboratories• Europe

Ascolab GmbHAm Weichselgarten 7D-91058 Erlangenwww.ascolab.com

• USAOPC Foundation16101 N. 82nd Street, Ste 3B Scottsdale, AZ 85260 www.opcfoundation.org

• Functionality testing verifies interoperability and compliance/adherence to the OPC Specifications. • Performance is tested and compared to the performance expectations as supported and claimed by

the vendor. • Stress Testing is done by pushing the software to the limits as defined by the vendor to check for

consistency in behavior as well as data throughput. • Recovery is tested by checking device failures and communications failures. • Resource testing conducted over many days to verify no resource leaks or performance degradation

occurs. • Usability is tested to ensure the product is easy to install, configure, use and troubleshoot. • Environment is checked to make sure the product works on the Device and O/S as claimed by the

vendor.

http://www.ascolab.com/

http://www.opcfoundation.org/


OPC UA resources

• Articles• White Papers• Brochures• Books• Webinars• Videos

• Road shows• Fairs• Trainings• Consulting


Thanks for listening !

Any Questions ?

Uwe Steinkrauss

from device into the enterprise -...

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