process data management with opc easy connect or echocollect€¦ · process data management with...

INDUSTRIAL NETWORKS

10.02.2012

Process Data Managementwith OPC Easy Connect or echocollect

Peter Jüngling

Process Data ManagementTable of Contents

Purpose of Process Data Management

PC-based Solution via OPC-Easy Connect

Embedded Solution via echocollect

Advantages of echocollect compared to a PC solution Configuration of echocollect in 4 steps Native Connection to SAP Silver Bullets Application Stories

© Softing IN GmbH 2011 / Seite 2

Purpose of Process Data Management

PC-based Solution via OPC-Easy Connect

Embedded Solution via echocollect

Advantages of echocollect compared to a PC solution Configuration of echocollect in 4 steps Native Connection to SAP Silver Bullets Application Stories

Process Data ManagementWhat is it needed for ?

You need Process data for Improving your production output

By condition monitoring (less downtimes) By OEE (i.e. Overall Equipment Effectiveness)

- ratio actual / planned output- ratio operating time / total time

(identify downtimes and other time killers)

- quality ratio good/bad output► Quality Management

Data Logging Data Backup Data caching

Energy Management to save costs on energy

Database


You need Process data for Improving your production output

By condition monitoring (less downtimes) By OEE (i.e. Overall Equipment Effectiveness)

- ratio actual / planned output- ratio operating time / total time

(identify downtimes and other time killers)

- quality ratio good/bad output► Quality Management

Data Logging Data Backup Data caching

Energy Management to save costs on energy

Process Data Management –Missing Connectivity as Bottle Neck

Process Data Management requires a high performant direct connectionbetween the controller/sensor level in the workshop and your database, MES,ERP, SAP systems.But how to achieve this without substantial changes in your existingsystems?


ProductionLine

ERP System

Process Data Management–PC-based Solution via OPC-Easy Connect

OPC Optimizer

OPC Concentrator OPC Server2Server

OPC2File


OPC Bridge

OPC Tunnel OPC Filter

OPCClient2Client(OPC Storage)

OPC2Database

OPC StoreAndForward

OPCEasy Connect Suite

2.0


Via Windows-PC• with OPC-server OPC-TCPIP-S• with OPC-Easy Connect Suite:

• OPC-to-Database• OPC-Store&Forward to OPC-Clients• OPC-Tunnel to avoid DCOM problems• Optimizer and Concentrator for

enhanced performance

MySQLMS-SQLOracle


Via Windows-PC• with OPC-server OPC-TCPIP-S• with OPC-Easy Connect Suite:

• OPC-to-Database• OPC-Store&Forward to OPC-Clients• OPC-Tunnel to avoid DCOM problems• Optimizer and Concentrator for

enhanced performance

TCP/IP connection to S7 or othre PLCs

Netlink-PRO-ETHMPI connection to S7-PLCs


OPC-to-Database:

Easy Connect OPC2DatabaseEasy Connect OPC2Database

OPCServer

OPCOPC


► Data written to the database through execution of simple SQL actions► OPC DA, OPC XML-DA or OPC Tunnel server data in SQL databases

(Microsoft SQL Server, Oracle, MySQL and any other ODBC-enabled DB)

Easy Connect OPC2Database

EasyConnect

DS

TunnelServer

OPC TunnelOPC Tunnel

SQLDatabase

DD

LocalItems

ODBC


OPC-Store&Forward:


► Configurable connection monitoring for one connection to an OPC client► Data value buffering while connection to OPC client is interrupted► Data forwarding when the connection to OPC-client is re-established


OPC2File: Easy Connect OPC2FileEasy Connect OPC2File

OPCServer

OPCOPC


Using OPC2File, local items and OPC server items can be stored in text files. The datacan be logged in different file formats, including ASCII, HTML and XML, to allow furtherprocessing of the process data by using standard software.

Easy Connect OPC2File

EasyConnect

DS

TunnelServer

OPC TunnelOPC Tunnel

Data FileFile SystemFile SystemDD

LocalItems

Process Data Management–Embedded Solution via echocollect:



echocollect• direct connection for write into and read from

database, no extra OPC server required• no change of PLC programme required• integrated OPC-Pipe for direct connection to

OPC-Clients• Store&Forward with time stamp (PLC, NTP-Server

or individual time stamp) on echocollect• separation between production network and

office network• connects up to 5 PLCs

- via Ethernet- via serial or MPI for PLCs without Ethernet-CP

MySQLMS-SQLOracle

TCP/IP

–office network

SCADA withOPC-Clientand OPC-Pipe


echocollect• direct connection for write into and read from

database, no extra OPC server required• no change of PLC programme required• integrated OPC-Pipe for direct connection to

OPC-Clients• Store&Forward with time stamp (PLC, NTP-Server

or individual time stamp) on echocollect• separation between production network and

office network• connects up to 5 PLCs

- via Ethernet- via serial or MPI for PLCs without Ethernet-CP

serialconnection tovarious PLCtypes

TCP/IPconnection tovarious PLCtypes

TCP/IP

–office network

MPI connection to S7-PLCs


MES PLC

echocollect is the universal gateway for direct data connection betweenall kinds of controllers/PLC, sensors, scales, bar code readers etc….andall kinds of databases, mail servers, OPC-Clients etc…

Ethernet Ethernet or serial


and all this withoutchanging the PLC program

MES

Oracle

MySQL

MS-SQL

DB/2

E-Mail-serverExcel

SD-Card

PLC

AllanBradleyBeckhoff

Melsec-Q

Phoenix

Schneider

Siemens

Wago

Ethernet Ethernet or serial

• hat rail mounted in cabinet• just in time reports• automatic store and forward onSD card in case of communicationinterrupts

• plug & play replacement due toconfiguration stored on SD card


Echocollect gives you a lot of benefits compared to a PC:Windows-PCOPC-serversDCOM-settings…..

Safe separation between office network and production networkFanless embedded device for easy hatrail mounting in cabinetLinux instead of Windows,

i.e stable performance under all conditionsQuick database access compared to OPCInternal diagnosis for serial and Ethernet

connections makes commissioning easierFTP data export from echocollect into file

for automatic logging of data Configuration stored on SD card,

quick and easy replacement ofechocollect by unskilledpersonal by inserting SD cardinto new echocollect and ready!

MySQLMS-SQLOracle

TCP/IP


Safe separation between office network and production networkFanless embedded device for easy hatrail mounting in cabinetLinux instead of Windows,

i.e stable performance under all conditionsQuick database access compared to OPCInternal diagnosis for serial and Ethernet

connections makes commissioning easierFTP data export from echocollect into file

for automatic logging of data Configuration stored on SD card,

quick and easy replacement ofechocollect by unskilledpersonal by inserting SD cardinto new echocollect and ready!

serial

MySQLMS-SQLOracle

TCP/IP

TCP/IP

► Graphical user interface with browsing– Define Connections– Select database / Elements– Select PLC Elements– Select the data conversion

► SQL statements defined automatically► Data logger integrated for easy analysis



► Graphical user interface with browsing– Define Connections– Select database / Elements– Select PLC Elements– Select the data conversion

► SQL statements defined automatically► Data logger integrated for easy analysis

Process Data Management with echocollectStep 1 - Define Source - PLC Connection


IT

Automation

Process Data Management with echocollectStep 2 - Define Destination (database, SAP, logfile, PLC etc…)


Process Data Management with echocollectStep 3 – Trigger & data conversion


Step 4 – Diagnostics and Troubleshooting

Status Display Diagnostic logger Commissioning logger NetSpector Recorder

Process Data Management with echocollect


Status Display Diagnostic logger Commissioning logger NetSpector Recorder

Process Data Management with echocollectSAP Connection by using „PCo“

Benefits: Rapid integration by using OPC Reduced Integration risk on brownfields Standardized GUI (MII Integration) Less maintenance costs by using standards (OPC, .NET, Web-Service)


© SAP

Benefits: Rapid integration by using OPC Reduced Integration risk on brownfields Standardized GUI (MII Integration) Less maintenance costs by using standards (OPC, .NET, Web-Service)

Process Data Management with echocollectSAP Connection by using „PCo“


Process Data Management with echocollectSilver Bullets

► Universal Connectivity To all common PLCs (Siemens, Rockwell, Schneider, Beckhoff, Melsec-Q To MySQL, MS-SQL, Oracle, dB2, SAP, PLC, loggers, files on SD, e-mail, OPC-Clients No change of PLC-Programs required No extra OPC servers required

► Advantages against a PC-based solution Installation in parallel to existing system. No need to touch a working system! Safe separation between office network and production network Fanless embedded device for easy hatrail mounting in cabinet Linux instead of Windows, stable performance under all conditions Configuration stored on SD card, replacement of echocollect by unskilled personal by inserting SD

card into new echocollect and ready! Internal diagnosis for serial and Ethernet connections makes commissioning easier FTP data export from echocollect into file for automatic logging of data Quick direct database access compared to OPC

No loss of data in case of interrupted communication Data are automatically stored locally on SD card Data will be forwarded automatically if communication is active again


► Universal Connectivity To all common PLCs (Siemens, Rockwell, Schneider, Beckhoff, Melsec-Q To MySQL, MS-SQL, Oracle, dB2, SAP, PLC, loggers, files on SD, e-mail, OPC-Clients No change of PLC-Programs required No extra OPC servers required

► Advantages against a PC-based solution Installation in parallel to existing system. No need to touch a working system! Safe separation between office network and production network Fanless embedded device for easy hatrail mounting in cabinet Linux instead of Windows, stable performance under all conditions Configuration stored on SD card, replacement of echocollect by unskilled personal by inserting SD

card into new echocollect and ready! Internal diagnosis for serial and Ethernet connections makes commissioning easier FTP data export from echocollect into file for automatic logging of data Quick direct database access compared to OPC

No loss of data in case of interrupted communication Data are automatically stored locally on SD card Data will be forwarded automatically if communication is active again

Application Storyifm Tettnang: Cable Box Production Facility

► Condition Monitoring Maintenance Optimization

► Production Tracking Production-time, Downtime measurement OEE Overall Equipment Efficiency TPM Total Productive Manufacturing (PQCDSM)

► Energy Management Optimization of:

- Compressed Air flow- Power Consumption- Cooling water Intake / discharge


► Condition Monitoring Maintenance Optimization

► Production Tracking Production-time, Downtime measurement OEE Overall Equipment Efficiency TPM Total Productive Manufacturing (PQCDSM)

► Energy Management Optimization of:

- Compressed Air flow- Power Consumption- Cooling water Intake / discharge

RTMpro OEEproCMSpro

ITResponsibilty


System Overview:


Database

PLC-DataCMS Sensor

AutomationResponsibiity

► Downtime reductionMotor failure of a packaging machine detected and avoid unplanned loss of production- 8 hours downtime shifted to production-free periods

► Return of Investbecause of the optimisation on Granules Drying Machines the compressed airconsumption has been reduced- ROI less than 2 months

Success Story:



► Downtime reductionMotor failure of a packaging machine detected and avoid unplanned loss of production- 8 hours downtime shifted to production-free periods

► Return of Investbecause of the optimisation on Granules Drying Machines the compressed airconsumption has been reduced- ROI less than 2 months

6 Machines►330 teabags / min►3 Shifts, 5-6 days / Week►2 Operator, 1 Mechanics►Maintenance:

90% reaktive10% preventive

Application StoryTeekanne Düsseldorf: Tea Bag Box Production Facility


6 Machines►330 teabags / min►3 Shifts, 5-6 days / Week►2 Operator, 1 Mechanics►Maintenance:

90% reaktive10% preventive

Effects / task:♦ 150 Products♦ 180 different problems♦ Ø 72% Availability only

► A constantly recurring error has been detected and solved (threader)

– achieves additional 45 min production time / shift (50h / month)

► Although the packaging machines are identical, the production efficiency was different:i.e. Herbal Tee („Sanfte Ruhe“)Machine A: 230 bags/minMachine B: 290 bags/min

► As a result, the different teas are now distributed on the appropriate facilities.

Application StoryTeekanne Düsseldorf: Tea Bag Box Production Facility


► A constantly recurring error has been detected and solved (threader)

– achieves additional 45 min production time / shift (50h / month)

► Although the packaging machines are identical, the production efficiency was different:i.e. Herbal Tee („Sanfte Ruhe“)Machine A: 230 bags/minMachine B: 290 bags/min

► As a result, the different teas are now distributed on the appropriate facilities.

Echocollect References (Abstract)


Thank you for your attention.

More infos are available onwww.softing-in.de


Thank you for your attention.

More infos are available onwww.softing-in.de

Ostendstr. 50 A90482 Nürnberg

Email: [email protected]

Tel.: +49 (0) 911 544 27-0Fax: +49 (0) 911 544 27-27

www.softing-in.de

www.softing-in.de

[email protected]

www.softing-in.de

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