manufacturing using ibm integration bus (ibm interconnect 2015 - session 1491)
TRANSCRIPT
© 2015 IBM Corporation
Integration of Manufacturing using IBM Integration Bus
Session 1491
Tim Kimber
Technical Lead, IIB Industry Packs
Agenda
• The Manufacturing Industry
• Standards
• Technologies
• Products
• IBM Integration Bus Manufacturing Pack
• Factory automation
• Analytics
• Internet of Things
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The Manufacturing Industry
Business Imperatives in Manufacturing
The Manufacturing world is moving from Mass Automation to Mass Customisation
The importance of capturing the “green dollar” – climate and eco-sensitive consumers
Demands for increased resource efficiency– Scheduling of production processes for optimal use of resources
– Production Performance Analysis.
– Equipment effectiveness and predictive maintenance.
– Increased competition means manufacturers need to become increasingly dynamic – highly
responsive and re-configurable production facilities
– Efficient despatch of production orders
Impact of BRIC and MINT economies and emergent middle class
Globalisation of supply chains, global competition with lower labour costs
$
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ISA 95 Purdue Model
Defines 4 separate Levels in industrial companies
Provides a simplified version of the Purdue Reference Model for CIM (Computer Integrated
Manufacturing)
Also builds upon the MESA (Manufacturing Execution Systems Association) model for
activities in the manufacturing control domain
Level 0 / 1
Process Control
Level 2
Supervisory Controls
Level 3
Operations Management
Level 4
Business Logistics
Level 5
Inter-Company
OPC DA / HDA
OPC UA
ISA-95/
B2MML
RosettaNet
OAGISMIMOSA
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“SMLC supports the manufacturing industry through pursuing a comprehensive technology that no one
company can undertake. Process control and automation systems implemented in piecemeal fashion will
continue to limit innovation and capability. SMLC will build the business, interoperability and technology
models, demonstrations, infrastructure, and project teams across multiple industry segments.”
Industrie 4.0
Industrie 4.0 is a German government strategy for promoting the computerization of
traditional industries such as manufacturing.
The 4.0 is refers to a heralded fourth great industrial revolution– Industrial Revolution 1 – mechanisation of production using water and steam power (coal!)
– Industrial Revolution 2 – Mass production using electricity
– Industrial Revolution 3 – The digital revolution (electronics and IT)
– Industrial Revolution 4 – Machine To Machine communication, SOA loose coupling
Industrie 4.0 is aimed at producing “Smarter Factories” which:– Are more adaptable e.g. logistics processes which can automatically react to unexpected changes
in production levels
– Are more easily configurable and connected to back-end enterprise functions
– Use resources more efficiently e.g. machines that predict failures, trigger maintenance processes
autonomously
SMLC is a non-profit organization whose membership is
available to industry, university, government laboratory,
independent consultant and organization / consortia.
SMLCSmart Manufacturing Leadership Coalition
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PLC (Programmable Logic controllers)
Talk to sensors and actuators
More actuators and sensors being built with in built Industrie 4.0 capability
Integrated OPC Servers
Some Industrie 4.0 enabled devices
The OPC Foundation is a non-profit organization that maintains specifications on behalf of the industry.
Total OPC market has 2,500+ vendors, providing 15,000+ OPC enabled products.
OPC Foundation product catalog provides 1,500+ OPC enabled products
The 1st specification, released in 1996 was for OPC Data Access
The 2nd specification, released in 1998 was for OPC Historical Data Access
The 3rd specification, released in 1999 was for OPC Alarms & Events
Most universally accepted standard for data exchange between:
SCADA and HMI Systems
PC-based control systems
Manufacturing Execution Systems
Quick adoption of the original OPC Data Access specification was driven by:
Windows Component Object Model (COM) and Distributed Component Object Model (DCOM)
Europe
(43%)North
America
(39%)
Asia
(13%)
Others (5%)
App A App B
Server 1 Server 2 Server 3
OPC OPC
OPC
Server 1
OPC
Server 2
OPC
Server 3
App A App B
The OPC Foundation
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The purpose of the OPC Unified Architecture was to enable a platform independent interoperability standard for moving data between the factory floor and the enterprise.
Contributions from over 30 companies over 5 years.
Specification first published in 2009
Original premise built on the existing OPC DA COM / DCOM based specifications BUT improved some of its flaws:
Platform dependence on Microsoft
Insufficient data models
Inadequate security
No reinvention! Standard builds upon other existing standards
OPC UA Server
OPC UA Client
Clie
nt
Req
ue
sts
Se
rve
r
Res
po
nse
s
No
tifi
ca
tio
ns
Most common services offered by an OPC UA Server:
Discovery – Servers provide a Discovery Endpoint which can be
accessed directly or through a discovery server.
Profile Support – So client devices can decide if the server can
support their needs – eg XML / Binary encoding and Security
Address Space – Read properties of the available nodes, and
read and write attributes of the variable type nodes.
Notification / Subscription – A client can define a set of nodes
which the server monitors for a specified condition(s) which
triggers a notification
+ +
OPC Unified Architecture
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OPC Unified Architecture
Node
Node
Node
Node
NodeNode
Node
NodeNode
View
OPC UA AddressSpace
Monitored Item
Subscription
OPC UA Server
OPC UA Server API
OPC UACommunication Stack
Request Response Subscribe Notify
From
OPC UA
Client
To
OPC UA
Client
From
OPC UA
Client
To
OPC UA
Client
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OPC Data Access OPC DA, or OPC Classic as it is sometimes known, was born in the 1990s – system
integrators in the manufacturing industry were trying to incorporate the PC into factory
floor applications using serial port connections.
Any application using a serial device was a candidate for a PC to replace a PLC, but
there was heavy dependence on writing drivers for the serial devices!
Mission: create a way for applications to get at data inside an automation device
without having to know anything about how the device works
OPC Client
OPC Server
Vendor A
OPC Server
Vendor B
OPC Server
Vendor C
Item 2: Value, Quality, Timestamp
Item 3: Value, Quality, Timestamp
Item 1: Value, Quality, Timestamp
Group (public | local)
Device
The OPC Foundation provided a solution by combining Windows
COM with an API for device protocols.
Vendor explosion providing OPC Servers
• OSIsoft, Matrikon, Kepware, Honeywell
Vendor code determines the devices and data which the server
can access, details for how it does this, and naming conventions
for the OPC resources
Application Logic
COM interface
Application Logic
COM interface
COM interface
OPC Data
Proprietary Driver
MICROSOFT COM
Serial
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OPC Classic versus OPC UA
DA
OPC UA Base
Vendor Specific Extensions
AC HA Prog
Specifications of Information Modelsof other organizations
Data Transport
Security
Information Modelling
OPC Overview
OPC Security OPC Common
Alarms & EventsHistorical DAData Access
PLC
Alarm Management Trend Display
COM / DCOM
OPC HDA Client
OPC HDA ServerOPC A&E Server
OPC A&E Client
DCS
OPC DA Client
COM / DCOM
OPC DA Server OPC DA Server
Vendor SpecificVendor Specific
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OSIsoft PI Server
Founded in 1980, HQ San Leandro California
– 1000+ professionals, 15,000+ customer installations across 110+ countries
Approximately $270million revenue, 50% North America
OSIsoft
PI Server
PI Server
“interfaces”
“outerfaces”PI Server has developed 400+ interfaces designed to gather data
from SCADA sources, convert to a PI readable format and then
send it to the PI Server to be stored. Example interfaces are OPC,
Modbus and PLCs.
Typically PI Server runs on a separate computer from PI Interfaces
and PI Client Applications.
A PI Server “Collective” describes an HA grouping of PI Servers
which can be considered as a single logical entity.
Elements are the building blocks
of a PI System. Structural
elements can be arranged into a
hierarchy, to represent a set of
organized objects. Equipment
List, Pumps, Tanks, Flow Meters
Heat Exchangers and Reactors
are all structural elements.
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Manufacturing - Business Problems and IT Solutions
Rig
Mine
Factoryπ r2 h
IIB
Social is driving up expectations of real-time availability, data accuracy and types of information
available across Enterprise and Supply Chain
Security through physical system isolation is no longer viable
Market drive to exploit advances in IT Security, distributed and virtualised IT solutions
Production locations are typically isolated and heavily
silo-ed from IT Enterprise. Highly heterogeneous
systems environments; no two locations the same
Need to make detailed operational information
available to an ever increasing range of consuming
applications and users without compromising
production efficiency
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Manufacturing Packfor
IBM Integration Bus
Manufacturing and IBM Integration Bus
IIB Manufacturing Pack
– Released 2Q 2014
– Fix Pack 1 4Q 2014
Plant Connectivity De Facto Standards
– Connectors and patterns that support current OPC industry standards for
integration of plant and machinery data and events, including a small
number of vendor-specific implementations
Plant Connectivity Emerging Standards
– Support for emerging OPC Unified Architecture standards to allow broader
integration to the enterprise
Enterprise Connectivity
– Integrations and connectors, including MQ Telemetry Transport (MQTT),
which facilitate the transmission of data from remote locations
– Web-based interface to provide operational views of data published from
plant and machinery
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Manufacturing Landscape
ODBC
JDBC
SQL
IBM Integration Bus in a Manufacturing context
Web Services
SOAP XML
Portal
Web Apps (internal)
IDOC, BAPI
Proprietary XML
Corporate Applications
ERP, Production Scheduling
Dynamics
Oracle
SAP
Web Services
HTTP, JMS
File, SQL
Web Services
SOAP, XML
Analytics
Manufacturing
Execution Systems
Decision Management
Product Quality
Management
Web Services
HTTP / JSON
Plant Staff
Mobile Applications
Supply Chain Management
Remote Telemetry Unit
SCADA
Web Services
IDOC, BAPI
SQL
MQTT
Remote Site
(satellite link)OPC Classic Server
(including Historian)
OPC DA
OPC HDA
OPC AE
OPC UA
Asset Management
OPC
B2MML
Web Services
OPC UA Server
(including Historian)
Web Services
Proprietary
interfaces
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IBM Integration Bus Industry Packs
Each pack is a fully supported software product, independently delivered from IBM
Integration Bus
The purpose of an IIB Industry Pack is to provide industry-specific development
accelerators which solve common industry integration problems
Help users to deploy working integration solutions in literally a few clicks of the mouse.
IIB Industry Pack content is structured around three delivery pillars:
Connectors
Data DefinitionsIntegration Patterns Monitoring
Association for Retail
Technology Standards
Open Applications Group
Data Format Description Language
Open Grid Forum
Health Level 7
Digital Imaging and Communication
in Medicine
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Manufacturing Pack High Level Architecture
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What does the Manufacturing Pack provide?
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Contains several moving parts
– OPC UA Read Node/ OPC UA Input Node
– OPC Classic Read/ OPC Classic Write
– PI Read Node/ PI Input Node
– MQTT Nodes
– Factory Pattern
– Web UI
• Operational Monitoring
• Manufacturing Integration Monitoring
– Ability to use B2MML schemas (imported from http://www.mesa.org/en/B2MML.asp)
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Manufacturing Pack OPC Classic Nodes
Output from the DA Read Node (TagData.xsd) can drive the DA Write Node
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Manufacturing Pack OPC UA Nodes
Can dynamically connect to OPC UA sever to retrieve valid tags at design time
Used to configure the OPC UA Read and OPC UA Input nodes
Can connect securely with SSL
'opc.tcp' style connection only
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Manufacturing Pack PI Nodes
Connect to your PI Server to retrieve series of PI Point tags
PI Read Node (PI SDK) and PI Input Node (PI AF SDK)
PI Input node allows wildcards
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Manufacturing Pack Nodes Commonality
Output of the Manufacturing nodes in TagData.xsd format
Common for all Manufacturing nodes
Schema shipped in pattern: enables validation, with null support and mapping
All midflow manufacturing nodes now have 'invalid tags' terminal
Decide how to handle tags which cannot be found on your server
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Manufacturing Pack example Flow and Output
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Manufacturing Pack Factory Pattern
Use the Factory Pattern to expose your sensors
Produces IIB artifacts in a few clicks
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Manufacturing Pack Web UI
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Future Roadmap (No priority order)
Integration Bus Nodes
– OPC Classic HDA
– OPC Classic AE
– OPC UA HDA
– OPC UA Write
– PI HDA
– PI Write
– S7 Siemens
IBM Confidential29
Internet of Things
Internet Of Things Forecast2020 View
Source: IDC, December 2013
212B Installed Things
30B autonomously connected things
Public Sector, Distribution & Services,
Manufacturing & Resources, and
Consumers Lead Segment Growth Rates
Approximately 3 Million Peta Bytes Of
Embedded Systems Data (Excludes
Streaming, Surveillance Type Data
$8.9Trillion Of Business Value
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Sense and ControlVisualise and Respond
Intelligence
and Analytics
Traditional
Backend Systems Big Data
Sensor Area
NetworkHome Area Network
Personal Area Network
Vehicle Area Network
Edge Gateway
The Realm of the IoT
Connectivity
Things
Mobile
Cloud
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MQTT and Remote Data Sources
Distance = > 250 km
Flow ControlPressureTemperatureOil Storage
Low-power, low-bandwidth / PLCs and RTUs
Upstream Center of
Operation and Control
Head officeIT Corporate Infrastructure
WAN
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Central Systems
Monitoring
- temp, pressure...
Control
- valves…
4000 devices integrated, need to add 8000 more BUT:•Satellite network saturated due to polling of device•VALMET system CPU at 100%•Other applications needed access to data ("SCADA prison")
Proprietary polling protocol
Billing
Maintenance
SCADA
low-bandwidth,
expensive comms
Pipeline: integration challenges
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Central Systems
Billing
Maintenance
SCADA
low-bandwidth,
expensive comms
Scalability for whole pipeline!
Network traffic much lower - events pushed to/from devices and report by exception
Network cost reduced
Lower CPU utilization
Broken out of the SCADA prison – data accessible to other applications
Billing customers immediately after delivery
Message Broker
pub sub
transformation
Enterprise MessagingMQTT
20 Field
Devices to 1
Concentrator
Creating an Open SCADA Pipeline
35
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