PREPARE FOR THE NEW ERA OF AUTOMATION USING OPC UA June ... · OPC UA Session 1 Arun...

OPC UA Session 1

PREPARE FOR THE NEW ERA OF AUTOMATION USING OPC UAArun Ananthampalayam

June 2017

Honeywell Internal

Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.

Plan to attend Delivering Outcomes With The Connected Plant, Shree Dandekar, VPGM,

Honeywell Connected Plant and Jason Urso, CTP, HPS (Tuesday June 20th, 2017)

Plan to attend the second session on OPC Connectivity (Tuesday June 20th, 2017): “Enable The Connected Plant with Matrikon

® FLEX OPC UA SDK”

1


Agenda

2

Digital TransformationThe Industrial Internet

of Things (IIoT)

Enablers of Digital

Transformation : OPC

UA

Next Steps…


How Does IIoT Work?

3

Advanced Analytics

Data Management and Onsite Control

Smart and Secure Collaboration

Smart & Connected Assets and Devices

Organize and visualize data in asset context

Capture real-time process and event data

VISUALIZATION

COLLABORATIONAcross Functions

Connect process intelligence to business KPIs

Apply powerful analytics to detect and predict issues

TODAY

1990s


IIoT Demands Access To Data

4

IIoT Solutions are Powerful with Access to All Data

Connectivity

OPC UA turns every field

device into an edge device

for direct cloud connectivity

Field Devices

Non- Honeywell Equipment

DCS

Maintain

Operate

Optimize

CONTROL BUS

CONTROL BUS / OPC*

Private / Public Cloud

All Data

OPC UA: Diagnostics, Calibration, Vibration, Process

OPC UA: Diagnostics, Calibration, Process, Analytics

OPC UA

Analysis + Outcome

Easy access to all plant data, combined with structured

and unstructured data from other sources, allows

optimization of the entire value chain

Non-process Data


Honeywell Connected Plant

5

Deliver and Sustain Improvements in Our Customers’ Profitability

by Increasing Throughput & Yield at Lower Cost via:

Increased ProductionEfficiency

Integrated Safety & Cyber Security

Workforce Competency

Improved ProcessReliability

OptimizedSupply Chain


Introduction To OPC UA

Industry Standard Ethernet based Connectivity for Industries – “USB” for Industrial Data

OPC Classic OPC UA (Unified Architecture)

Security non native Native security

Microsoft Windows onlyMulti-platform implementation, including ANSI C, Java and

.NET

Designed for desktop Scalability: from embedded smart sensors to mainframes

Frequent configuration issues Easy engineering

Connectivity without context:

• Value & timestamp

Connectivity with context:

• Value & timestamp → tag → equipment → plant → site

Holger Junker, German Federal Office for Information

Security, (BSI), Head of Division

“OPC UA is one of the most important modern standards for

industrial facilities and many further scenarios in an intelligent and

connected world. OPC UA is considered a central building block on

the way towards Industrie 4.0. It is the first unified, worldwide

recognized industrial protocol for a secure smart factory.”

6

• Developed and sold by Honeywell Matrikon

• Developed by OPC Foundation

- Open Source

• Developed and sold by Honeywell Matrikon

• Many competitors: OPC vendors, automation vendors, software vendors, etc.

- Architecture components and data analytics offer value add beyond connectivity

- Differentiators: Compliance with specification, ease of use, performance, robustness

Drivers &

Applications

... novels, poems, essays,

etc.

Software Development

Toolkits (SDKs)

.... spell/grammar checker

OPC Stack (OPC UA and Classic)

.....the alphabet


Matrikon Flex OPC UA SDK

7

The first high-performance, scalable OPC UA SDK that quickly and easily enables any application, regardless of size or hardware platform.

High

Performance

Secure, reliable design built from embedded-first principles maximizes uptime.

Smaller

Footprint

Optimized memory and CPU bandwidth enables OPC UA in any hardware or software product.

Scalable Scalable to all products – from the smallest MCUs to the most powerful multi-core CPUs.

Easy to Use Faster to market with drop-in 'OPC UA Server & Client Inbox' design.


ERP

MES Firewall

DCS FirewallHMI

ControllersControllers

Corporate Network

Operations Network

Plant Floor Network

Evolving Data Sharing Network Model

8

How It’s Implemented How It’s Used


Cloud Based Data Collection A Reality

9

Edge to Cloud connectivity making it possible to:

• Reduce IT costs

• Improve diagnostic visibility

OPC UA

Server

OPC UA

Server

OPC UA

Server

AM

QP

Clo

ud

Ga

tew

ay

Complex

Compute

Machine

Learning

At-Rest

Analytics

Near Real-

Time Analytics

Long-Term

Storage

Bu

sin

es

s In

teg

ratio

n

Bridge

OPC UA

Client

OPC UA

Client


Today

• ISA 99/95 (Perdue Model)

• Many data islands

• Large middle-tier

• High infrastructure cost

• Complex setup

• OPC UA = Differentiator

10

Level 3PCN

Level 3.5DMZ

Level 4+CORP

Level 3PCN

Level 3.5DMZ

Level 4+CORP

Level 3PCN

Level 3.5DMZ

Level 4+CORP

Level 4+

Corp

Level 3.5

DMZ

Level 3

PCN

Today Tomorrow Future


Tomorrow

• Perdue/IIoT Model

• Greater data visibility & context

• Shrinking middle-tier (Fog Computing)

• Cost savings

- Infrastructure

- Efficiencies

• OPC UA = Migration

11Today Tomorrow Future

Legacy

InfrastructureNew

Infrastructure

Phased

Migration

Proprietary

Device

Classic OPC

Server

Native

OPC

OPC UA

AMQP | MQTT + OPC UA

Cloud

Historian

IIoT HUB

IIoT Gateway

OPC UA

Wrapper

OPC UA

Device


Future12

Today

Tomorrow

Future

IIoT HUB

IIoT

Gateway

OPC UA

Device

OPC UA |Client/Server| PubSub

OPC UA PubSub | Native AMQP

OPC UA

DeviceOPC UA

DeviceOPC UA

Device

OPC UA PubSub

| Native AMQP

Analytics

OPC UA

Legacy

• IIoT Model / Perdue Model

• Data As Intelligence (Fog + Cloud)

• Optimized middle layer (Fog Computing)

• Cloud Historians collecting contextualized data

• Minimized costs

• OPC UA = Norm


Coming Soon: OPC UA Publish-Subscribe

• OPC UA Part 14 adds native

PubSub capabilities

• Enables:

- Highly scalable infrastructure

- Secure cloud connectivity

using AMQP

- High Speed data exchange

13Today Tomorrow Future

Subscriber

(Client)

Subscriber

(Client)

Subscriber

(Client)

Publisher/Sender

(Server)

Publisher/Sender

(Server)Relay

Broker

Option: Publish/Subscribe in the Cloud

Option: Secure Multicast

Cloud Application: AMQP

Local Application: UDP

Subscriber

(Client)

Subscriber

(Client)

Subscriber

(Client)

Subscriber

(Client)

Subscriber

(Client)


Example PoC: Data Connectivity

Platform/Shop Floor Environment)

Device1

OPC Classic

Server

OPC UA Tunneller

Cloud

Native

OPC

OPC UA

Cloud Data Storage (Data Lake)

OPC UA Component

Classic OPC Component

Non-OPC Component

Scalable Cloud based

data collector:

• Preserved Data Context =

easy reference, fast setup,

reduced errors:

• Device X

• Temp: 120

• EU: F

• Min: 80

• Max: 250

Benefit: Cost Reduction & Security

• Eliminate Middle ware PC

• Eliminate Windows Patching &

Antivirus upkeep costs

• Eliminate IT engagement

• Eliminate use of wrong data registers

using on-board human readable values

• Maximize Device ROI by extending

device lifespan

• Secure legacy devices that have no

built in security

Modbus

Device

UA

Modbus

Gateway

Modbus

Universal Data Interface (OPC UA)

IIoT Data Publisher

Consistent Data Model: Context preserved

Scalable Data Collection

IIoT Collector

IIoT Gateway


OEMPoCPhased Migration / Adoption

Putting OPC UA To Work

15

“Dark” Devices

Custom

Gateways

& Sensors

OPC UA

OPC UA Enabled

Devices

OPC UA

Windows PC

+ Classic OPC

OPC UA

Tunneller

Software

OPC UA

Classic OPC

Native Proprietary

Protocol

Industrial

Data Logger

OPC UA

Proprietary

Native Open

Protocol

UA

Modbus

Gateway

OPC UA

Modbus


Migration from OPC To OPC UA

using UA Tunneller (releasing in Q3 2017)

16


Classic OPC Client UA Server

17

PLCOPC UA

Server

Opc.tcp://192.168.10.2:4840

Modbus

TCP

OPC UAOPC UAServer

Opc.tcp://192.168.10.1:4840

PLC

Serial / TCP

OPC UA

OPC Classic

Client

Historian

Windows

UA Tunneller (client side)

OPC UAServerOPC UAServer

(COM/DCOM)

Classic OPC

OPC UA Client

HMI

OPC UA


UA Client Classic OPC Server

18

OPC Classic Server

OPC UA Client

PLC

HMI

UA Tunneller(Server side)

Classic OPC

OPC UA

Serial, TCP, etc.

Windows

(COM/DCOM)


Migrating Toward True Digital Business Transformation

19

Sub-net

Cloud• Digital Business Models

• Integrated Cloud + Edge (Fog Computing)

• From ‘Me’ to ‘We’ Ecosystems

• Smart Workforce - Augmented

• Legacy ROI + Migration

• Industry vertical silos

• Open data connectivity

• Data Security

Emerging Challenges

Existing Infrastructure

Today

OPC UAOPC UA

OPC UA

OPC UA OPC UAOPC UA

OPC UA

OPC UA


Conclusion

• Digital Business Transformation is a multistep process

• Fog Computing @ Edge

• Local Analytics

• Local Filtering – reduction of data noise/volume

• Cloud

• Improved Analytics

• Improved access across enterprise and eco system

• Workforce training/alignment

NEXT STEP: Start Your IIoT PoC

20

• UA Tunneller

• UA Modbus Gateway

• Industrial Data Logger

• Matrikon FLEX OPC UA SDK

• Industrial Data Logger

• IIoT Cloud collector

• IIoT HUB

OPC UA Data Connectivity benefits:

• Extended & secure visibility to Field/Shop Floor

• Context rich Data

• Ease of deployment and maintenance

• Reduction in IT and middleware costs

NEXT STEP: Start Phased Migration


21

Please visit www.MatrikonFlex.com

for more information and contact

information

http://www.matrikonflex.com/


22

Q&A

Thank you for your time

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