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OPC Today and in the Future

Explore the past, present, and future of OPC with Thomas Burke and Jim Luth from the OPC Foundation. Learn about the vision of OPC for interoperability and the challenges faced in the plant environment. Discover the benefits of OPC Unified Architecture and its impact on connectivity and integration.

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OPC Today and in the Future

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  1. OPC Today and in the Future Tom Burke - President and Executive Director, OPC Foundation Jim Luth, Technical Director, OPC Foundation

  2. OPC : Past, Present, & Future Thomas Burke, OPC Foundation President

  3. OPC Foundation • International Industry Standard Organization • 400+ Member Companies / 40+ end-users Members • 2500+ Total Companies Build OPC Products = 15000+ Products • The vision of OPC is to be the Foundation for interOperability • for moving information vertically from the factory floor through the enterprise of multi-vendor systems (with stops in between…) • For moving information horizontally between devices on different industrial networks from different vendors; • Not just data but information……. • Reliable, Secure Integration is not an Option • Collaboration is key to pulling multiple “open” standards into unified open platform architecture….

  4. The Plant : a Complex Environment with many opportunities for standards for interoperability Other Computing Devices Plant Servers hours PLANT INFORMATION NETWORK - Ethernet Personal Computer Network Manager Archive Replay Module min Control Stations Area Servers Plant Network Modules Additional CN Modules Application Module History Module secs Fiber Optics CONTROL NETWORK Network Gateway Network Gateway PLC Gateway Network Interface Module Subnetwork Gateway 1 sec Control Network Extenders Other Data Hiway Boxes PLC Other Subsystems Multifunction Controller msec Logic Manager Process Manager Subnetwork Extended Controller CONTROL NETWORK Advanced Process Manager Basic Controller Advanced Multifunction Controller LocalProcessors • sec Smartine Transmitters Transmitters • Asynchronous Processing • Multiple Interfaces • Mission Critical • How To Manage Changes? • Complex Information Flows • Multi-vendor • Proprietary

  5. PLC Controller DCS ... Application X Application Y InterOperability InterOperability A standard object model and set of interfaces for applications and servers Performance Before OPC: With OPC: Custom interfaces Client and Server write to a standard • costly • inefficient • risky • reduce cost • protect investment • more choices • increase productivity Connectivity Display Application Trend Application OPC OPC PLC DCS Controller

  6. OPC Data Access Architecture MES and/or HMI Applications (OPC Client) Software App provides a linkage between OPC Client(s) and devices OPC Server PLC PLC Proprietary Messaging OPC Data Access

  7. OPC Market Acceptance Technology Life Cycle Curve $ Chasm Time Innovators Early Adopters Early Majority Late Majority Laggards Technology Visionaries Pragmatists Conservatives SkepticsEnthusiasts Source: Inside the Tornado by Geoffrey A. Moore, HarperBusiness, 1995 pages 14 & 19 • Dramatic Market Acceptance & Growth • Clear business benefits & risk mitigation • Many vertical industry applications OPC OPC UA

  8. OPC – Functional Areas

  9. Today’s Integration Challenges • Numerous incompatible protocols • Complex configuration and maintenance • Islands of automation • Rigid infrastructure • Vulnerability to system and network failures • Security

  10. Numerous Incompatible Protocols DDE RS-232 HART Lonworks UNICODE 802.3 V.35 ProfiBus Interbus Bluetooth CC-Link DNS IPsec RS-485 DeviceNet TCP OAGIS CAN Kerberos ControlNet CORBA DHCP RS-422 netDDE BAPI EBCDIC SNMP HTTP 802.11 SOAP DeviceLogix ANSI FIPIO FieldBus COM IPX USB CANopen IndustrialEthernet RS-423 AS-I .NET Remoting DCOM OPC-HDA OPC-A&E ARP XML Firewire OLE Modbus WMI IPv6 802.1x IPv4 UDP OPC-DA FDI RARP ICMP J1939 Ethernet FTP

  11. Numerous Incompatible Tiers ERP CRM SCE continuouscontrollers sensors SCP field networks NCcontrollers PLM valves batchcontrollers robots discretecontrollers NC machines R&D SCADA cellcontrollers process monitoring Enterprise processhistory transmitters material dispatch area controllers Equipment Station WIP tracking HMI DCS quality systems production planning PDM production planning product genealogy operatorinterfaces performance measurement resource management time and attendance Section/Area Cell maintenance management Facility/Plant

  12. OPC Unified Architecture Motivation .NET new Communication architecture DCOM retires Internet OPC-UA Better Integration (DA, HDA, AE) More Areas of Application (MES, ERP) Service Oriented

  13. OPC Unified Architecture • Web Services / XML • Easy Configuration and Maintenance • Increased Visibility • Broader Scope • Reliability • Security • Performance • Platform Neutrality • Legacy Products Plug Right In…

  14. OPC Unified Architecture Base • Architecture • Integration of DA, A&E, Commands, Complex Data, and Object Types • Designed for Federation • abstract data/ information from the plant floor, through information models, and up to enterprise systems • Information Modeling • development and deployment of standard information models to address industry domains specifics • Complex Data • OPC Standard & Domain & vendor specific…..

  15. OPC Unified Architecture Base • Security • Collaboration, Development & Reference • Enterprise Integration • OPC UA standard messaging system • Robustness / Reliability Designed & Built in…. • NO Failures • Sequence numbers, keep-alives, resyncing, and support for redundancy • Commands • Companion Standards • industry groups define what OPC Unified Architecture “transports”

  16. Unified Architecture Evolution Asset Management ProductionControl Inventory Management Purchasing HMI Visualization SCADA The Enterprise paradigm The Automation paradigm ProductionManagement Systems

  17. OPC Unified Architecture P P P P L L L L Open Standards to Deliver Interoperability Device to Device and Device to the Enterprise MIS Device Data Enterprise Integration (ERP, Asset Management, Advanced Diagnostics, etc.) APPLICATION PACKAGES Configuration Subsystem Integration Device Integration (FF, Profibus, HART, etc)

  18. OPC Provides Industry-Standard interOperability, Productivity & Collaboration ERP, SAP … Corporate Enterprise OPC Unified Architecture Manufacturing, Production and Maintenance OPC Unified Architecture Adv. Control HMI MES SCADA Batch OPC OPC OPC PC-Based Control OPC PLC DCS Industrial Networks Data Acquisition ??.......??

  19. OPC Unified Architecture Jim Luth, OPC Technical Director

  20. OPC-UA Fundamentals • Based on standards for the Web • XML, WSDL, SOAP, WS-* • WS-Policy negotiates protocol and encoding • WS-SecureConversation provides secured sessions • Optimized for the Intranet • OPC Binary encoding over TCP

  21. OPC Interface Unification • SOA (Service Oriented Architecture) • Single set of Services • Query, Read, Write, Subscribe… • Named/Typed relationships between nodes. Alarms&Events DataAccess Historical DataAccess Commands ComplexData UA Server The UA Server embodies the functionality of existing OPC Servers using a single set of services

  22. Unified Object Model

  23. OPC-UA Address Space • Full Mesh – Network Model • Unlimited Named/Typed Relationships • “Views” are used to present hierarchies

  24. Robustness • Subscription Update Features • Keep-alive (heartbeat) messages • Allows clients to detect a failed server or channel • Sequence Numbers in each update message • Allows client re-sync to obtain missed messages • Decouples callback channel from notification mechanism, allowing callback channel to be reset without loss of data • Redundancy Features • Designed for easy (optional) redundancy of both Clients and Servers • e.g. re-sync request can be sent to a backup server

  25. Security • UA Clients present credentials to UA Servers (x509 certs on both sides). • UA Servers require authentication and authorization. • Access control can be fine-grained down to the property level. • Optional message signing and encryption.

  26. Communication Layering .NET (WCF) Version Portable C/C++ Version Java Version Tool orLanguageDependent(e.g. .NET) Scalable Platform Independent Messaging Model Business Model, Adaptable to Platform Independent Messaging Models (e.g. WSDL)

  27. Specification Layering Vendor Information Models Information Model Specifications OPC UA Base Services DA A&E HDA CMDs All Necessary Services OPC Information Model IEC, ISA, MIMOSA … Clients written to just the base can still discover and access all data from the derived layers!

  28. Scalability • OPC UA “Server Profiles” defined to allow servers with different capability levels • Client can discover server profile • Profiles and wrappers defined for migrating existing servers to UA • More capable profiles also defined

  29. Server Diagnostics • Standard “Server” node defined in address space • Standard diagnostic data items defined for the server, such as “SubscriptionCount” • Server specific diagnostics can be added, with semantics defined by object type definitions

  30. UA Server Chaining UAServer UAServer UAServer UAServer UAServer UAClient UAClient UAClient UAClient UAClient UAClient EnterpriseSemantics “Aggregating” UA Servers extract and process data from lower level “Device” UA Servers.Data is recast using different information models appropriate for the clients at the higher level. “Aggregating” UA Servers extract and process data from lower level “Device” UA Servers.Data is recast using different information models appropriate for the clients at the higher level. Enterprise Network Operations Network ProcessSemantics Plant Floor Network DeviceSemantics

  31. OPC Address Space Today • Pure Hierarchy • Parent/Child Relationships Only

  32. Data Items and Alarms Today

  33. UA Coherent Address Space

  34. UA Coherent Address Space Integrated data and alarms

  35. Object Classes and Instances Top Layer Relationship Complex Data Top Base Types Schema Type Layer Instantiation (between layers) Subclassing (Inherit ance) Data Type Reference Standard and System - defined Other relation- ship such as “contained”, “operated by”, “controls”, etc. Data Type Definitions Instance Layer

  36. Complex Data Features • Tells clients how to parse structured data • Allows use of XML Schemas for describing XML data • Defines OPC Binary data description language that uses XML to describe binary data structures • Allows client to access device specific data descriptions (e.g. Fieldbus Foundation OD)

  37. Methods vs. Programs • Programs built on top of Methods • Programs represent executable components of objects , e.g., • DownloadProgram(Name, InitState) • MonitorNetwork (From, Till, Interval) • Execution time may vary from milliseconds to indefinitely. • Asynchronous invocation is non-blocking. Results are returned using notifications. • The client can control the execution. • Methods part of UA Base • Synchronous invocation similar to blocking function calls. • AckAlarm()

  38. Programs can have State Executing 3 2 Opening Sending Closing State Machine • UA defines the basic state machine. • State transitions may cause notifications. • Sub-states can be defined in particular for the executing state.

  39. Scalability • OPC UA “Server Profiles” defined to allow servers with different capability levels • Client can discover server profile • Profiles and wrappers defined for migrating existing servers to UA • More capable profiles also defined

  40. Server Diagnostics • Standard “Server” node defined in address space • Standard diagnostic data items defined for the server, such as “SubscriptionCount” • Server specific diagnostics can be added, with semantics defined by object type definitions

  41. UA Services • Common services support DA, A&E, and HDA operations • Protocol independence • Timeless durability • Integrated with the UA Data Model • Partitioned into Service Sets

  42. UA Service Sets • Secure Channel Service Set • Open & Close Channel, GetPolicies • Session Service Set • Create, Close, Activate, ImpersonateUser • Node Management Service Set • Add & Delete Objects and References • View Service Set • Browse, BrowseNext

  43. UA Service Sets (2) • Query Service Set • QueryFirst, QueryNext • Attribute Service Set • Read, Write, ReadHistory, UpdateHistory • Method Service Set • Call • Monitored Item Service Set • Create / Modify / Delete • Subscription Service Set • Create / Modify / Delete, Publish, Republish

  44. Putting it all together Abstract Services Type Descriptions Data Model SOA Model Object Model OPC UA Protocol Independent DA, HDA, and A&E Comms Model Platform Independent Plant floor and Internet Access

  45. UA Programmers’ Interface • Designed to provide an abstraction layer between the application developer and the SOAP stack/wire encoding • Defined by UA to match the abstract specification instead of the WSDL Client Proxy Stub Server SOAP

  46. Interoperability with UAPI Client Application UA Programmers’ Interface WSE 2.0 Indigo Java UA TCP XML UA Binary XML UA Binary Indigo Binary UA Binary WSE 2.0 Indigo Java UA TCP UA Programmers’ Interface Server Application

  47. The UA SDK (II) WSE 2.0 Indigo Java UA TCP UA Programmers’ Interface UA Reference Server UA Reference Server Extensibility Interface COM Wrapper XML-DA Wrapper Native Vendor Specific

  48. UA –Enable all OPC COM Servers • UA clients can instantly connect to hundreds of existing OPC COM Servers UAClient UAServer Wrapper COMDA Server SOAP over UA HTTP or TCP

  49. UA –Enable all OPC COM Clients • Use the UA Client Proxy to connect existing COM clients to new UA Servers COMDA Client UAClient Proxy UAServer SOAP over UA HTTP or TCP

  50. Disable Remote DCOM • Use the UA proxy and wrapper to replace DCOM as remote communication protocol COMDA Client UAClient Proxy UAServer Wrapper COMDA Server SOAP over UA HTTP or TCP

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