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Manufacturing IoT - OPC UA Information Revolution

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Internet of Things Manufacturing Business Value

Presentation by Bill Lydon, Chairman - PLCopen North America at the OPC Foundation Information Revolution 2014 Conference held at Microsoft's Redmond Campus. Bill Lydon is an experienced industrial, process control, and building automation professional with technology and business experience including product design, corporate experience, co-founder & president of a start-up company. Bill is an industry consultant, editor of Automation.com and editor International Society of Automation InTech magazine.

For more details contact Bill Lydon
bill@automationfocus.com
414-704-5004
* LinkedIn: www.linkedin.com/in/billlydon
* Twitter: https://twitter.com/wlydon

Published in: Technology

Manufacturing IoT - OPC UA Information Revolution

  1. 1. Bill Lydon • Chairman of PLCopen North America • Editor of Automation.com & InTech Magazine • Automation Consultant
  2. 2. Entrepreneur Applications Hardware & Software Design Bill Lydon Background Controls &Automation
  3. 3. • Customer Responsiveness • Profits • Order Synchronization • Supply Chain Synchronization • Work In Process Tracking • Genealogy & Traceability (TnT) • WEB Visibility • Compliance Documentation • Paperless Systems • Investment Justification? Manufacturing systems NOT advancing at the rate of other business systems.
  4. 4. ERP Local HMIs Automated Controls MES/Historians/HMI Sensor/Actuators Hardwired, Proprietary; Semi Proprietary Low Quality Data Sources Multiple Databases Historians, Batch Records, LIMs etc. DUPLICATION Crude Data Non-Standard Low Refinement Poor Syntax No Context
  5. 5. ERP Local HMIs Automated Controls MES/Historians/HMI Sensor/Actuators Hardwired, Proprietary; Semi Proprietary • Duplicated Data • Multiple Layers • Throughput Bottlenecks • Communication Translators • Complicated Routing • Low COTS Adoption • Configuration Control Challenges • Holding back innovation • Holding back productivity Complicated & creates a great deal of cost, ongoing configuration control and lifecycle investment. Low Quality Data Sources Crude Data Non-Standard Low Refinement Poor Syntax Multiple Databases Historians, Batch Records, LIMs etc. DUPLICATION
  6. 6. Striving for Manufacturing Success Creative & Innovative Automation Low labor cost is not a winning manufacturing strategy… Industry 4.0 Smart Factory Industrial Internet Manufacturing IoT Intelligent Manufacturing
  7. 7. Copyright 2010 Synchronize: Customer, Supply Chain; Manufacturing Make to Order Manufacturing Increase Factory Throughput Increase Quality Frictionless Communication Reduce Application Engineering Time Simplify Enterprise Software Interfaces continuous real-time business optimization The Big Ideas: Real-time Digital Factory Precision & Efficiency
  8. 8. Analytics Macro Level Processes, Machines & Plants
  9. 9. Embedded Computing -Sensors , Actuators, Pumps, Flow Sensors, … Control & Automation Driving to the Edge “the internet of things” 32/64 bit CPUs, Integrated Communication (Wired & Wireless), Embedded Real-time Operating System, Web Server, Email, Web Services Analytics Micro Level Drives, Motor Controls, Sensors, Actuators Etc… Macro Level Processes, Machines & Plants
  10. 10. Wider Application Possibilities Machine •Multi-Process •Multi-plant •Supply Chain •Energy Methods Understood -Model Based Control * Model Free * Self Learning Limiting Factors –Processing Power, Communications, & Weak Software Platforms Analytics Macro Level
  11. 11. Wider Application Possibilities Machine •Multi-Process •Multi-plant •Supply Chain •Energy Micro Level Sensor & Actuator Embedded Computing -Sensors , Actuators, Pumps, Flow Sensors, … Control & Automation Driving to the Edge Refinement Analytics Web Server Email Web Services OPC UA Methods Understood -Model Based Control * Model Free * Self Learning Limiting Factors –Processing Power, Communications, & Weak Software Platforms Analytics Micro Level Drives, Controls, Sensors, Actuators, Etc… Macro Level Processes, Machines & Plants
  12. 12. OP C UA OP C UA OP C UA ERP Automation & Controls Sensor/Actuators OP C UA OP C UA the cloud
  13. 13. Copyright 2010 P L P L P L P L • ISA-95 • ISA-88 • B2MML • IEC 61131 • MTConnect • PackML • OPC UA • OPC UA ADI • OPC UA -WITSML Open Standards Deliver Interoperability Device to Device and Device to the Enterprise Enterprise
  14. 14. IEC = International Electrotechnical Commission Founded in 1906 Over 50 participating countries Common Industrial Control Programming Standard IEC 61131-3 Global Standard Founded in 1992 Worldwide Vendor Independent Not for Profit Focus –Open Architecture Controls Programming PLCopen
  15. 15. STRONG DATA TYPES Open Controls Programming Standards BOOLREAL & LREAL INTEGERSTRING TIMEARRAY VENDOR DEFINED USER DEFINED STRUCTURES Ladder Diagram (LD) Function Block Diagram (FBD) Sequential Function Chart (SFC) Structured Text (ST) Instruction List (IL)
  16. 16. • Transparent Access • Transparent Communication • XML Interchange Standard
  17. 17. Goal: to define a set of FBs for UA Client communication Basis for Machine-to-Machine communication
  18. 18. OP C UA OP C UA OP C UA ERP Automation & Controls Sensor/Actuators OP C UA OP C UA the cloud
  19. 19. Copyright 2010 Synchronize: Customer, Supply Chain; Manufacturing Make to Order Manufacturing Increase Factory Throughput Increase Quality Frictionless Communication Reduce Application Engineering Time Simplify Enterprise Software Interfaces continuous real-time business optimization The Big Idea: Real-time Digital Factory Precision & Efficiency
  20. 20. Design Specification Risk Analysis Verification Coding Testing Refining Integration Commissioning Maintenance
  21. 21. Design Specification Risk Analysis Verification Coding Testing Refining Integration Commissioning Maintenance Open Standards Simplify Automation (Just as it has in other applications.)
  22. 22. Mapping between BACnet and OPC-UA Building Automation Function Block Libraries
  23. 23. • Standard IEC 61131 Programming • 230 Beckhoff BC9000 Controllers • HMI: Webpage/Internet Explorer • Ethernet TCP/IP I/O • 27,500 I/O Points • Room Control via Internet Use Case: Building Automation Courtesy of OPC Foundation/PLCopen Member Beckhoff
  24. 24. Copyright 2010 Building Blocks Real-time Digital Factory continuous real-time business optimization OPC UA Business Value Bill Lydon • Chairman of PLCopen North America • Editor of Automation.com & InTech Magazine • Automation Consultant bill@automationfocus.com 414-704-5004

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