Transcript Exponentially Great Results Require the Right Tools - X

Exponentially Great Results Require
the Right “Box of Tricks”
John Weber - President
Kevin Rutherford – Applications Engineer
Agenda
Symbol Factory ArchestrA/Gadget Wizards
Information Integration Solutions
Case Study – BHP Hillside/CSS
Case Study - Green IT
Case Study - Task Force Tips
Summary
Symbol Factory ArchestrA
Overview
► Over 4,000
►
►
►
►
►
►
►
►
ArchestrA Symbols
for InTouch 10
Vector Graphics!
Resolution
Independent
Deployable
Embeddable
Vertical Industries
Easily joined pipe
pieces
Over 60 categories
Let us focus on
graphics, you focus
on your system!
Symbol Factory for ArchestrA
Licensing
► Runtime Free Distribution - Licenses Only
Needed for InTouch 10 Development
Workstations
► Works with
Benefits
▪ InTouch10
Managed
▪ InTouch10
Managed
with System
• Reduced
Engineering
Time Platform
► No Licenses needed for deployment!
• Improved graphics quality
► Catalog of Symbols on DVD you can pick
up at our stand at the Expo
► Come by Expo Stand for a 1-to-1 demo
Gadget Wizards for
Wonderware
► Ideal for InTouch 10 Compact Edition & Wonderware
Panels
► Photorealistic Buttons, Lights, Switches, Meters, Sliders,
Fills & Panels
► Economical - Runtime free licensing
Data Integration Challenges
Connect
to nonIs this you
daring to
Wonderware
face
your challenges
MES
databases
without
the proper Bridge Data
tools?
Between
OPC
Servers?
Connect Live
OPC Data to
Excel
Log to nonInSQL/
Historian
Databases
Move
data w/o
DCOM?
Monitor &
Advise if
Processes
stop or restart
Connect
OPC to nonWindows
OS?
Data Integration Solutions
The Swiss Army Knife of OPC!
The Perfect Tool to Leverage
Your ArchestrA Investments
OPC Data Aggregation
Without Data Aggregation…
► Multiple Data Sources & Clients
► Each Client makes it’s own connection to each OPC Server
► Redundant data flow
► High network utilization, negative impact on control network
OPC
Clients
Multiple & Varied
Data Sources
OPC DataHub Aggregation
With Aggregation
► Reduced # Connections
Benefits:
• Unified data
► Common connection for multiple data
• Controllable update rates
sources
• Isolate
control network from unruly client applications
• Limit # of OPC connections
Efficient
data from
flowprojects
•►Common
tag naming
• Reduce network traffic
• Improve system performance
• Overcome OPC server or client limitations
OPC
• Single separable point of troubleshooting for clients
Clients
• Save money on OPC client & server licensing (Hint – ABB robotics)
OPC
DataHub
Multiple & Varied
Data Sources
OPC without Tunnelling
Full of Challenges
► OPC remote connections without tunneling
► Many points of failure
► Forget working through firewalls
► Does not recover well from network issues
X
PC – 1 OPC Client
OPC Client
COM run-time
Security
Provider
I want to
connect
to
you
My
user
name
ison
Or
youyou
might
get:
Yes,
are
Jislaaik,
you
are
so
“vernon_koekoemoer”
Han
Weg
– Ithis
my
list…
will
last
year…I’ll
and
password
is is
boet:
Tell PC – 2 OPC
aHowzit
no
Vernon
Zone!
grant
you
access!
“bleddie_lekker”
check
my
access
me
listyour
justlogin
now
name and COM run-time
password!
Security
Provider
Server
OPC
Server
3 Steps to Tunnelling with OPC
DataHub
► Step 1: Connect Master to OPC Server
► Step 2: Connect Master to Slave
► Step 3: Connect OPC Client to Slave
Or… Windows NT, 2000,
XP, Vista, or 2008
Or… Windows NT, 2000,
Vista, 2003, or 2008
OPC Tunnelling
Why Tunnel with DataHub?
► Clean Network Interruption Handling
▪ Heartbeat and reconnect settings
▪ OPC transactions all local
► Reduce Network Traffic for Low Bandwidth
Connections
▪ No polling – event driven transfers
▪ Single connection for multiple tunnels
► Improve System Performance & Reliability
▪ Mirrors data – both side share data
• Clients connected to OPC DataHub always get an answer
▪ Non-blocking calls
OPC Tunnelling
Why Tunnel with DataHub?
► Increase Data security (passwords & SSL)
► Connecting to Non-Windows Systems
► Multiple clients on same PC,
▪ One remote connection to remote OPC
sources, managed by OPC DataHub Database
Server
▪ Competing solutions N clients = N connections
► Connect from NT forward to any current
Windows OS
► OPC DataHub tunnels DATA
▪ Any data source – OPC DA, DDE, ODBC
OPC Server
▪ Any data
that DataHub
TCP/IP can read
Tunnel
▪ Competing solutions
tunnel only OPC
OPC Tunnelling
But wait – can’t I use these…
► VPN - Does not solve problems of
▪ DCOM, Network stability, bandwidth and
Benefits
of OPC
DataHub
Tunnelling
crossing
domains
– only
provides security
• Tunnel
any type of data
►
OPC XML/DA
• Recover
from network
issues easily
▪ Not secure,
more overhead,
not for high
speed,features
limited products,
OPC
UA replaces
• All other
of DataHub
included
free
• FastXML/DA
– 30 to 50k points/sec in field, have done
►100k
OPCinUA
test
▪ Requires
products
involved
• Less
time onall
DCOM
= More
timeto
onsupport
thingsitthat
▪ Only tunnels
generate
profitsOPC
▪ You can use DataHub TODAY! and it will be
adding OPC UA to give you more choices
OPC DataHub
System Monitor Function
► Monitors any windows performance monitor
counter & makes it available via OPC, web, & can
alarm/notify off of it
► Combine with tunnelling to monitor remote
systems
OPC DataHub
Email / SMS Notifications
► Easy to configure
► Flexible
► Get data from almost any source
Multiple & Varied
Data Sources
OPC
DataHub
Send message based
on Conditions and
Triggers from any
source
OPC Data Hub
Connecting Excel to OPC
► Value – Quality – Timestamp
► Array tag support
► Combine with tunnelling for easy remote
data access!
► Writes without scripting
Anyone’s Desktop PC
Drag & Drop DDE
Connections to OPC
DataHub
DataHub Connectors
More Sources = More Solutions
► OPC DA
▪ Acts and OPC Server and OPC Client
► DDE
▪ Acts as aNow
Local DDE
Serverall
thatClient
weorhave
►
►
this
ODBC
data
into
the
DataHub
–
▪ Can write to ODBC systems or Read from using scripting
if weTCP
want
to move it
API’s – letswhat
you make
connections
between
systems?
▪ C++ - Windows
or Linux
▪ JAVA – support web browser applications
▪ .NET – C#, but works with any
► TCP Socket connection with DataHub protocol
► Linux/QNX via Cascade Data Hub
► Connect to your custom application
Bridging Solutions: Moving Data
Doesn’t Have to Be Like Mountains
► What Can Bridging
Mean?
▪ Simple Data Exchange
▪
▪
▪
Between Control Systems
Data Exchange and
Manipulation Between
Systems
Timed or Triggered Data
Exchange between
Control Systems
Data Exchange Between
HMI Systems
DA Server
DA Server
X
OPC
Bridging
Tool
Control
System A
(DCS /
PLC /
Etc.)
Control
System B
(DCS /
PLC /
Etc.)
Bridging Solutions: Moving Data
Doesn’t Have to Be Like Mountains
► Traditional Solutions
▪ Scripting in the SCADA/HMI
• Read Resulting
from one system
in:
• Write •toMore
the other
system
Time
• Scripted
calculations
• More
Moneyor formulas to modify the data
▪ Custom Application
• Development Expertise
• Scripting
Bridging Data Made Easy
► Software Toolbox Solutions
▪ OPC Data Hub
• On Change Transfers Only (without scripting)
• Checkbox Configuration for Forward/Inverse
Transfers
• Simple Linear Transformations (Multiply/Add)
▪ OPC Gateway
• On Change/Polled/Triggered Data Transfer
• Complex Calculations/Transformations on
Source Values
Bridging with OPC Data Hub
► Move Data Between
Many Different
Disparate Systems
► Email/SMS
Notifications
► Avoid DCOM via
Tunnelling
OPC DataHub: Diversity of
Connection Types
► OPC DA
▪ Acts and OPC Server and OPC Client
► DDE
▪ Acts as a Local DDE Client or Server
►
►
Bottomline:
ODBC
you
getorthe
data
into scripting
▪ Can writeOnce
to ODBC
systems
Read
from using
DataTCP
Hubconnections
– You can
API’s – letsOPC
you make
▪ C++ - Windows
moveoritLinux
ANYWHERE!!!
▪ JAVA – support web browser applications
▪ .NET – C#, but works with any
► TCP Socket connection with DataHub protocol
► Linux/QNX via Cascade Data Hub
Bridging Solutions: OPC Gateway
► OPC-to-OPC Bridging
► Data Transfers via:
▪ Data Change Events
▪ Specified Polling Period
▪ Monitored Item Condition
► Data Transformations
▪ Simple & Complex
▪ Wide range of
Mathematical Operators
to use for calculations
▪ Transform data values
prior to transfer
OPC Gateway: Update Methods
► Multiple Update
Methods Available
▪ On Data Change
▪ Polled
▪ Monitored Item Trigger
OPC Gateway: Transformations
► Simple & Complex
Calculations
▪ Formulas
▪ Conversion to
Engineering Units
▪ Scaling
► Test Transform
Expressions
▪ Confirm that your
formula has the
desired result
OPC Data Hub & OPC Gateway:
How to Choose
Exchange type
OPC Gateway
OPC Data Hub
Yes
Yes
Yes
Yes
Data Exchange and Transformation
Yes
Yes (Scripting)
Triggered or Polled exchange
Yes
Yes (Scripting)
Simple data exchange (Source Value to
Target Value Transfer Only)
Exchange between HMI systems
(as OPC Servers)
Data Exchange between Non-OPC
Systems
Yes
Exchange over different Networks –
No DCOM
Yes
Case Study – CSS & BHP
Billiton Hillside
► Cast first metal June 1995.
► 685 000 tons per annum.
► Largest smelter in the southern hemisphere
► One of the world's most advanced and
efficient smelters
► Major Wonderware User
Case Study – CSS & BHP Billiton
FTC’s
4 PLC’s
15K I/O
GTC’s
40 PLC’s
25K I/O
Treatment
&
Logistics
Logistics
30 PLC’s
13K I/O
Over 230 PLCs
Over 230 000 tags!
Paste
1 second scan rates
Plant 1
PLC’s
Entire Hillside facility on1020K
TOP
Server
I/O
Reduction
10 PLC’s
20K I/O
Rodding
Shop
34 PLC’s
20K I/O
Carbon
Handling
& Storage
21 PLC’s
15K I/O
Paste
Plant 2
10 PLC’s
20K I/O
HDC
10 PLC’s
20K I/O
Casthouse
ICM
10 PLC’s
20K I/O
Substation
10 PLC’s
30K I/O
Case Study – CSS & BHP Billiton
System Detail
InTouch View Nodes
FTC’s
4 PLC’s
15K I/O
GTC’s
40 PLC’s
25K I/O
Redundant
I/O Servers
Topserver
Treatment
&
Logistics
Redundant Historian
Servers Logistics
30 PLC’s
13K I/O
Reduction
10 PLC’s
20K I/O
Mass Auto
Save Server
Case Study – CSS & BHP Billiton
2009 System Improvements
• 4 systems/line, 5 lines
• Skimmer
• Stacker
• Label Applicator
• Gantry
TOP Server OPC Client Driver
Problem – ZAR 200 000
TOP Server OPC Client Driver For non local OPC
connections!
• Used in Paste Plant for anode production
• Adjusts setpoints to adapt process
• Need data on control status, setpoints, process
variables, and fault indications
• Data needed:
• Position
• Status
• Sequence
• Fault Status
Case Study – CSS & BHP Billiton
2009 System Improvements
HDC
10 PLC’s
20K I/O
OPC
DataHub
ODBC
Send messages &
reports based on
Conditions and
Triggers from any
source
Casthouse
► Added OPC DataHub to do notifications
ICM
10 PLC’s
20K I/O
directly from TOP Server AB Suite
► Monitoring about 100 points
► Plans for same in other 3 plant areas
► Future: Direct connect to Oracle DB for existing
plant MES system – no added cost!
Green IT - Monitoring Data
Center HVAC Systems
► System Integrator
► Industry – IT Data Center Management
► Background
▪ Data centers accounted for 1.2% of energy
used by the United States in 2005 and is
expected to be 2.5% by 2011.
▪ Objective
• Minimize cost of running Data Centers.
▪ Key requirements
• Allow operators to view a graphical interface with real-time
data.
Green IT - Monitoring Data Center
HVAC Systems
► Lower Energy Cost with Real-time
Data
▪ Operating at higher temperatures
▪ Controlling air flow between server rack
aisles
▪ Using cold outside air for cooling
Case Study – Task Force
Tips
► Problem
▪ Robotic picker
• Controlled by COBOL program on a Linux system
• Slow response times
• High downtime
► Solution – revamp the robot
▪ AB ControlLogix PLC & Servos
► Challenge!
▪ Can’t rewrite the pick program easily
▪ Must interface it with the ControlLogix
► How????
Case Study – Task Force
Tips
Benefits
• Improved efficiency
“It is magical what this has done for our application. The OPC DataHub and TOP
Server allow the PLC to share any data point. The possibilities that this opens up
• Nearly
downtime
for real-time connections
betweeneliminated
PLCs and corporate
data processing systems
will bend your imagination. It is so much faster than what we had before! Now we
are trying to find other problems to solve. This solution has been VERY effective
for our business results.”
Stuart MacMillan – President, Task Force Tips
Dankie - Thank You!
► Visit our stand at Expo
▪ Free demo DVD with training videos & trial
software
▪ Discuss your integration challenges
► Contact us to discuss your challenges
▪ [email protected]
▪ Kevin Rutherford
• [email protected]
▪ John Weber
• [email protected]
► Order licenses from the Wonderware South
Africa team!