softing (oldi): data exchange with controllogix. are dedicated modules right for my application?

© 2015 Softing Inc. All Rights Reserved.

Are Dedicated Data Exchange Modules Right for My Application?

A Comparison of Data Exchange Approaches for ControlLogix

Alex Tabora

Applications Engineer


• Who is Softing Inc.?

• Definitions

• Points to Consider When Choosing an

Approach to Transfer Data

• Data Transfer Methods

− Computer-based

− Module-based end-to-end data exchange

− Module-based OPC UA Server

Topics


Softing Inc.

Softing is a leading global provider of products for industrial automation

and automotive electronics.

For over 30 years, the core business of Softing Industrial Automation

has been industrial data communication, offering hardware and

software solutions for process data integration, network diagnostics and

asset management.


Softing Inc.

• Softing acquired OLDI in 2014

• OLDI is an Original Design Manufacturer (ODM) that designs

and sells PAC/PLC modules under other company brands

and a few with the OLDI brand

• OLDI as a company will continue as an ODM

• OLDI branded products will transition to the Softing brand in

2015

• As of January 1, 2015, the official North America company

name is Softing Inc. – Headquartered in Knoxville, TN


Softing Inc. Products Sold Through the Rockwell Automation Channel

eATM

Enterprise

Appliance

Transaction

Modules

cATM

Controller

Appliance

Transaction

Modules

SAM

Special

Application

Modules

PCI; PCI

Express

Network Cards

for High Temp

Environments

WireXpert

Advanced Cable

Certifier for

Ethernet copper

or fiber

Move Data Run Custom Code Connect Certify


Definitions: Transactional versus Historian Data

Transactional (Relational Data) – Bidirectional (data is exchanged)

– There is a record with reference data about every transaction (e.g. time and date, recipe, batch, shift, order number, equipment used, etc.) – could be complex data structures

Historian (Time Series Data)

– Unidirectional (data collection)

– Relatively simple data (pressure, temperature, etc.) recorded very fast

There is room for both in a good plant data model but this

presentation will focus on transactional data exchange

6


Definitions: Transactional Data

7

Examples of transactional data usage:

– Instructions/recipes

• Process to order

• Assemble to order (e.g. Dell computers)

• Build to order (e.g. aircraft)

– Measure & Monitoring

• Product/material tracking and tracing

• Equipment health

• Overall equipment effectiveness (OEE)

• Events and alarms

Transactional data is time stamped, has numerical values

and is associated with one or more objects


Industries


Points to Consider When Choosing an Approach to Transfer Data

• Architecture

– Do you have a single or multi-vendor installation?

– How many sources and recipients of data?

– What are your local data storage needs? (e.g. logging, buffering)

– Would you prefer the data transfer be running in a module or in a computer?

– Is it desired/required that switchover (failover) to other databases be available should the primary connection fail?

– Do you want email notification of system or data transfer status?

• Computers and Software

– Are there existing computing platforms in the system that you could use?

– Would software updates and patches be an issue?

– Viruses/Malware concerns

– “Ownership” of factory-floor computing

9



• Security

– How will your system security be affected?

– Do you need to control access to:

• Data?

• System Configuration?

– How is the data sent? (e.g. certificates, encryption)

• Value of the Data

– For industries with high value work-in-process (e.g. semiconductor)

– For industries requiring complete traceability to the source (food, pharma, and increasingly automotive)

10



• Support/Maintenance

– Who will set up the initial data transfer solution? Who will maintain it?

– How often will the data transfer configuration be changed?

– What is the relationship between IT and the plant floor?

• Cost/Budgeting

– How is budgeting/funding arranged between plant floor control systems and higher level information systems?

– What is the budget? Will there be funds available for future support, maintenance and updates?

11


Data Transfer Methods Example

Downloading of Instructions

• Control system triggers a transaction

• A stored procedure in the database

downloads data to the control system.

Stored Procedure Example:

1. Barcode scanner reads pallet ID

and control system sets a value

2. Execution of the stored procedure

is initiated by CLX value change

3. Stored procedure “looks up” pallet

information to decide what needs

to be loaded

4. Stored procedure values are

mapped to the controller

5. Controller tells palletizer what to

load


Data Exchange Model

13


Computer-Based Data Transfer Custom Code, Scripting or Dedicated Software

14


Advantages

• Ultimate flexibility (if developing custom code)

• Could use an existing computer platform

Disadvantages

• Development time

• Impact of platform changes (new hardware or versions of operating system or application software)

• Maintenance/Support

– Can plant floor people support?

– Does IT need to be called? What is the response time?

16



Data Transfer with tManager Module

17


Advantages

• Physically integrated in ControlLogix chassis

• Hardware solution (software only required to configure)

• Plant floor maintainable

• Secure

– No open computer/operating system

– Set-up/maintenance access only via GUI

• All configuration information stored in a single CompactFlash card

– Fast system restore after shutdowns

– Fast module swap out

Disadvantages

• Only available in CLX form factor

• Expandable only by adding more modules



tManager Module vs PC-based Solutions

Characteristic tManager Module Separate Computer with OPC , Custom SW

or SW package

Physical Integration CLX module with full backplane communications

None (external white box or industrial computer)

Plant Floor Maintainable Dedicated device, spare parts, single file restore

Potentially complex requiring involvement of IT personnel

Security Configuration access only via GUI w/ password protection Depends on IT process and discipline

Software Update Control No forced updates

Flexibility to configuration change

Change-on-the-fly with GUI Requires SQL expertise

Total Cost of Operation Low – single module (includes configuration software) + labor to configure

Med to High – external computer + operating system + application(s) software + labor to program

Store and Forward Yes

Could be written with custom software or available in software packages

Database Failover Yes Email Notification of Errors and Warnings

Yes

Automatic Logging Yes

20


tManager Overview

• Configurable, dedicated module used for data exchange

• No PLC code modification

• Industrialized packaging

• Replaces a software/PC-based solution

• Data exchange takes place in the controller chassis

• No code development or management

– Data exchange is configured via straightforward mapping with a drag and drop GUI

• Don’t have to deal with OS upgrades, patches or viruses

Reduces installation and maintenance costs


Controllers Computer Adapters

Database •Microsoft SQL •Oracle •MySQL •MS Excel/Access • IBM DB2

•AS400/iSeries

Messaging

•Red Hat Jboss JMS • IBM WAS JMS

Communication

• TCP/UDP • FTP •Bi-Directional Email

tManager® Module Maps /Triggers

Store & Forward

Database Failover

Audit Logs

Transaction Logs

New Installations or Add to Existing Systems

tManager Overview “Configure & Go” Data Transfers

Ethernet Ethernet or

Rockwell Bridges


tManager Overview Configurable Elements

Database Tables

PLC Tags

Automatically Found

Maps

Endpoints

Message Paths

What You Define/Configure

Triggers


tManager Overview Configuration Software

Drag and Drop to Map Data


Benefits: Faster Implementation

• The tManager enumerates controller & database tags/structures

• Easy configuration via graphical user interface

– Define path to controller(s)

– Define path to database or message queue

– Map data sources to data destinations

– Setup triggers

– Place into run

• Functoids - provide tag manipulation without the need to modify PLC code

• Copy/Paste & Search/Replace reduce configuration time

• SQL code can be shared with IT to aid in start-up troubleshooting

• Entire User-Defined Data Types (UDTs) can be mapped to a database XML column as one item to optimize communication


Benefits: Robust Data Handling & Auditing

• Once configured, all data transfers are handled by the module itself – no other software is required

• Data Buffering and Destination Failover

– Store & Forward: If communication is lost, data can be stored on the tManager

– Failover: on loss of communication to the database, messages can be transferred to/from an alternate destination

• Logs and Notification

– Diagnostics, status and transaction monitoring via user configurable logging

– Configurable email alerts for transactions failures, loss of connectivity, server interruptions and other errors

– Email Notification adapter included with every tManager

• Time-Stamped data

– The time the data is retrieved from the controller can be sent to the database along with the tag data (TIMESTAMP macro)


Store & Forward

• Data will be written to the tManager’s CompactFlash if communication is interrupted, and written to the original destination once communication is resumed

• Optional email notification


Failover

• Can specify alternate database(s) or messaging endpoint(s) that data is sent to/read from when the original destination/source is not available

• Optional automatic recovery attempt


Benefits: Security and Traceability

• No open computer/operating system - virus resistant

• 2 electrically isolated Ethernet ports

– 1 for enterprise network

– 1 for configuration/control network

• Module supports persistent routes through gateways, compatible with your network security features

• Access for configuration only though the tManager GUI

– Granular user privileges

• Audit and Transaction logging


Benefits: Straightforward Maintenance

• Configuration is stored in a single backup file

– Restore file to spare CompactFlash or module

• Flexible and easy-to-implement spare part options

• No restrictions on loading GUI software on multiple PCs

• Extensive help

– Context sensitive online help

– Knowledgebase (http://kb.oldi.com)

– Service Requests

– Live support sessions via WebEx


• Challenge: upgrade a system that uses MS-SQL for recipe download and production data upload, and includes a mix of PLC families. Replace VB scripting with faster more robust approach.

• Results and Why Chosen:

– Faster data exchange between MS-SQL database and legacy PLCs

– Decreased data transmission time to under 100ms per exchange vs ~20 seconds

– Increased manufacturing throughput by 16%

– Reduced time to configure by 75%

– Payback in days

tManager: Turbine Blade Heat Treatment Process-to-Order


Furnace B, PLC-5 Furnace A, PLC-5

Cleaning Machine

CompactLogix Robotic Cell #2

SLC

Robotic Cell #1

ControlLogix

Solution:

• Data transfer via tManager module

– Download recipes for turbine blade manufacturing

– Upload process data

– Log manufacturing operations on employee timecards

• Monitored by visualization software

tManager

Module

Server

Room

Microsoft®

SQL Server

ENBT Module

ControlLogix

Continued use of entire

legacy system

tManager: Turbine Blade Heat Treatment Process-to-Order


Aluminium Melting

Casting Finishing Quality Control

Finished Product

Resins &

Sands Cores

Sand Recycling

Birth Certificate

tManager: Automotive Track & Trace Finishing Line - Plant 2

Lookup Lookup Lookup

Storage Storage Storage


tManager: Automotive Track & Trace Finishing Line - Plant 2 (Before)

Challenge

• Automotive plant assembly lines:

– Create unique part ID/”birth certificate”

– Track and trace

– Record equipment used

• For data transfer

– Connect to legacy controllers

– Replace VB scripting in SCADA

– Buffer data in case of lost wireless

communication

Isolated lines with no

connectivity among

controllers and no upload

to the enterprise


Solution Results • Speed

– Fast data exchange between MS-SQL and PLCs – Transaction execution times faster than customer expectations

• Robust

– Ability to have another tManager module available for quick

disaster recovery and reuse at multiple locations

– Customer confident in validity of transactions due to

handshaking and error messaging from tManager module

• Add 3 ControlLogix systems as data

concentrators/gateways

• Use tManager modules to transfer data to

and from Enterprise Server

tManager support for RA

bridge modules simplifies

connection to older PLC

systems

tManager: Automotive Track & Trace Finishing Line - Plant 2 (After)


OPC Unified Architecture (UA)

• OPC provides a common interface for communications between different products from different vendors.

• OPC UA’s key advantages over OPC Classic:

– Platform independence and scalability

– Use of web services allows connections over a VPN and through firewalls

– Built-in security provides authentication and encryption capabilities to protect data

36

Without OPC With OPC


OPC Unified Architecture (UA) Connecting to RA Integrated Architecture

• Rockwell Automation provides products which are OPC DA 2.05 compliant. However, RA has no OPC UA connectivity.

• RA has worked with encompass partners to provide OPC UA connectivity to integrated architecture.

• Softing (OLDI) as an Encompass Partner provides:

– The 56eATM® (Enterprise Appliance Transaction Module) OPC UA Server Module, which fits in the chassis and communicates via the ControlLogix backplane to controllers and Ethernet to clients.

37


OPC UA Server ControlLogix Module

38

• The eATM® (Enterprise Appliance Transaction Module) OPC UA Server Module for ControlLogix, fits in the chassis and communicates via the CLX backplane or by EtherNet/IP

• The module is configured via a graphical user interface (GUI)

• Fully certified for OPC UA compliance by the OPC Foundation:

• Specifications

– Standard UA Server Profile (6.5.47)

– OPC UA client-server communications security

– OPC UA client compatibility for scalar tags, UDT component tags & arrays

– Complex Type Facet ControlLogix UDT Support (6.5.11)


OPC UA Server ControlLogix Module

39

• Hardware and Environmental

– Two 10/100/1G Ethernet ports

– ControlLogix single-slot module

– Windows 7 (for config software)

– Temperature

• Non-operating 0° to +80°C

• Operating 0° to +60°C

– Humidity: 5 – 95% non-condensing

– Vibration: 2g @ 10 - 500Hz

– Shock

• Non-operating 50g

• Operating 30g

– Power dissipation: 7W


OPC Classic/OPC UA Client/Server Architecture

40

Data transfer

Software/Hardware

Enterprise/Business/Plant System

Client

Enterprise Network

Main PAC/PLC

(Data Concentrator)

Other PACs/PLCs

Operating System

(e.g Windows for OPC, various

for OPC UA)

• PLCs & Other Devices

• Database

• Custom Application

OPC/OPC UA Server

Data transfer

Software/Hardware

Operating System

(e.g Windows for OPC, various

for OPC UA)

OPC/OPC UA Client

Other Clients


OPC UA Client/Server with PC-based Server

41


OPC/OPC UA versus other PC-based Data Transfer Methods

42

Advantages

• Flexibility

• Can have multiple clients and multiple servers

• Many participating vendors

• Broad user base

Disadvantages

• Multiple locations to commission and maintain

• Data security (with OPC Classic, but fixed with OPC UA)

• Data handling

– No Store and Forward

– No Failover


OPC UA w/Softing OPC UA Server Module Client/Server Architecture

43

Enterprise/Business/Plant System Client

Enterprise Network

Main PAC/PLC

(Data Concentrator)

Other PACs/PLCs

• Database

• Custom Application

Softing OPC UA Server Module

Data transfer

Software/Hardware

Operating System

(e.g Windows for OPC; various

for OPC UA)

OPC UA Client (third-party)

• PLCs & Other Devices

Other Clients


OPC UA Client/Server with Module-based Server


OPC UA with ControlLogix Module versus other PC-based Data Transfer Methods

45

Advantages

• Same as OPC UA, plus…

• Physically implemented as a ControlLogix module

• Takes load off of Ethernet bridges

Disadvantages

• Same as OPC UA, plus…

• Only available in CLX form factor


Softing Sales Contacts

Scott Sibenac Jim Ralston Pete Desmarais Christophe Renard

Regional Sales –

Western & Mexico

Regional Sales –

Eastern US &

Canada

WireXpert Business

Manager

Regional Sales –EMEA

& Asia Pacific

+1 214-755-1905 +1 724-554-8498 +1 603-289-3691 +34 93 241 47 05

[email protected] [email protected] [email protected] [email protected]


Resources

• Softing US Web – Softing US main website: http://www.softing.us/ra

– To place an order http://www.softing.us/contact/

– Product information http://www.softing.us/products/

– Knowledge Base http://kb.oldi.com

– Service Request https://ssl.oldi.com/ecustomer_enu

• Phone & FAX – In the US: 800-625-8678

– International: +1-865-251-5252

– FAX: +1-865-579-4740

• Address – Softing Inc.

– 7209 Chapman Hwy

– Knoxville, TN 37920

• Rockwell Web – Softing’s Encompass Listing http://www.ab.com/db/encompass/bps_ext.SEARCH

– Knowledge Base https://rockwellautomation.custhelp.com

(Softing reposts many Knowledge Base articles in Rockwell’s Knowledge Base)

http://www.softing.us/ra

http://www.softing.us/contact/

http://www.softing.us/products/

http://kb.oldi.com/

https://ssl.oldi.com/ecustomer_enu

http://www.ab.com/db/encompass/bps_ext.SEARCH

https://rockwellautomation.custhelp.com/

softing (oldi): data exchange with controllogix. are dedicated modules right for my application?

Technology

reference data

recipients of data

transactional data exchange

alarms transactional

transfer data architecture

softing brand

industrial data communication

process data integration