Softing (OLDI): Data Exchange Approaches for ControlLogix Controllers. Christophe Renard EMEA Sales Manager Softing

Transcription

1 Softing (OLDI): Data Exchange Approaches for ControlLogix Controllers Christophe Renard EMEA Sales Manager Softing

2 Softing Softing is a leading global provider of products for Industrial Automation and for Automotive Electronics. For over 30 years, the core business of Softing Industrial Automation has been industrial data communication between fieldbus devices, controllers, and hosts. Softing acquired OLDI in May OLDI is an Original Design Manufacturer (ODM) that designs and sells products with other brands as well as OLDI-branded products.

3 Softing in the Rockwell Encompass Program Sells Softing and OLDI branded products Products for Rockwell Authorized Distributors: Data Exchange Modules Communication and Protocol Modules Network Test Tools

4 Products sold through the Rockwell Automation Channel Move Data Run Custom Code Connect Certify 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

5 Topics - Data Exchange Approaches for ControlLogix Definitions Points to consider when choosing Data Transfer methods Computer-based OLDI tmanager OLDI OPC UA Server tmanager Customer Success Story: Bridgestone Tire Curing Production Monitoring Nemak Automotive Genealogy 5

6 Definitions

7 From Shop floor to Top Floor, You Need Data.. Data transfer - 2 basic categories: Download on what to make (aka Build-to-Order) Recipes Manufacturing instructions Upload on what is happening (aka Measure & Monitor) Track and trace of product OEE of equipment

8 Applications Enabled Include: Track and trace Recipes and build-to-order requirements Equipment configuration Measuring and control Sensor data reporting Feedback for OEE

9 Example: Stored Procedure Enterprise/Business/Plant System 3 Downloading of Instructions Control system triggers a transaction A stored procedure in the database downloads data to the control system. Main PAC/PLC (Data Concentrator) Data transfer Software/Hardware Enterprise Network 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 Scanner

10 Historian vs Transactional Data Historian (Time Series Data) Uni-directional..upload only Large volume of data very quickly FactoryTalk Historian ME..as fast as 10ms and 2500 events/sec Compresses data significantly to reduce the amount of memory needed Relatively simple data (pressure, temp etc.) Transactional (Relational Data) Bi-directional Used for storing process and production data as records and relationships such as product recipes, units, machines, orders, order lines, batches, etc. Can retrieve complex relationships of data records quickly Supports retrieval of multiple records from a table or view There is room for both in a good plant data model but this presentation will focus on Transactional Data

11 Points to consider when choosing

12 Points to Consider When Choosing an Approach to transfer Transactional Data Part 1 Architecture Do you have a single or multi-vendor installation? How many sources of data and recipients of data? What are your local data storage needs? (e.g. 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? Computers and Software Are there existing computing platforms in the system? (e.g. HMI or Enterprise) Have software updates and patches been an issue? Viruses/ Malware Ownership of factory-floor computing

13 Points to Consider When Choosing an Approach to transfer Transactional Data Part 2 Security Are you trying to improve your system security? How to you control access to: Transactional Data System Configuration How is the data sent? 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 and related)

14 Points to Consider When Choosing an Approach to transfer Transactional Data Part 3 Support, Maintenance Who will set-up the initial data transfer solution? Maintain it? Are multiple companies involved? (e.g.si then End-User) How often will the data transfer configuration be changed? Do you want notification of system or data transfer status? 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? Have there been any maintenance or cost issues by having a separate computer or server?

15 Data Transfer methods

16 Computer-Based Data Transfer Custom Code or Scripting 22

17 Computer-Based Data Transfer Custom Code or Scripting (or dedicated software) Advantages For fully custom code, ultimate flexibility..limited only by the creativity of the programmer. VB and scripting can be part of another package (e.g. HMI) Leverages 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? 23

18 Computer-Based Data Transfer Custom Code or Scripting (or dedicated software) 24

19 OLDI tmanager Module 25

20 Data Transfer with OLDI tmanager 26

21 Data Transfer with OLDI tmanager 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 Single CompactFlash for all configuration information Fast system restore after shutdowns Fast module swap out Disadvantages PLC module form factor limits available memory and CPU power 27

22 tmanager Module vs PC/SW-Based Solutions Characteristic Plant Floor Maintainable Security Software Update Control OLDI tmanager Dedicated Device, Spare Parts, Single File Restore Excellent access only via GUI; w/ password protection; no remote desktop, FTP or other access means Excellent no forced updates Separate Computer with OPC, Custom SW or Packaged SW Potentially complex requiring involvement of Plant and IT Poor to Excellent Depends on IT process and discipline Flexibility to configuration change Easy.change-on-the-fly with GUI Requires SQL expertise Total Cost of Operation Store and Forward Database Failover Notification of Errors and Warnings Automatic Logging Low.single module (includes configuration software) + person to configure Yes Yes Yes Yes Med to High.external computer + operating system + application(s) software + people to program Not Available with OPC Could be written with custom software 28

23 eatm Enterprise Appliance Transaction Modules ControlLogix and CompactLogix versions Available for two types of data handling tmanager for complete end-to-end data handling OPC UA Server for OPC UA Client/Server systems

24 eatm Product Overview Configurable, dedicated modules used for Data Exchange No PLC code modification Industrialized packaging Replace software/pc-based solutions Data exchange handled in the controller chassis Bi-directional transfer of Transactional information Enterprise Network No code development or management Data exchange is configured via straightforward mapping with a drag and drop GUI No need to deal with O/S upgrades, patches or viruses Reduce installation and maintenance costs

25 tmanager Configure & Go Data Transfers Computer Adapters Database Microsoft SQL Oracle MySQL Excel/Access IBM DB2 AS400 System i Messaging Red Hat Jboss JMS IBM WAS JMS Communication TCP/UDP FTP Bi-Directional Ethernet tmanager Module Maps /Triggers Store & Forward Database Failover Audit Logs Transaction Logs Ethernet or Rockwell Bridges New Installations or Add to Existing Systems Controllers ControlLogix PLC-5 Rockwell Automation MicroLogix CompactLogix SLC 500 Schneider Quantum Siemens S7-300 or S7-400

26 eatm OPC UA Server Module for ControlLogix 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) 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) For customers seeking OPC UA Server connection with a dedicated in-chassis module 32

27 Configuration example

28 Configurable Elements Automatically Found What You Define/Configure Database Tables Message Paths Triggers PLC Tags Maps Endpoints

29 tmanager Configuration Software Drag and Drop to Map Data

30 Store & Forward Data written to compact flash if communication is interrupted, and written to the original destination once communication is resumed Optional notification

31 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

32 Industries Automotive & Construction Equipment Tire & Rubber Oil & Gas Food & Beverage Material Handling & Packaging Metals & Mining Life Sciences & Pharma Other Machinery & Equipment

33 tmanager Customer Success Story

34 tmanager: Tire Curing Data Collection Challenge: Implement an automatic system to collect process data (M/C status, press open and close, curing time, cycle counter ) from 120 curing presses and upload to a central Oracle database. Bridgestone Italia S.p.A.

35 tmanager: Tire Curing Data Collection Solution: A PLC installed on each Press formats the data in a single array of values [35] and sends this array to the PLC Gateway. The PLC Gateway collects data into a bi-dimensional array [120,35]. When key elements change in the array, tmanager raises a Trigger that calls a stored procedure in order to manage and store data. Press 1 Press 2 Press 3 Press 120 PLC Gateway with tmanager tmanager Triggers Triggers from tmanager call Stored Procedure for managing and storing data into Oracle DataBase ORACLE DataBase Bridgestone Italia S.p.A.

36 Results and Why Chosen? Process Parameters Management Plug & Play Hardware Faster Data Exchange Robustness Auto enumeration

37 About NEMAK Founded in 1979 Aluminium powertrain components production 35 manufacturing facilities in 14 different countries 20,000 people worldwide Revenue 2012 US$3.9 billion

38 Nemak - Production Process Aluminium Melting Casting Finishing Quality Control Finished Product Resins & Sands Cores Sand Recycling Cylinder Head Engine Block Transmission Other Components Components

39 Nemak - Production Process Aluminium Melting Casting Finishing Quality Control Finished Product Resins & Sands Cores Sand Recycling

40 Nemak - Transactions Lookup Lookup Lookup Aluminium Melting Casting Finishing Quality Control Finished Product Resins & Sands Cores Sand Recycling Storage Storage Storage Birth Certificate

41 The Challenge Global project - Automotive Aluminum engine parts Requirements: Real Time data for each part produced Unique ID Complete tracking and tracing Birth certificate Equipment used Connectivity to legacy controllers Replace Visual basic scripting in SCADA Buffering of data in case of lost wireless communication

42 Plant Overview (Before)

43 Plant Overview (After)

44 Finishing Line - Plant 2 (Before) Línea Fiat Fire Gage 6.2 Línea Ford 5.0 Carga Impactores Sierra Gage 6.2 Rebabeo Impactores Sierra Línea Ford 6.2 Sierra1 Impactor Impactor Línea GM Carga GateWay & tmanager Cubado AirDecay Calidad

45 Finishing Line - Plant 2 (After) Windows 2008 R2 SQL Server 2008 R2 NORIS Gage 6.2 Línea Ford 5.0 Carga Impactores Sierra Gage 6.2 Línea Fiat Fire Rebabeo Impactores Sierra GateWay Ford 5.0 Windows 2008 R2 SQL Server 2008 R2 NORIS GateWay & tmanager Línea Ford 6.2 Impactor Sierra1 Impactor Carga GateWay & tmanager Cubado AirDecay Calidad Línea GM

46 The results Realtime Data Validated transaction Disaster recovery plan

47 Why did Nemak choose tmanager Off-the-shelf GUI configuration Hardware solution Data Security Support for all Allen-Bradley PACs/PLCs

48 Questions?