A Standard Model for Machine toSupervisory Systems Data Exchange
Rainer Beudert
Ludwig Leurs
Steve Zuponcic
October 14, 2015- Schneider Electric- Bosch Rexroth- Rockwell Automation

Machine to Supervisory Communication

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2Line Integration Real Life
• Importance of a standardization of machine states

T-DiscFeeder

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Sorting
Robot

T-DiscFeeder

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FillSealPacker
Robot…

Palletizer3

Base Machine Object – State Model•••State of the machine is important to operator and supervisory systems
Shown at operator panel, traffic light on top of machine
Difference state versus status– Status just indicates the state of a machine without any transient states– State is shown in a model with events leading via transient states to a changedstate– State changes can be triggered by commands••

Machine State models are specific to the industry branch
A simple Machine Status can be generalized for a common view by allsystems

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PackML machine state diagram
internal condition..ing

external condition
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Machine state comparision matrix
ANSI/ISA 88

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PackML

Weihenstephan

GEM

Machine States

executepausing
pausedidle
stoppedstarting
suspending

execute (6)operating (128)executingidle (4)stopped (2)starting (3)suspending (13)suspendedsuspended (5)un-suspending
stopping
abortingun-suspending (14)stopping (7)aborting (8)abortedaborted (9)holding
held
un-holding
completingcomplete
resettingclearing

holding (10)held (11)un-holding (12)completing (16)complete (17)resetting (15)clearing (1)idle (32768)
idlingstopped (1)starting (2)initializing
prepared (4)lack (8)tailback (16)pausinglack in branch line
(32)
tailback in branch line
(64)
stopping
aborting
equipment failure(1024)
external failure(2048)
emergency stop(4096)
holding (8192)
held (16384)
setting up

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MTConnect
activeidlestopped

interrupted

Base Machine Status

Machine Statusgreen (execute)green (execute)orange (stopped)
yellow (idle)orange (stopped)
yellow (idle)
green (execute)orange (stopped)orange (stopped)orange (stopped)
red (aborted)

emergency

feed holdwww.odva.org

red (aborted)

green (execute)orange (stopped)orange (stopped)
green (execute)orange (stopped)orange (stopped)
red (aborted)

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ODVA Common Machine State Diagram
Simplified model for status

Basic machine state model

resetresumeidle(yellow)

Start

execute(green)

stopped(orange)stop

abortreset

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Targeted Machine Types
Machine Classes classified by NAICS

Machinery classes
Food Product Machinery Manufacturing
Packaging Machinery Manufacturing
Plastics and Rubber Industry Machinery Manufacturing
Machine Tool (Metal Cutting Types) Manufacturing
Oil and Gas Field Machinery and Equipment Manufacturing
Engine, Turbine, and Power Transmission Equipment Manufacturing
Conveyor and Conveying Equipment Manufacturing
Paper Industry Machinery Manufacturing
Semiconductor Machinery Manufacturing
Mining Machinery and Equipment Manufacturing
Printing Machinery and Equipment Manufacturing
Mounting and Handling Machines
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NAICS Code33329433399333322033351233313233361
333922333291333295333131333293not classified
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Applications for Data Use• Administration• Alarms & Events• ANDON• Batch/recipe management• Condition Monitoring• Data Exchange• Energy Management• Laboratory Management• Machine Data Access (MDA)• Maintenance Management

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• Material Management• Order Management• Performance Management• Process Data Access (PDA)• Quality management• Time-series data (historian)• Tool Management• Traceability & genealogy• Version Management• …and many more

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9Base Machine Data Structure

Machine Data Flow
Base Machine Data Structure• Machinery Configuration• Input Data
• Commands• Tracking ID• Material• Output Data
• Machine Identifier• Mode, Status• Material• Tracking ID• Events
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Machinery Configuration Data•
•••••
•
•••
•

AssetID
EquipmentType
MachineVendorId
EndUserDescription
VendorName
VendorModel
VendorMachineSerialNumber
VendorContact
VendorInstallDate
VendorDescription
Utilities

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Machinery Configuration Data•••••••••••

AssetID
EquipmentType
MachineVendorId
EndUserDescription
VendorNameVendorModel
VendorMachineSerialNumber
VendorContact
VendorInstallDate
VendorDescription
Utilities

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EUDescript[xx]• Country• State/Province• City• Facility• Level• Cell/Quadrant/Zone• Machine ID• User Defined• User Defined• User Definedwww.odva.org

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Machinery Configuration Data•
••
•
•
•
•
•
•
•
•

AssetID
EquipmentType
MachineVendorId
EndUserDescription
VendorName
VendorModel
VendorMachineSerialNumber
VendorContact
VendorInstallDate
VendorDescriptionUtilities

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VendContact[xx]• Street number• Street Name
• City• State/Province• Country• ZIP/Postal Code• Contact Name
• Phone number• Phone extension• Email address
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Machinery Configuration Data
•
••
•
•
•
•
•
•
•
•

AssetID
EquipmentType
MachineVendorId
EndUserDescription
VendorName
VendorModel
VendorMachineSerialNumber
VendorContact
VendorInstallDate
VendorDescription
Utilities

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Utilities[xx]• ID• Name• Value• Units• ScalerValue• ScalerUnits
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Machinery Input Data

•
••
•
•
•

State
CommandRate
CommandRateUnit
TrackingID
ResetCounts
Material

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Machinery Input Data

•
••
•
•
•

State
CommandRate
CommandRateUnit
TrackingID
ResetCounts
Material

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Material_In[xx]• ID• Name• TrackingID• Scalerwww.odva.org

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Machinery Output Data
•
••
•
•
•
•
•
•
•
•
•
•

RemoteEnabled
ModeStateStatus
TrackingID
Consumed
InProcessProduced
Waste
EventActive
EventDescription
EventID
ResetCountsDone

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Machinery Output Data
•
••
•
•
•
•
•
•
•
•
•
•

RemoteEnabled
Mode
State
StatusTrackingID
Consumed
InProcessProduced
Waste
EventActive
EventDescription
EventID
ResetCountsDone

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Material_Out[xx]• ID• Name• TrackingID• Available• IdealRate• RawTotal• Scaler• Totalwww.odva.org

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Extended Machine Data Structure

General Machine Information STRUCTURE
Machine Name Plate(minimum ident)
Static2

Basic ID / Name

Dynamic
Base Modes /States1

Mandatory feature set4

Basic Machine Data(COMMON)
Statice.g. Energy*

Exhaustive details per request / (Local/Remote)5

Dynamic

Optional Feature
Description A

Optional Feature
Description B

Optional Feature
Description …**

StaticStaticStaticDynamic

Dynamic*Data structure is known

e.g. Condition*

Dynamic
Extensible Structure3**Data structure is unknown6

Benefits

Basic ID / Name: UUID
Each object (structure) needs a unique identifier.
In case of a machine the Universally Unique Identifier (UUID) would be the combination of the• OEM Machine Serial Number and the• End User Asset Number

SN + AssetNumber -> UUID

General MI Strucutre
Benefits
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Definition Static and Dynamic Data
Static Data
Static data does not change over time and therefore can be stored outside the device.
The minimum data set would be the identification data set that enables any client touniquely identify the device. All other information could be stored outside and represented
by a link.
Dynamic Data
Dynamic data are subject to changing over time. This makes it likely that this data will be
stored in the device. The minimum set of dynamic data needs to be stored locally.
Additional data can be store remotely. The mandatory set of dynamic data (Common)should be stored locally.

General MI Strucutre
Benefits

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Extensible Structures
Extensible structures are structures that can be extended from a predefined data
set and offer a very flexible way to fulfill varying and future requirements.

Some reasons to introduce these are:• Enable low cost devices to offer full information support.
This works by reducing the info to be kept in the device to the mandatory data set.
• Other data may be stored outside the device and referenced by a link.
• Common data does not need to be stored in the device and inconsistentcopies cannot occur.
General MI Strucutre
Benefits
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Mandatory / Optional Features

Manadatory Features are …
• are listed in the mandatory set of machine information.
• Only supported features are listed.
• Predefined features can reference a public available description. (PackML)• Worldwide available on a public server (e.g. B2MML or Javascript styles).
Optional Features are …
• …described by a unique tag name• …in XML file either local or pointed to by URL• …static or dynamic• …local or remote

General MI Strucutre
Benefits

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Local / Remote: Linked Information
Linked Information
would reside on a server in an XML data file(e.g. //Server/dir/machine/uuid/ODVA.desc.xml). relative path names and permalinks are permitted.

URI to server– //Server/DIR/Machine/UUID/ODVADESC.xml
This file contains all the non local informations– Concept of Local / Remote– see car registration in Europe
OVADESC.xml contains list of known features– As Tag e.g. ODVA_energy: <supported>
d.h. supports odva energy management– General: just list things which are supported
General MI Strucutre
Benefits
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XML Description

XML files• contain syntax and semantics,
but also pure text readable by humans, not by machines
OVADESC.xml• contains list of extended known / unknown features<EXT feature: A> „Name“< URI struct>„Description“.
.
< /URI struct><DATA >
„Data“. „Dynamic or static“. „Local or remote“</ DATA>
General MI Strucutre
Benefits

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Benefits of a Standard Method for
Machinery-to-Supervisory Information Exchange••

For machine builders, optimization of machinery integration (OMI™) will
create additional value through simplified communication from machines tosupervisory systems such as SCADA and MES.
By transforming data into information, OMI will:– Provide tools for dynamic decision-making to maximize machine productivity andimprove machine performance– Enhance maintainability of machinery assets– Create more value from machines

OMI will Emerge as a natural sweet spot to help manufacturers meet their overallbusiness objectives, including workforce, profitability and sustainability goals.
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Thank you!