Machine-To-Supervisory Communication Framework
based on OPC Unified Architecture

Pedro Reboredo, M.Sc.
Bosch Rexroth AG
Technical Trackwww.odva.org

Outline

Introduction
Requirement Analysis
Information ModelingCommunication Architecture
Controller-To-Field Level Communication
Machine-To-Supervisory Communication
CIP Data Modelsercos Data Model

OPC Unified Architecture
Framework Concept
Conclusion and Outlook

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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IntroductionIndustrial manufacturing is an
important factor for global economy
Automated production machinesEnable constant product qualityEnsure wealth of industrial nations
Ensure high flexibility
Flexible manufacturing systems are
required due to:Decreasing product life cycle times

Variety of product configurations
Holistic Machine Optimization
Ensures business turnoverEnables productivity awareness
Needs high engineering efforts due
to variety of communication protocols

Sample Applications © Bosch Rexroth AG

Universal framework for machine-to-supervisory (M-to-S)
communication enabling interoperability

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2012 ODVA Industry Conference & 15th Annual Meeting
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Today’s Communication Architecture

ISA-95 Manufacturing Levels according to [1] from [2]Control feedback loops are implemented between supervisory
and machine level (ERP to technical process)High efforts exist for vertical integration due to variety of device
suppliers and communication protocols
Hardware gateways are mandatory

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Controller to Field Device Requirements

Industrial Ethernet based fieldbus
protocols have gained acceptanceduring the last years
Ethernet was already known from theoffice world
Main industrial requirements:
 Determinism (defined time slots)
including Integration ofSynchronization mechanisms
 Integration of COTS hardware Availability of products andcomponents

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M-to-S Communication RequirementsOpen Standards
 Reduces vendor dependencies/ minimize risks
Semantic Interoperability
 Same “language understanding” for informationexchange between different suppliers
Security Mechanisms
 Prevent communication mechanisms from being
misused (user authentication and authorization, dataencryption)
Defined Interfaces
 Abstraction of application and communication bydefining a way to describe (service) interfaces

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Information Modeling
Goals:
 Achieve Semantic Interoperability by … defining a common information interpretation
 … creating entities and relationships
 … using defined mechanisms / a framework
Maximize Use Case Coverage by … using an application layer of
established protocols CIP and sercos



Main Goal:
Use information models in a standardized architecture
enabling secure communication mechanisms

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CIP Data Model OverviewObjects include attributes
and services
Classes group objects
Addressing data values by:
Device.Class.Instance.Attribute
8Bit, 16Bit and 32Bit addressing supported

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sercos Data Model Overview 1/2
sercos Data Profiles:
SCP – sercos Comm. Profile

configuration of comm.

GDP - Generic Device Profile
Independent from device classe.g. diagnosis, archiving

FSP - Function Specific Profile

Dedicated device class functionality
E.g. drive control parametersEach device includes several profiles covering different functional areas
Leads to modularity within a device

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sercos Data Model Overview 2/2
sercos Parameter Model:sercos III IDN

4 byte identification number

Data Block Number
Data contentParameter Set
Multiple parameter sets
S/P Parameter Bit
Standard or
Product Specific Parameter
Structure ElementIndex of Element to beaddressed
Structure InstanceInstance of structure to beaddressed

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OPC Unified Architecture

Middleware-technology
Extends the OLE for process control (OPC) standard
Established technology for data exchange within factory
automation and other applications
OPC UA TechnologyIntegrates a semantic capable information model
Is based on SOA
Has platform independency (no Microsoft DCOM)
Has TCP/IP based communication protocol

OPC UA is an industrial de facto standard
for higher level interoperability

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OPC UA Data ModelingNodes are “atomic entities”
Nodes are organized within theserver address space
Objects can

ReferencesInclude Variables
Include Methods
Send out Event Notifications
Define relations between objects
Are typed to express the relationship

Each OPC UA Server consists of an integrated address
space containing information

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OPC UA Services


OPC UA server provides standardized services

Discovery Service Set

Secure Channel Service Set

Server and endpoint discovery services
Servers can register themselves to one discovery server
Servers provide own discovery services
Useful with complex factory networks
Security mechanisms
Secure channel establishing between Client and Server
Security mechanisms are stack integrated

Methods Service Set

Method invocation services
Includes interface definition (input and output arguments)
browse and query services for method discovery

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Framework concept

OPC UA based communication between
supervisory systems and machine level
Machine Controller Information Modelhas standardized and non standardized
Information Objects
Server can be placedOn Controller Level
On Field Device Level
Standard models are defined via
companion specifications forinteroperability
Non-Standard models include application
data and enable flexibility
Field Device Data is provided within theServerTechnical Track© 2012 ODVA, Inc.

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Conclusions and OutlookMachine-to-supervisory communication is essential for holistic
optimization of machinery
Standardized information models facilitate the implementationefforts for machine data integration
Introduced CIP, sercos and OPC UA data modeling concepts
Communication framework to solve the problems of integration

Standardization of suitable information models has to be advancedE.g. Energy Management, Condition MonitoringWork in O.M.I. task force is still in progressTechnical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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Thank you for your attention !

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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