IBM Integration Bus Manufacturing Pack

IBM Integration Bus Manufacturing Pack
Dom

Please Note IBM’s statements regarding its plans, directions, and intent are subject to change or withdrawal without notice at IBM’s sole discretion. Information regarding potential future products is intended to outline our general product direction and it should not be relied on in making a purchasing decision. The information mentioned regarding potential future products is not a commitment, promise, or legal obligation to deliver any material, code or functionality. Information about potential future products may not be incorporated into any contract. The development, release, and timing of any future features or functionality described for our products remains at our sole discretion. Performance is based on measurements and projections using standard IBM benchmarks in a controlled environment. The actual throughput or performance that any user will experience will vary depending upon many factors, including considerations such as the amount of multiprogramming in the user’s job stream, the I/O configuration, the storage configuration, and the workload processed. Therefore, no assurance can be given that an individual user will achieve results similar to those stated here.

Agenda Background to Manufacturing Integration
Standards Technologies Products IBM Integration Bus Manufacturing Pack

Industrie 4.0 Industrie 4.0 is a German government strategy for promoting the computerization of traditional industries such as manufacturing. The 4.0 is refers to a heralded fourth great industrial revolution Industrial Revolution 1 – mechanisation of production using water and steam power (coal!) Industrial Revolution 2 – Mass production using electricity Industrial Revolution 3 – The digital revolution (electronics and IT) Industrial Revolution 4 – Machine To Machine communication, SOA loose coupling Industrie 4.0 is aimed at producing “Smarter Factories” which: Are more adaptable e.g. logistics processes which can automatically react to unexpected changes in production levels Are more easily configurable and connected to back-end enterprise functions Use resources more efficiently e.g. machines that predict failures, trigger maintenance processes autonomously SMLC enables stakeholders in the smart manufacturing industry to form collaborative R & D, implementation and advocacy teams for development of the approaches, standards, platforms and shared infrastructure that facilitate the broad adoption of manufacturing intelligence. The SMLC is a non-profit organization committed to overcome barriers to the development and deployment of Smart Manufacturing (SM) Systems through an implementation agenda for building a scaled, shared infrastructure called the Smart Manufacturing Platform (SM Platform). SMLC activities are built around industry- driven development, application and scaling of a shared infrastructure that will achieve transformational economic-wide impact, manufacturing innovation and global competitiveness. SMLC supports the manufacturing industry through pursuing a comprehensive technology that no one company can undertake. Without a modern industrial infrastructure, adoption of SM Systems is not economically viable. Process control and automation systems implemented in piecemeal fashion will continue to limit innovation and capability. SMLC will build the business, interoperability and technology models, demonstrations, infrastructure, and project teams across multiple industry segments. SMLC is a non-profit organization whose membership is available to industry, university, government laboratory, independent consultant and organization / consortia. SMLC Smart Manufacturing Leadership Coalition “SMLC supports the manufacturing industry through pursuing a comprehensive technology that no one company can undertake. Process control and automation systems implemented in piecemeal fashion will continue to limit innovation and capability. SMLC will build the business, interoperability and technology models, demonstrations, infrastructure, and project teams across multiple industry segments.”

The Aim: Industrial Process Control
Monitoring Predicting Deciding Integrating OPC SAP BAPI SCADA OPC 1. OPC events from the manufacturing plant floor report the current power consumption of the machinery. [Blue] 2. Monitoring displays summary data in a Web UI. [Yellow] 3. SCADA events from the machinery report its current operational temperature. [Blue] 4. OPC events from the machinery report its current vibrations. [Blue] 5. Power consumption, temperature and rate of vibration Events are sent to the Analytics engine. [Green] 6. A prediction is made regarding the likelihood of imminent machinery / part failure. [Red] 7. Based on the prediction the Rules engine decides whether to pre-emptively order a replacement. [Industry Red] Power Consumption Temperature Vibration RPM Order Part

Manufacturing Landscape
Corporate Applications ERP, Production Scheduling Product Quality Management Portal Web Apps (internal) Supply Chain Management Dynamics Oracle SAP Analytics Decision Management Asset Management IDOC, BAPI Proprietary XML ODBC JDBC SQL Web Services IDOC, BAPI SQL Web Services SOAP, XML Web Services Proprietary interfaces Web Services HTTP, JMS File, SQL Web Services SOAP XML IBM Integration Bus Manufacturing Pack OPC DA OPC HDA OPC AE OPC UA OPC B2MML Web Services SCADA Web Services HTTP / JSON MQTT OPC Classic Server (including Historian) OPC UA Server (including Historian) Manufacturing Execution Systems Remote Telemetry Unit Plant Staff Mobile Applications Remote Site (satellite link)

IBM Integration Bus Industry Packs
Each pack is a fully supported software product, independently delivered from IBM Integration Bus The purpose of an IIB Industry Pack is to provide industry-specific development accelerators which solve common industry integration problems Help users to deploy working integration solutions in literally a few clicks of the mouse. IIB Industry Pack content is structured around three delivery pillars: Connectors Data Definitions Integration Patterns Monitoring Association for Retail Technology Standards Open Applications Group Data Format Description Language Open Grid Forum Health Level 7 Digital Imaging and Communication in Medicine

Manufacturing Pack High Level Architecture

Some Industrie 4.0 enabled devices
PLC (Programmable Logic controllers) Talk to sensors and actuators More actuators and sensors being built with in built Industrie 4.0 capability Integrated OPC Servers

What does the Manufacturing Pack provide?
Contains several moving parts OPC UA Read Node/ OPC UA Input Node PI Read Node/ PI Input Node MQTT Nodes Factory Pattern Web UI Operational Monitoring Manufacturing Integration Monitoring

The OPC Foundation App A App B App A App B Server 1 Server 2 Server 3
The OPC Foundation is a non-profit organization that maintains specifications on behalf of the industry. Total OPC market has 2,500+ vendors, providing 15,000+ OPC enabled products. OPC Foundation product catalog provides 1,500+ OPC enabled products The 1st specification, released in 1996 was for OPC Data Access The 2nd specification, released in 1998 was for OPC Historical Data Access The 3rd specification, released in 1999 was for OPC Alarms & Events Most universally accepted standard for data exchange between: SCADA and HMI Systems PC-based control systems Manufacturing Execution Systems Quick adoption of the original OPC Data Access specification was driven by: Windows Component Object Model (COM) and Distributed Component Object Model (DCOM) Europe (43%) North America (39%) Asia (13%) Others (5%) App A App B App A App B Server 1 Server 2 Server 3 OPC OPC OPC Server 1 OPC Server 2 OPC Server 3

OPC Unified Architecture
The purpose of the OPC Unified Architecture was to enable a platform independent interoperability standard for moving data between the factory floor and the enterprise. Contributions from over 30 companies over 5 years. Specification first published in 2009 Original premise built on the existing OPC DA COM / DCOM based specifications BUT improved some of its flaws: Platform dependence on Microsoft Insufficient data models Inadequate security No reinvention! Standard builds upon other existing standards UA + + Most common services offered by an OPC UA Server: Discovery – Servers provide a Discovery Endpoint which can be accessed directly or through a discovery server. Profile Support – So client devices can decide if the server can support their needs – eg XML / Binary encoding and Security Address Space – Read properties of the available nodes, and read and write attributes of the variable type nodes. Notification / Subscription – A client can define a set of nodes which the server monitors for a specified condition(s) which triggers a notification OPC UA Server OPC UA is the new generation of technology generated by the OPC Foundation for the secure, reliable and vendor-neutral transport of raw data and pre-processed infoamtion from the sensor and field level up to the manufacturing level and into the production planning or ERP syste. It is independent from the programming language in which the applications were developed, independent from the operating system on which the software is used, and independent of the maufacturer from which the applications originate. OPC UA is no longer based on DCOM but has been conceived on the basis of a service oriented architecture. OPC UA uses an optimized TCP-based UA binary protocol for data exchange with a standard IANA defined port “4840”; Web Services and HTTP are additionally supported. It is sufficient to just open a single port in a firewall to integrate. Integrated security mechanisms ensure secure communication via the internet. Security mechanisms use X509 certificates, OpenSSL encryption, User / password and Access rights for each attribute Requests Client Responses Server Notifications OPC UA Client

OPC Unified Architecture
OPC UA Server OPC UA AddressSpace Node Node Node Monitored Item Node Node Node Node Subscription Node View Node OPC UA Server API Request Response OPC UA Communication Stack Subscribe Notify From OPC UA Client To OPC UA Client From OPC UA Client To OPC UA Client

OSIsoft PI Server PI Server OSIsoft PI Server
The PI System collects, stores, and manages data from your plant or process. You connect your data sources to one or more PI interface nodes. Interface nodes retrieve data from your data sources and send it to one or more PI Servers. Interface Nodes: Interface nodes run PI interfaces. PI interfaces get the data from the data sources and send it to the PI Server. Each different data source needs a PI interface that can interpret it. OSIsoft has over 300 different interfaces. PI Server Nodes: The PI Server stores the data and acts as a data server for Microsoft Windows-based client applications. You can also use the PI Server to interact with data that is stored in external systems, that is data that is not generated by the PI System. The PI Server is the heart of your PI System. It gets the data and routes it in real time throughout the PI System and your entire information infrastructure, making it possible for everyone to work from a common set of real-time data. Operators, engineers, managers, and other plant personnel can use client applications to connect to the PI server and view manufacturing data from the PI data archives or from external data storage systems. PI Server typically runs on a separate computer from those that run PI interfaces and client applications. This distributed data collection architecture is scalable, robust, and flexible. When the high availability (HA) architecture is used, the PI server runs on two or more computers that are automatically synchronized and act as one logical PI server, called a PI server collective. These computers can be geographically dispersed. OSIsoft provides two tools for creating and editing PI AF objects: • PI System Explorer (PSE) provides a graphical user interface for creating, editing and managing PI AF objects. Use PSE to create and manage your asset framework including PI AF databases elements, templates, and all other PI AF objects. If you are new to PI AF, start with PSE. To open PSE from the Windows Start Menu, choose All Programs > PI System > PI System Explorer. • PI AF Builder is a Microsoft Excel add-in that allows you to work with PI AF objects in bulk. For more on PI AF Builder, see the PI AF Builder User Guide. In addition, many PI client applications allow users to view PI AF elements and attributes. An element is basically the same thing as a PI “Asset”. A PI AF Asset has “PI AF Attributes”. An example of an attribute could be the temperature of a building, or the square footage. An example of an attribute of a tank could be the capacity, or how full it is Pump – rotations per minute, when it was installed, calendar date of last maintenance. An attribute is something we could then graph or put in an or spreadsheet etc. Attributes have a type … could refer to a constant value … such as capacity of a tank. It is set and never changes. Constants. “Formula” is a result of a calculation. So the cylindrical volume of a tank is the height multiplied by the surface area … hence formular requied “Table lookup” … this is an example of pulling data from an external source such as a calendar of when maintenance was done. A PI Point is the storage point for real-time data. A PI Tag is the same as a PI Point. PI Tag is an example of a PI AF Attribute. It’s a way of storing data in realtime. All PI Tags can be graphed against time. For decades the PI System was built on PI Tags. Gradually adding other kinds of PI AF Attributes has expanded PI Server capability. “Point Type”: PI Tags can be Decimal / Float, Integers, Boolean, Blob, String, Digital states Every PI Tag has a name … It is a unique string name Point Source (refers to where the data is coming from) Description PI AF Assets can be replicated using the concept of a template. PI Clients: PI DataLink, PI ProcessBook, PI CoreSight, PI DataAccess, PI ProcessBook ================ PI System Explorer used to be called the AF Explorer Elements are the building blocks of PI AF. Elements can represent: Physical objects, such as pumps or tanks. Physical objects are typically pieces of equipment. To associate data with an element, you create attributes on the element. Building-block objects, for organizing your data. When you have a lot of elements representing physical objects, you need to set up a logical tree structure to organize them. For example, in the following figure, The Equipment List element, and the Pumps, Tanks, Flow Meters, Heat Exchangers, and Reactors elements are all structural elements. They might or might not have associated data but their primary purpose is to make it easy to find the equipment elements and to provide a bigger picture of what assets are available. Similarly, the elements SL Tank 001, SL Tank 002, and SL Tank 003 represent specific pieces of equipment. OSIsoft PI Server Founded in 1980, HQ San Leandro California: professionals, 15,000+ customer installations across 110+ countries Approximately $270million revenue, 50% North America PI Server has developed 400+ interfaces designed to gather data from SCADA sources, convert to a PI readable format and then send it to the PI Server to be stored. Example interfaces are OPC, Modbus and PLCs. Typically PI Server runs on a separate computer from PI Interfaces and PI Client Applications. A PI Server “Collective” describes an HA grouping of PI Servers which can be considered as a single logical entity. PI Server “interfaces” “outerfaces” OSIsoft PI Server Elements are the building blocks of a PI System. Structural elements can be arranged into a hierarchy, to represent a set of organized objects. Equipment List, Pumps, Tanks, Flow Meters Heat Exchangers and Reactors are all structural elements.

OSIsoft PI Tags π r2 h PI AF Asset h PI AF Asset Attribute Water Tank Max Height Water Tank Max Volume Pump Rotations per min Oil Temp PI AF Asset Type Constant Formula Float Int32 A PI Tag / Point is a storage point for real-time data. A PI Tag is an example of a PI Asset Framework Attribute. All PI Tags can be graphed against time. Every PI Tag defined by a given PI Server, has a unique name PI Tags have been the foundation of the PI System since its original version was released. The PointType attribute (assigned at creation time) specifies its data type. For example, Digital (enumerations), Int16, Int32, Float16, Float32, Float64, String, Blob, Timestamp The PointSource attribute is a string that associates a tag with an interface or PI application. An interface uses the point source to retrieve all its points. The Descriptor is a text field that appears on various client application displays, and can be used in reports. It can be any length up to 65,535 characters. PI AF Assets can be replicated using the concept of a template. PI Server is all about taking assets which you own and discovering information from them which you want to know … So you might own water tanks, pumps, You might want to know what the RPM of a pump is, what the temperature is like in the building and get a notification if it goes too high. So how do we get this information? How is the information organised in the PI System (which is actual stored in a SWL software PI Assets, PI Asset Attributes and PI Tags. AF means Asset Framework. A PI Asset is something which we can graph. Attriubutes have a variety of types … they could be a constant value, so the water tank’s maximum height does not change. You can also deine an asset type of formula which can be calculated The first step is to take the concrete items we have and give them representations in the database: Such as a Water Tank for example, or Oil Barrel, or a Pump. You can then express a further hierarchy underneath these representations and express the whole lot in a tree structure in the PI System Tools. So the PI Asset can be an organisational entity or Another word for a PI Asset is a PI Element. They are the same thing. You cant just chart “Pump” or “Tank”, so next we need some way of describing the physical entity … This is where PI AF Attributes come in. A PI AF Attribute is something which helps us describe the Asset. So for example we can describe the Temperature of the oil, the capacity of the tank, or the number of rotations per minute for the pump, or the installation date, or the calendar date when we last did maintenance on the pump. You can also pull information in from remote A PI Point is the item which stors real time data.

MQTT MQTT (MQ Telemetry Transport) is a publish / subscribe based, lightweight messaging protocol. Original design principles are to minimise network bandwidth and device resource requirements whilst attempting to ensure reliability and some degree of delivery assurance. Ideally suited to the emerging Internet of Things and for mobile applications where bandwidth and battery power are very important. A WebSphere MQ Server can handle up to 100,000 concurrent MQTT connections MQTT stands for MQ Telemetry Transport. It is a publish/subscribe, extremely simple and lightweight messaging protocol, designed for constrained devices and low-bandwidth, high-latency or unreliable networks. The design principles are to minimise network bandwidth and device resource requirements whilst also attempting to ensure reliability and some degree of assurance of delivery. These principles also turn out to make the protocol ideal of the emerging “machine-to-machine” (M2M) or “Internet of Things” world of connected devices, and for mobile applications where bandwidth and battery power are at a premium. IBM WebSphere MQ has long served as a reliable, universal messaging backbone enabling any-to-any connectivity. It runs on wide variety of platforms, has a number of language bindings, and a stable, backward- compatible API. It has become the accepted method of gluing disparate applications together. The piece that has been missing until recently is the ability to reliably connect the edges, the frontiers of the data network. Systems already exist that understand what actions to take based on the status of remote devices. However, communicating that status to the system has been a challenge, particularly if the network is constrained or if the device lacks the computational power required for traditional messaging. With MQTT, smart energy meters, industrial control systems, satellite receivers, healthcare monitoring devices, and sensors on everything from planes to trains to automobiles can communicate with each other and with other systems or applications. WebSphere MQ Telemetry is a feature of WebSphere MQ that extends the universal messaging backbone with the MQTT protocol to a wide range of remote sensors, actuators and telemetry devices. It enables instrumented devices that are located virtually anywhere in the world to connect to each other, and to enterprise applications and web services, with WebSphere MQ. The use of MQTT extends WebSphere MQ to remote devices and enables massive scalability. A WebSphere MQ Server can handle up to 100,000 concurrent MQTT connections. Eclipse PAHO MQTT open source project 2004 MQTT.org open community 2013 – MQTT Technical Committee formed

MQTT: Open Technologies for Integration
IIB initiative to develop integration components as open source Source freely available on popular Github website under flexible Eclipse Public License Community contributions (including modifications) actively encouraged! Fully supported technologies delivered into IIB as appropriate Initial contributions MQTT Client connectors Easy-to-use inbound and output connectors to MQTT servers Uses open framework for platform-independent connectors DFDL Schemas for popular industry formats E.g. HL7, ISO8583, IBM4690-TLOG, NACHA … more to come … Show / explain concept of MQTT nodes & the connector framework

MQTT and Remote Data Sources
Low-power, low-bandwidth / PLCs and RTUs Oil Storage Temperature Pressure Flow Control Upstream Center of Operation and Control Distance = > 250 km WAN Head office IT Corporate Infrastructure

Manufacturing Pack OPC UA Read Node
Connects at invocation to an OPC UA sever to retrieve tag values Is driven by any input node Can connect securely with SSL 'opc.tcp' style connection only Can replace incoming Message or use Local Environment Any unfound tags sent to failure terminal or event log

Manufacturing Pack OPC UA Input Node
Polls a OPC UA Server for tags Subscription based Any unfound tags are sent to the failure terminal or syslog Catch terminal handles up flow thrown exceptions

Manufacturing Pack OPC UA Discovery
Can dynamically connect to OPC UA sever to retrieve valid tags at design time Used to configure the node Can connect securely with SSL 'opc.tcp' style connection only Also used in the pattern for the OPC UA Input

Manufacturing Pack PI Read Node
Connect to your PI Server to retrieve series of PI Point tags Uses the PI SDK which comes with the PI Clients to handle the connection (So can be used with older PI Servers) All nodes output in the same style XML

Manufacturing Pack PI Input Node
Connect to your PI Server to subscribe to PI Point tag changes Uses the PI AF SDK Wildcard * support for tags

Manufacturing Pack Nodes TagData.xsd
Output of the Manufacturing nodes Common for all Manufacturing nodes Schema shipped in pattern: enables validation, with null support

Manufacturing Pack Factory Pattern
Use the Factory Pattern to expose your sensors Produces IIB artifacts in a few clicks

Manufacturing Pack Web UI

Questions? . Dom Storey

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Backup charts...

The second machine age .. Andrew McAffee, Erik Brynjolfsson
Historical characters - Matthew Boulton ( ) Industrialist and Entrepreneur Matthew Boulton, born in Birmingham, was a leading entrepreneur of the Industrial Revolution. He became renowned in two main fields of activity: the development, production and sale of steam engines and the minting of high quality coins. James Watt ( ) Engineer and Scientist James Watt, born in Greenock, Scotland, was the great improver of the steam engine. His work reduced the steam wastage inherent in earlier designs and delivered considerable efficiencies. Watt also introduced the term 'horsepower' and the metric unit of power is named after him. In 1775 Boulton and Watt entered a partnership to develop and market steam engines. Initially these were for use in the mining and textile industries before they extended the innovation to benefit a wider range of industries in the UK and worldwide. Boulton and Watt were members of the Lunar Society, which helped to foster links between philosophy, arts, science and commerce.

Business Imperatives in Manufacturing
The Manufacturing world is moving from Mass Automation to Mass Customisation The importance of capturing the “green dollar” – climate and eco-sensitive consumers Demands for increased resource efficiency Scheduling of production processes for optimal use of resources Production Performance Analysis. Equipment effectiveness and predictive maintenance. Increased competition means manufacturers need to become increasingly dynamic – highly responsive and re-configurable production facilities Efficient despatch of production orders Impact of BRIC and MINT economies and emergent middle class Globalisation of supply chains, global competition with lower labour costs The term Mass Customisation was first coined by Stan Davis as long ago as 1987 in his publication Future Perfect. Brazil, Russia, India, China Mexico, Indonesia, Nigeria, Turkey Optimising resources: The National Science and Technology Council in the United States estimates that commercial and residential buildings consume a third of the world's energy. In North America, for example, this translates to 72 percent of the electricity generation, 12 percent of the water use, and 60 percent of non-industrial waste. [IBM website] Energy statistic: If worldwide energy-use trends continue, buildings will become the largest consumer of global energy by 2025―more than the transportation and industrial sectors combined. And waste as much as half of the electricity and water that they use. $

Manufacturing - Business Problems and IT Solutions
Social is driving up expectations of real-time availability, data accuracy and types of information available across Enterprise and Supply Chain Production locations are typically isolated and heavily silo-ed from IT Enterprise. Highly heterogeneous systems environments; no two locations the same π r2 h Factory Mine IIB Need to make detailed operational information available to an ever increasing range of consuming applications and users without compromising production efficiency Rig Security through physical system isolation is no longer viable Market drive to exploit advances in IT Security, distributed and virtualised IT solutions

IIB in a Manufacturing Context
IIB provides a range of licenced offerings which allow a user to select their required level of functional capability and scalability. Standard Advanced Scale Express Capacity Capability IIB Industry Packs help to increase the product’s appeal to integration specialists from particular Lines of Business. Manufacturing Integration Specialists: Responsible for developing and maintaining operation systems at manufacturing locations. Have knowledge of OPC and operational production automation systems May not be familiar with Enterprise integration products Need to create, deploy and manage solutions to integrate plant floor and enterprise systems Enterprise Cloud Factory Factory

Manufacturing and IBM Integration Bus
IIB and Manufacturing Statement of Direction released on 22nd April 2014 Plant Connectivity De Facto Standards Connectors and patterns that support current OPC industry standards for integration of plant and machinery data and events, including a small number of vendor-specific implementations Plant Connectivity Emerging Standards Support for emerging OPC Unified Architecture standards to allow broader integration to the enterprise Enterprise Connectivity Integrations and connectors, including MQ Telemetry Transport (MQTT), which facilitate the transmission of data from remote locations Web-based interface to provide operational views of data published from plant and machinery OPC Classic OPC UA Vendor Specific MQTT Statements regarding IBM plans, directions, and intent are subject to change or withdrawal without notice at IBM's sole discretion. Information regarding potential future products is intended to outline our general product direction and it should not be relied on in making a purchasing decision. The information mentioned regarding potential future products is not a commitment, promise, or legal obligation to deliver any material, code, or functionality. Information about potential future products may not be incorporated into any contract. The development, release, and timing of any future features or functionality described for our products remains at our sole discretion.

The PI System Explorer The PI System Explorer allows an administrator to quickly and easily search through the Element hierarchy to locate a PI AF Asset (PI Element – same thing!) Searches can be made to cover multiple levels in the hierarchy Attributes tab shows deeper property information Element Templates Elements can be based on templates. When based on an element template, the element derives its initial definition of categories, attributes, and ports from the template. If the template later changes, then those changes are propagated to all elements created from that template. If the template allows it, then the element's categories, ports, and attributes can be augmented with additional members. An element template defines all the necessary attributes and properties for the role of an element in a model, model analysis, or other applications. When you create an element based on a template, the element gets this configuration automatically, from the template. Element templates make creating displays, notifications, calculations, and analytics much simpler because equipment of the same type can share the implementation. Element templates can specify the allowed parent and child references (Parent Reference Types and Child Reference Types) for an element that is created from the template. This restricts the allowed relationships between elements in the hierarchy

OPC Data Access OPC DA, or OPC Classic as it is sometimes known, was born in the 1990s – system integrators in the manufacturing industry were trying to incorporate the PC into factory floor applications using serial port connections. Any application using a serial device was a candidate for a PC to replace a PLC, but there was heavy dependence on writing drivers for the serial devices! Mission: create a way for applications to get at data inside an automation device without having to know anything about how the device works OPC Server Vendor A The OPC Foundation provided a solution by combining Windows COM with an API for device protocols. Vendor explosion providing OPC Servers OSIsoft, Matrikon, Kepware, Honeywell Vendor code determines the devices and data which the server can access, details for how it does this, and naming conventions for the OPC resources OPC Server Vendor B OPC Client OPC Server Vendor C A Programmable Logic Controller, PLC or Programmable Controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, orlight fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory. Application Logic Application Logic Item 2: Value, Quality, Timestamp Item 3: Value, Quality, Timestamp Item 1: Value, Quality, Timestamp Group (public | local) COM interface COM interface MICROSOFT COM COM interface OPC Data Proprietary Driver Serial Device

OPC Historical Data Access
OPC DA provides access to real-time, continually changing data OPC HDA provides access to data which has already been stored by the OPC Server An OPCHDAServer object created in the server by an OPC client connection Read and Update (insert, replace, delete) methods An OPCHDABrowser object created in the server by an OPC client connection Browse methods for navigating and querying the available data Device OPC Client Historian HMI Historical Data can be retrieved in 3 ways: Read variable(s) for specified timestamps Read raw data from the archive where the client defines the variable(s) and a time domain and the server returns all values archived for the specified time range up to the maximum number of values defined by the client. Compute aggregate values for variable(s) for specified time domain Device OPC Client Device OPC Client h Height of Water Level in Tank 1 Max return 5 T17:30:00 T17:31:00 HWLT1[1] = metres T17:30:05 HWLT1[2] = metres T17:30:20 HWLT1[3] = metres T17:30:35 HWLT1[4] = metres T17:30:50

OPC Alarms & Events A condition is a named state of the Event Server, or of one of its contained Items, which is of interest to its Client e.g. The level of a tank. An alarm is a notification that a condition has changed state e.g. The level of a tank has exceeded a defined maximum threshold. Many alarms include the requirement that they must be acknowledged. An event is a detectable occurrence which is of significance to the Event Server, the device it represents, and its OPC Clients. An event may or may not be associated with a condition e.g. set point changes, informational messages, logins and operator requests. There are three COM objects associated with the implementation of an OPC Alarms and Events server: OPCEventServer OPCEventSubscription OPCEventAreaBrowser Severity value provides an indication of urgency or priority. Range from 1 (lowest) to (highest) A client can limit the quantity of events by setting filter criteria e.g. filter by event types, by priority or by event source.

OPC Classic versus OPC UA
OPC Overview OPC Security OPC Common Alarms & Events Historical DA Data Access Data Transport Security Information Modelling Alarm Management Trend Display OPC A&E Client OPC HDA Client COM / DCOM DA OPC UA Base Vendor Specific Extensions AC HA Prog Specifications of Information Models of other organizations OPC A&E Server OPC HDA Server OPC DA Client COM / DCOM OPC DA Server OPC DA Server Vendor Specific Vendor Specific PLC DCS

OPC UA Application Architecture
00 05 O P C U A 5 <LocalizedText> <Locale>EN</Locale> <Text>OPCUA</Text> </LocalizedText> Application Code Client API Server API OPC UA SDK Subscriptions Nodes Sessions Alarms Events History Client API Server API Binary, XML Encoding OPC UA Stack NONE, SIGN, SIGN+ENCRYPT UA-SecureConversation WS-SecureConversation Security Transport Transmits and receives messages in the network layer e.g. Attaches / Detaches transport headers and verifies transmission lengths C or .NET or Java Platform Specific

OPC UA Communication Stack
The OPC UA specification defines abstract services following Service Oriented Architecture principles The Specification defines protocol bindings to map these services to a network transport. Four protocol bindings combination of Encoding (XML / Binary), Security, Transport and Network: Native UA Binary (mandatory) HTTPS with UA Binary HTTPS with SOAP and XML Encoding HTTP with SOAP and WS SecureConversation and XML Encoding UA Binary UA XML UA Secure Conversation WS Secure Conversation The OPC UA specification defines abstract services following Service Oriented Architecture. The Specification defines protocol bindings to map these services to a network transport. Currently there are four protocol bindings defined. The mandatory UA Binary protocol is intended to be used by all UA enabled software and devices. It is highly optimized and very fast, hence is the preferred protocol between embedded devices, SCADA/HMI level devices and DCS systems. TCP port is reserved for OPC UA Binary transport. The “Hybrid” protocol runs UA Binary Encoded content inside an HTTPS message. Instead of message based security this binding uses TLS encrypted transport security. UA TCP SOAP HTTPS HTTP TCP/IP 4840 443 443 80

Encoded Service Message
OPC UA Security Message Header Security Sequence Encoded Service Message Footer Padding | Sig Signed Encrypted Application Session Secure Channel UA Client UA Stack Transport UA Stack UA Server

OPC UA Secure Channel OPC UA Server OPC UA Client DiscoveryEndpoint
SessionEndpoint ValidationAuthority GetEndpointsRequest GetEndpointsResponse Validate Server Application Instance Certificate Validation Results Validation Results Validate Client Application Instance Certificate OpenSecureChannelRequest OpenSecureChannelResponse OpenSecureChannelRequest: If SIGN: Signed by Private Key of the Application Instance Certificate of the Client If SIGN_AND_ENCRYPT: Also Encrypted using Public Key of the Application Instance Certificate of the Server GetEndpointsResponse contains: Choice of Security Mode: NONE, SIGN or SIGN_AND_ENCRYPT Server Application Instance Certificate

OPC UA Specifications Access Type Specifications Core Specifications
Part 1 - Concepts Part 2 – Security Model Part 3 - Address Space Model Part 4 - Services Part 5 – Information Model Part 6 - Service Mappings Part 7 - Service Mappings Core Specifications Part 8 – Data Access Oct 2011 Feb 2010 Part 9 – Alarms & Conditions Jul 2012 Feb 2010 Part Programs Jul 2012 Jul 2010 Part 11 – Historical Access Aug 2012 Oct 2011 Oct 2011 The Access Type specifications contain the information model extensions for the typical UA access types – DA, A&C, HA and Programs. The Utility Type specifications provide Utility Type Specifications Jan 2014 Release candidate Oct 2011 Part Discovery Jul 2012 Part Aggregates Aug 2012

ISA 95 Defines 4 separate Levels in industrial companies
Provides a simplified version of the Purdue Reference Model for CIM (Computer Integrated Manufacturing) Also builds upon the MESA (Manufacturing Execution Systems Association) model for activities in the manufacturing control domain Level 0 / 1 Process Control Level 2 Supervisory Controls Level 3 Operations Management Level 4 Business Logistics Level 5 Inter-Company OPC DA / HDA OPC UA B2MML RosettaNet OAGIS MIMOSA A simplified version of the complete model defined in the Purdue Reference Model for CIM (Computer Integrated Manufacturing), combined with the MESA (Manufacturing Execution Systems Association) model for activities in the manufacturing control domain. ISA-95 defines 4 levels in industrial companies. Level 0, 1 en 2 are the levels of process control. Their objective is the control of equipment, in order to execute production processes that end in one or more products. Level 3 could be called the level of MES (manufacturing execution system) activities. Level 3 consists of several activities that must be executed to prepare, monitor and complete the production process that is executed at level 0, 1 and 2. For example activities like detailed scheduling, quality management, maintenance, production tracking, and so on. The highest level (level 4) could be called the level of ERP (Enterprise Resource Planning) systems. At this level financial and logistic activities are executed. These activities are not directly related to production. For example Long term planning, Marketing and sales, Procurement.

ISA-95 Conceptual Hierarchy for Industrial Operations
I / O From Sensors Instrumented Systems Supervisory Controls Operations Management Business Logistics Level 0 Level 1 Level 2 Level 3 Level 4 I / O System H/W Machine OPC Server OPC Server OPC Client Sensors Safety Control System Batch Automation System Manufacturing Execution System Customer Relationship Management Process Control System Distributed Control System Enterprise Resource Planning Programmable Logic Controller Product Lifecycle Management SCADA Device

B2MML and SAP Integration
MESA (Manufacturing Enterprise Solutions Association) is a global community of manufacturers, producers, industry leaders, and solution providers B2MML is Business to Manufacturing Markup Language B2MML Provides an implementation of the ISA-95 data models as XML schemas B2MML-Common B2MML-Personnel B2MML-Equipment B2MML-Maintenance B2MML-Material B2MML-ProcessCapability B2MML-ProcessSegment B2MML-ProductDefinitions B2MML-ProductionSchedule B2MML-ProductionPerformance Conceptually equivalence can be drawn with the operational characteristics and attributes of an ERP system such as SAP for example: An SAP Material Master has a Material Group property which is conceptually equivalent to the B2MML Material Class. The SAP Material itself is conceptually equivalent to the B2MML Material Definition. MESA (Manufacturing Enterprise Solutions Association) International is a global community of manufacturers, producers, industry leaders, and solution providers who are focused on driving business results from manufacturing information. B2MML is short for Business to Manufacturing Markup Language. It consists of some schemas based on ISA B2MML implements the ISA-95 data models as XML schemas. The following schemas have been developed: B2MML-Common, B2MML- Personnel, B2MML-Equipment, B2MML- Maintenance, B2MML-Material, B2MML- ProcessCapability, B2MML-ProcessSegment, B2MML- ProductDefinitions, B2MML- ProductionSchedule, and B2MML-ProductionPerformance. SAP XI / SAP PI allow you to create your own mappings between SAP Idoc structures and B2MML but this is not pre-defined. It is not even predefined in SAP-MII(!) … Some first best guesses: LOIROU02 --> Product Definition ZMATMAS05 --> Material Definition ZWMIVID01 --> Material Lot LOIPRO01 --> Production Schedule LOIWCS02 --> Equipment SAP Material Master should map to B2MML Material interface. December 2013: The above blog post (from SAP) neatly summarizes why there is no OOTB integration mapping defined between SAP MII and B2MML. In short they prefer to directly integrate point-to-point with MES providers rather than go in and out of a canonical XML format such as B2MML. Reading between the lines, this protects the position of SAP and avoids clients doing heterogeneous system integration. N-Link solution: Show picture of existing SAP to Microsoft Dynamics patterns Take similar garphics to nlink

SAP Integration SAP is an example of an Enterprise Information System (EIS). An EIS offers a well-defined set of services exposed as local or remote interfaces, for example ERP and CRM systems The IIB SAP nodes use an “Adapter component”: The Adapter component uses the SAP Java Connector (SAP JCo) API to communicate with SAP. Adapter component utilises the Java Connector Architecture (JCA) 1.5 which standardizes the way in which application components, application servers and EISs interact. You can invoke a message flow when data changes on the SAP server by generating an adapter component that listens for events on the SAP server and notifies message flows with the update. Message Model Adapter Component SAP Input Message Model Adapter Component SAP Request The adapter uses the SAP Java™ Connector (SAP JCo) API to communicate with SAP applications. An application sends a request to the adapter, which uses the SAP JCo API to convert the request into a BAPI function call. The SAP system processes the request and sends the results to the adapter. The adapter sends the results in a response message to the calling application. With WebSphere® Adapter for SAP Software you can create integrated processes that include the exchange of information with an SAP server, without special coding. By using the adapter, an application component (the program or piece of code that performs a specific business function) can send requests to the SAP server(for example, to query a customer record in an SAP table or to update an order document) or receive events from the server (for example, to be notified that a customer record has been updated). The adapter creates a standard interface to the applications and data on the SAP server so that the developer of the application component does not have to understand the lower-level details (the implementation of the application or the data structures) on the SAP server. WebSphere Adapter for SAP Software complies with the Java™ Connector Architecture (JCA) 1.5, which standardizes the way in which application components, application servers, and Enterprise Information Systems (EIS), such as an SAP server, interact with each other. The adapter, which you generate with the Adapter Connection wizard, uses a standard interface and standard data objects. The adapter takes the standard data object sent by the application component and calls the SAP function. The adapter then returns a standard data object to the application component. The application component does not have to deal directly with the SAP function; it is the SAP adapter that calls the function and returns the results. For example, the application component that requested the list of customers sends a standard business object with the range of customer IDs to the SAP adapter. The application component receives, in return, the results (the list of customers) in the form of a standard business object. The adapter completes all the interactions directly with the SAP function. Similarly, the message flow might want to know about a change to the data on the SAP server (for example, a change to a particular customer). You can generate an adapter component that listens for such events on the SAP server and notifies message flows with the update. In this case, the interaction begins at the SAP server.

B2MML to SAP

The Power of Patterns

IBM Integration Bus Manufacturing Pack

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