OPC in Smart Manufacturing 4.0

John WeberFounder, Software Toolbox

Our Asean Partner

New to Automation? - Terminology

• OPC – Open Platform Communications. A standard for software to software communications within the industrial automation space. Created in 1995/96 and is the leading means of sharing data between software applications in automation

• OPC DA – the original Data Access part of the OPC Standards – used for real-time data

• OPC UA – the modern name for the latest OPC standards which address real-time, alarming, historical data and more. UA = Unified Architecture

• ODBC – Open DataBase Connectivity – a Microsoft standard for connecting to different databases

• DDE – Dynamic Data Exchange – the first way Microsoft ever offered, in Windows 2.0, in 1988, for sharing data between software applications.

• MQTT - Message Queuing Telemetry Transport – a standard for sharing data through a publish subscribe methodology that is widely adopted in IoT Applications

• IOT – Internet of Things

• Want to learn more?

– Download our OPC 101 guide at https://info.softwaretoolbox.com/free-opc-da-ua-questions-guide

– Visit our Automation 101 blog at https://blog.softwaretoolbox.com/topic/automation-101

The Software Toolbox Difference

• Variety of Offerings

• + Interoperability Knowledge

• + Trusted Support Since 1996

• 14,000 Users

• 115 Countries

• = Success Assurance through

Risk reduction

• Technical team focused on device and data integration

• Test Lab with Hardware

• We deal with protocols all the time

• We deal with communications troubleshooting every day

Why Software Toolbox

Our clients are in every industry

Our Products Help Our Clients To

Get connected

To the Right Data

Sources

So the Right

People

Can Make Real-Time Decisions

And address problems before they ruin their day, week, month, quarter, year, or career

Where we fit in IoT

Without Data from the Edge, Nothing

Happens

What is TOP Server?

8

One Install

One *.EXE

Many types of

driversAggregate from

other software

Advanced

Functionality

Most Industry

Std Protocols

Most Client

Connections

softwaretoolbox.com/topserver

TOP Server Gets You Connected – 100+ Drivers!• AB Bulletin 1609 UPS

• AB Bulletin 900 Temp. Controllers

• ABB Totalflow Serial

• AB Micro800 Serial & Ethernet

• AB ControlLogix Ethernet & Gateway

• AB ControlLogix Unsolicited Ethernet

• AB PLC5,SLC5/05 Ethernet

• AB DF1 Full/Half-Duplex/Radio Serial

• AB Data Highway Plus (DH+)

• Alstom Redundant Ethernet

• Advanced Simulator

• Analog Devices 6B

• Aromat Serial & Ethernet

• Automation Direct DirectNet Serial

• Automation Direct K-Sequence Serial

• Automation Direct ECOM Ethernet

• Automation Direct P3000

• Automation Direct EBC Ethernet

• BACnet

• Bailey Fisher & Porter Micro-DCI

• Beckhoff TwinCAT

• Bristol/IP Ethernet

• BUSWARE Ethernet I/O

• CODESYS Ethernet

• Contrex/Fenner CX1000

• Contrex/Fenner M Series

• Custom Interface Driver (CID)

• Cutler Hammer D50/100

• Cutler Hammer ELC

• Mitsubishi A Series Ethernet

• Mitsubishi Q/QnA Series Ethernet

• Modbus RTU & ASCII Serial Master

• Modbus RTU Serial RTU Slave

• Modbus Plus

• Modbus Ethernet Master & Slave

• MQTT Client

• MTConnect Client

• ODBC Client Driver

• Omni Flow Computer

• Omron Hostlink & FINS Serial

• Omron Process Suite

• Omron FINS Ethernet

• Omron NJ/NX Ethernet

• OPC DA / UA / XML-DA Client

• Optimation OptiLogic I/O

• Opto 22 Ethernet

• Oracle Connectivity Suite

• Partlow ASCII Serial

• Philips PC8/PC20

• Red Prairie Logistic Systems

• Sattbus & Sattbus Ethernet

• Scanivalve Ethernet

• Siemens S5 AS-511

• Siemens 3964R

• Siemens S7-200 PPI & Modem

• Siemens S7-300/400 MPI

• Siemens S7-200/300/400 Ethernet

• Siemens S7-300 Ethernet Slave

• Siemens Plus (OPC UA Client for S7-1500)

• Danfoss AKC55 Serial

• Dataforth IsoLynx

• DDE Server to OPC Client Bridge

• DeviceNet/Profibus (Hilscher Universal)

• DNP3 Serial + Ethernet

• Enron Modbus Serial

• EUROMAP 63

• Fisher ROC & ROC Plus

• Fuji Flex PLCs

• GE Focas1 Ethernet

• GE SRTP Ethernet

• GE EGD Ethernet

• GE CCM Serial

• GE SNP

• GE SNP-X Serial

• Honeywell UDC & HC900

• Idec Micro

• IEC 60870-5-101 Master Serial

• IEC 60870-5-104 Master Ethernet

• IEC 61850 MMS Client

• Intelligent Actuator SuperSEL

• IOTech PointScan Ethernet

• Keyence KV Ethernet

• KraussMaffei MC4 Ethernet

• Lufkin Modbus Serial

• Mettler Toledo Scale Serial

• Mitsubishi FX Serial Programming Port

• Mitsubishi FX-Net Multidrop Serial

• Mitsubishi A Series Serial

Plug-Ins

• Advanced Tag

• Connection Sharing

• Data Logger

• Local Historian

• Media-Level Redundancy

• OPC Alarms & Events

• Real-Time Scheduler

• SNMP Agent

• Security Policies

Vertical Industry Suites

• Building Automation

• IT & Infrastructure

• Manufacturing

• Oil& Gas

• Power Distribution

EFM Suite (Electronic Flow Measurement)

• EFM Exporter Plug-In

• Omni Flow Computer

• Enron Modbus Serial

• Fisher ROC Suite

• ABB Totalflow Serial

• EFM Simulator

• Simatic/TI 5x5 Ethernet

• Simatic/TI 5x5 Serial

• Simatic/TI Unilink TIWAY Host Adapter

• Sixnet UDR & Ethertrak Ethernet I/O

• Simulator Suite

• SquareD Serial

• System Monitor (Windows Performance)

• Telemecanique Unitelway

• Thermowestronics Serial+Ethernet

• Torque Tool Ethernet

• Toyopuc PC2 Serial & PC2/PC3 Ethernet

• Toshiba PLCs Serial + Ethernet

• Triconex TSAA Ethernet

• User Configurable Driver (UCON)

• Wago 750 Ethernet I/O

• Weatherford 8500 Serial

• WITS Level 0 (Active & Passive)

• Wonderware Intouch Client

• Yaskawa MemoBus Plus

• Yaskawa MP Serial & Ethernet

• Yokogawa CX

• Yokogawa DX100/200 & Darwin Serial

• Yokogawa DX(P)100/200

• Yokogawa Darwin Ethernet

• Yokogawa DXP

• Yokogawa HR

• Yokogawa MW

• Yokogawa MX

• Yokogawa YS100 Serial

Compatibility

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Windows 7, Windows 8, 8.1, Windows 10Windows Server 2008, 2008 R2

Windows Server 2012, 2012R2, 2016

Windows 7 Standard Embedded

32 and 64-bit OS Support

Virtualized Environment Support

Remote Desktop/Terminal Services/ACP ThinMan Supported

Marathon and Stratus High Availability Supported

HistorianInTouchSystem

Platform

softwaretoolbox.com/topserver

TOP Server Security Out-of-the-Box

• TOP Server Secure Deployment Considerations Guide

• Current OS and OPC UA Capabilities & Security

• Project File Encryption• Administrator Password

during Installation• Back-end Security Updates

TOP Server – What & Why?

• 100 000+ Tags - 1 Second Scan update• 7% – 10% for Top Server• 33% for Entire Wonderware System

• Highly Scalable • 350 000+ Tags• << 50% Total CPU Usage (WW + Top

Server)• Water & Wastewater / Oil & Gas Apps• 1 000 000 Tags with over 1000 devices

TOP Server Performance Empowered By

• User controllable threading

• Thread-safe application

• Multi-core and multi-CPU machines fully supported

• Processor affinity settings

• Processor priority settings

• Runs as service

Redundancy Support

• Redundant App Servers

• Single TOP Server

• Single PLC network

• Non-Redundant PLCs

Redundancy Support

• Redundant App Servers

• Redundant TOP Servers

• Single PLC network

• Non-Redundant PLCs

Redundancy Support

• Redundant App Servers

• Redundant TOP Servers on App Server machines

• Single PLC network

• Non-Redundant PLCs

Redundancy Support

• Redundant App Servers

• Redundant TOP Servers

• Redundant Communication Paths

• Non-Redundant PLCs

Redundancy Support

• Redundant App Servers

• Redundant TOP Servers

• Redundant Communication Paths

• Redundant PLCs

• Modbus Suite – 1 solution many drivers– Modbus RTU Master & Slave– Modbus ASCII Master– Modbus TCP + Gateway– Modbus Plus

• Modbus Variant Drivers– Enron Modbus– Lufkin ELAM– Omni Flow Computers– Honeywell UDC 3000/3300/HC900

TOP Server Modbus Offerings

Can be used to make an HMI/SCADA look like a Modbus Device with full Modbus Register memory map! Excellent way to integrate to other systems

that want to be a Modbus TCP Master!

5/13/2019 21

• Flexibility, flexibility, flexibility

TOP Server Modbus Differentiators

5/13/2019 22

TOP Server DNP Suite

• DNP 3.0 Master in Level 3 Implementation– Serial– Ethernet

• Uses Timestamps from DEVICE!• Buffered event playback in order• Used as a reference by Wonderware

development in their Historian improvements as an example data source

• Field experience since 2006 enables us to know when a device is following DNP specs….

• And when it isn’t… • and how to deal with it…

Water Industry Experience

TOP Server Oil & Gas Suite

• TOP Server OPC & Suitelink Server Core• Drivers for

– ABB TotalFlow– Bristol/IP– Enron Modbus– Fisher ROC & ROC Plus Serial– Lufkin Modbus (ELAM)– Modbus ASCII, RTU, & TCP/Ethernet w/highly flexible

options– Omni Flow Computer– WITS Level 0 Active & Passive– Weatherford 8500 protocol serial– User Configurable Driver– Custom Interface Driver (CID)

TOP Server EFM Suite

• Also Oil & Gas Oriented• EFM Exporter – Flow-Cal,

PGAS, CSV, SQL formats• Drivers supporting EFM

– Enron Modbus– Omni Flow Computer– ABB TotalFlow– Fisher ROC/ROC+

• EFM Simulator

5/13/2019 26

IEC61850

• IEC61850 Master– IEC 61850-6 (SCL)– IEC 61850-7-3 and 7-4 (all logical node and

data object templates)– IEC 61850-8-1 (MMS)

• Item timestamps from devices• Buffered data playback• SCL file import for auto-configuration

– Filter import by device and functional constraints

• Report Block (RCB) support• Control command capability

5/13/2019 27

IEC 60870 Driver

• Anywhere power distribution and substations are involved –not just for utilities

• Connect to IEDs, RTUs such as ABB, SEL, Siemens, GE, Schneider

• Found more in existing applications

• Part 101 & 104 supported• Great companion to our

existing IEC61850 driver

TOP Server EUROMAP 63 Driver

• Add OPC to Injection Molding Machines (IMMs)

• Integrates EUROMAP 63 enabled IMMs including:– Cincinnati Milacron– Fanuc– Engel– Sumitomo DEMAG– Toyo– KraussMaffei– More

Great way to learn morehttps://info.softwaretoolbox.com/topserver-videos

30

Keep Up with TOP Server!

http://blog.softwaretoolbox.com/topic/top-server

Connecting The Rest of Your Devices

Linear Scalesi.e. Mitutoyo,

Digimatic

Bar Code Scanners

i.e. Intermec, Symbol, Z-Tron

Measuring Systems

Message Displays &

Scoreboards

Barcode Printers Gas analyzers

Mass Spectrometers

Combustion Analyzers

Gas Chromatographs

Laser MarkingSystems

Ethernet: TCP/IP, UDP, Telnet, RS-232, RS-422, RS-485

Weigh Scales

Historian System

Platform

InTouch InBatch

All of these are1. Costly2. Risky3. Suboptimal for

Operations Needs

Typical Solutions1. Custom Code/Applications 2. Hardwired Interfaces to controller if possible3. Choose different hardware with standard I/F4. Don’t Integrate

OmniServer Connects Them

• Proven solution

• No Coding or Development Required

• Field proven since 1995

• Over 7000 Installed Licenses Worldwide

Historian

System

Platform

InTouch

InBatch

MES

https://info.softwaretoolbox.com/omniserver-protocol-guide

Food Packaging Proof Point

• Global MES Implementation

• Standardized on OmniServer for all connectivity to these device types

• Can Printers• Barcode printers• Weigh bridges• Weigh Scales• Barcode readers

How? - Typical Implementer Journey Step 1

• Implement Device Specific Protocol– Point & click

configuration– One time step per device

protocol type the you’re done, forever

– Done by SI or our professional services

– 12 sample protocols included

Software Toolbox Confidential

Typical Implementer Journey Step 2

• Device Physical Connection– RS-232/422/485 Serial

– USB provided it presents as virtual com port

– TCP/IP, UDP, Telnet over Ethernet – wired, wireless, including terminal server (serial/ethernet converters)

• Done by user or integrator

• CSV Import for Mass Configuration

Software Toolbox Confidential

Typical Implementer Journey Step 3

• Connect Protocols to Devices to make Topics – One Per Field Device

• Up to 1000 devices in a single Omniserverinstance – CSV import for mass configuration

Software Toolbox Confidential

Typical Implementer Journey Step 4

• Connect your Client application– OPC DA– OPC UA (DA profile)– Suitelink– Plug-Ins

• Log to CSV• Log to DB• Email• Keyboard wedge• Future: MQTT client

Software Toolbox Confidential

OPC DataLogger – OPC DA/UA to SQL, CSV, Text, AzureSQL, MySQL, Oracle

• Log on data change

• Start/stop logging on other tag condition(s)

• Scheduler based logging (i.e by shifts, etc)

• Handshake with PLC/device once data written to data store

Cogent DataHub

• Ultimate data integration middleware

• New Connections– MQTT

– Azure IoT Hub

– Amazon IoT

– Google IoT

Watch this space for more!

https://info.softwaretoolbox.com/datahub-videos

Any other OPC DA or UA Server

OPC DA & UA

Proof Point - Award Winning Solutions SetBrewing in a Desert! & Green Manufacturing

• TOP Server & Cogent DataHub

• Wonderware Historian

• BrewMaxx

• SAP

https://blog.softwaretoolbox.com/wonderware-brewmaxx-sap-integration

DataHub Connects – OPC UA

• OPC UA Client and Server

• Easy OPC UA SSL Certificate Management

Any other OPC UA Data Access

Data Source

DataHub Connects – OPC DA

• Data Access Client and Server

• Flexible options to deal with about any DA server

Any other OPC DA Data Access

Data Source

DataHub Connects - Databases

• SQL server

• Oracle

• MySQL

• Any ODBC Compliant DB

• Log To

• Extract From

• Connect to OPC

Proof Point: First Gas New Zealand

• Integration of Foxboro SCADA History DB

• Move data to Wonderware historian for faster reporting

• OPC DA, ODBC, & Scripting Features Used

DataHub Connects - Excel

Non-Windows Data Sources

Data Bridging

Rockwell ControlLogix

Controller Type 1 Controller Type 2

• Oracle MES DB on Linux

• Wonderware OPC Data Sources

• Custom C++ application to be replaced

• DataHub as solution

https://blog.softwaretoolbox.com/linux-mes-opc-database-integration

Proof Point: Database to OPC Integration

OPC DA/UA Gateway & Tunneling

Proof Point: Trans Anatolian Natural Gas Pipeline

• 1 DataHub V9• 2.1 mm points• Tunneling• Bridging• Redundancy• OPC Alarms &

Events• Honeywell and ABB

systems

Modbus

DataHub IoT Gateway

• If you can get it into Datahub…

• You can use with the IoTGateway

MQTT Client

• Publish any DataHub Data

• Subscribe to 1-N MQTT brokers

• Flexible configuration options

MQTT Broker

• Premise hosted secure broker

• Integrate OPC DA, UA, ODBC, Modbus

• Highly Configurable

• Hierarchical Data Sets

IoT Destinations - Azure

IoT Destinations – Amazon IoT Core

IoT Destinations – Google IoT

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jweber@softwaretoolbox.com