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OPC SCADA

Jul 08, 2023

OPC SCADA


OPC SCADA, an acronym for OLE for Process Control and Supervisory Control and Data Acquisition, plays a crucial role in industrial automation. In this section, we will explore the key aspects of OPC Server DA (Data Access) and OPC UA (Unified Architecture) protocols, highlighting their differences and use cases.


OPC DA has long been the standard for data exchange between automation systems. However, with the introduction of OPC UA, a more advanced and secure protocol, the landscape of industrial communication has evolved significantly.


We will delve into examples of how OPC UA is implemented in various programming languages such as C, Python, and explore available resources on platforms like GitHub. Additionally, we will discuss the fundamentals of OPC UA protocol and provide tutorials in PDF format to aid your understanding.


Furthermore, we will touch upon Siemens' involvement in OPC UA by examining methods they employ within their systems. We'll also shed light on licensing considerations for Siemens' OPC UA solutions and provide insights into downloading their client software or accessing server manuals.

OPC DA and OPC UA Protocols


By the end of this section on OPC SCADA, you will gain a comprehensive understanding of both OPC DA and OPC UA protocols. This practical knowledge will enable you to effectively utilize them in industrial automation scenarios.


SCADA is a cutting-edge concept and tool used to control and monitor technological processes. It is a computer-based system that includes both software and hardware components, specifically designed for this purpose. The hardware collects and transmits the data to a PC with installed SCADA software. The PC then efficiently processes the data within an acceptable time period.


Thanks to the significant progress in this field, SCADA systems are now applicable in various industries including consumer goods manufacturing, metallurgy, industrial hydraulics and pneumatics, chemistry, power engineering, and even the nuclear field.

A SCADA system includes two key hardware components:

- The server(s) are connected to the (process) field elements through various data acquisition systems.

Microcontrollers are widely used to achieve data acquisition systems. The main purpose of OPC SCADA is to gather data from the process and effectively oversee and manage the operation of the process. Acquiring data can be done either by using intelligent sensors that connect directly to the computer or through intermediate devices known as stations or communication masters. These stations efficiently gather data from various intelligent sensors. Programmable automata dominate the industry field as the main devices for data acquisition and process control.

  • PLC's, or Programmable Logic Controllers, are utilized to collect and process data from the process. The server not only handles the database but also maintains communication with the PLC's throughout the entire process.
  • The Viewer (the Client) is connected to the network through the server. The OPC SCADA system utilizes the data and facilitates communication with the human operator. Multiple communication drivers are available to connect the servers with controllers, offering compatibility with numerous PLCs from reputable companies.

 

A single server has the capability to achieve simultaneous communication across multiple protocols, and it is also possible to develop new communication drivers.


Both servers and viewers are connected to the Ethernet network. You can now conveniently view a process online using the selected web technology.


The monitoring and control function of SCADA systems holds utmost importance.


Graphical pages, also known as HMI's (Human Machine Interfaces), are essential for effectively monitoring and controlling technological processes. HMI's are used to imitate the technological process and are displayed on computer monitors. The control operation, also known as monitoring, is carried out using HMI's for the monitoring and control of technological processes.


The SCADA system has several key functions, which are as follows:

- Automating the control of the technological process maximizes output parameters and significantly improves efficiency.

- The technological process condition is displayed in real-time.

- Graphically displaying process data is essential for developing efficient operating strategies.

- Efficiently control process quantities logging, equipment condition, and alarm status.

- Generate operating reports periodically.

- Users have the right to directly intervene in the process based on their access rights.

- You can achieve remote process control by utilizing SCADA client stations.


The OPC Foundation has meticulously and definitively outlined comprehensive specifications for the widely recognized OPC (OLE for Process Control) standard, as well as the innovative Openness Productivity Connectivity. These meticulously crafted specifications were purposefully designed to significantly amplify connectivity in industrial automation. The OPC greatly relies on the powerful Microsoft DCOM technology to establish a robust and seamless communication link between OPC servers and clients. This cutting-edge technology ensures efficient data exchange, real-time monitoring, and rapid response times, making it an essential component in facilitating smooth and reliable interactions between OPC systems. By leveraging the unmatched capabilities of Microsoft DCOM, the OPC guarantees a rock-solid foundation for secure and efficient data transfer within industrial automation environments. Ensuring secure communication across various industrial processes is absolutely paramount to the success and safety of the operations. It is imperative that all measures are taken to safeguard the integrity and confidentiality of sensitive information.


By implementing robust encryption protocols and utilizing state-of-the-art security technologies, organizations can confidently protect their data from unauthorized access and potential threats. This category proudly encompasses a wide range of industries, including but not limited to electric power generation and distribution, industrial hydraulics and pneumatics, petrochemical refining, assembly lines for motor vehicles, and various other sectors. These industries are the backbone of our economy, driving progress and innovation in their respective fields.


SCADA systems have advanced control capabilities that incorporate modern data transmission and management methods. They also utilize drive and control software to offer numerous benefits. The process control chain involves several key steps. First, parameters are estimated and the linearized transfer function is identified. Next, a controller is designed for optimal control. Finally, the entire chain undergoes rigorous validation and testing to ensure its efficiency in industrial settings.



OPC Server


The OPC (OLE for Process Control) industry standard was developed through a collaboration between major automation software and hardware suppliers and Microsoft. The standard has been created to clearly establish the data communication methods between real-time automation systems and client applications on computers with Microsoft operating systems. Its goal is to ensure that client applications can access automation data in a consistent and uniform way.


There are countless undeniable benefits to wholeheartedly conforming to this industry standard, such as:

- Customers are absolutely required to utilize a single set of highly efficient and standardized software components for their applications, without any exceptions, irrespective of the hardware manufacturer. It is imperative that they adhere strictly to this rule in order to ensure seamless compatibility and optimal performance across all their systems.

- You absolutely do not need to waste time rewriting the drivers for new hardware versions because they are fully compatible right from the start.

- Customers now have an extensive and diverse array of options available to them in order to achieve top-notch, seamlessly integrated production systems within any kind of computer environment. The possibilities are vast and can cater to the unique requirements of each individual customer, ensuring that their production processes are efficient, effective, and highly productive.

The OPC standard allows production and economic applications to easily access field information in real-time, promoting seamless interoperability between different equipment. It also facilitates convenient "plug and play" connectivity. Integrating, developing, and assembling process automation or control systems offer more flexibility and lower costs.


An OPC server, without a doubt, operates in a remarkably similar manner to an API or protocol converter application. It seamlessly bridges the gap between different systems and protocols, enabling smooth communication and data exchange. Just like an API or protocol converter application, an OPC server effortlessly handles data conversion, ensuring compatibility and seamless integration between various devices and software. It serves as a robust intermediary that guarantees efficient and reliable communication between systems, leaving no room for errors or bottlenecks.


OPC servers were specifically and ingeniously designed to enable absolutely seamless and flawless communication between production and economic computer systems. Their primary purpose is to ensure that there are no obstacles or hindrances in the transmission of vital information, allowing for a highly efficient and productive exchange of data between these crucial systems. Significant challenges have emerged due to the glaring and frustrating incompatibilities that exist between custom communication interfaces and automation hardware and software from various vendors. These incompatibilities create unnecessary complications, hindering smooth operations and impeding efficiency in the workplace. It is imperative that these issues are addressed promptly to eliminate any further delays or setbacks.


The OPC specifications clearly define a standard COM (Component Object Model) interface that must be implemented for industrial applications in order to acquire and control data.


The specifications clearly outline the protocol for defining objects, determining their properties, and standardizing function calls and events. To successfully accomplish these tasks, the OPC is composed of a diverse range of data sources.


Input and output devices play an absolutely crucial and indispensable role in a wide range of systems. They are the backbone of communication and interaction, enabling seamless data exchange between users and machines. Without these devices, the functionality and effectiveness of various systems would be severely compromised. The comprehensive range of components that make up these systems includes highly advanced data acquisition devices, powerful actuators, efficient communication bus systems, and cutting-edge programmable logic controllers (PLC). These components work in perfect harmony to ensure seamless operation and optimal performance. The comprehensive specifications rigorously encompass numerous critical aspects, including well-defined protocols for seamlessly working with state-of-the-art data control systems (DCS) and cutting-edge database applications. These OPC SCADAs are not just limited to basic functions. They go above and beyond by providing clear and concise instructions on how to access online data, efficiently control alarms and events, and easily retrieve crucial data logs from various sources.


The COM interfaces utilized in the OPC architecture provide a convenient mechanism for extending OPC functionality. The architecture and design of OPC servers enable client applications to access data from multiple OPC servers, even if they are from different vendors and running on different nodes.


Nowadays, all commercially available SCADA systems, process control systems, and PC-based controllers come with free OPC client interfaces. You have the ability to access any OPC server effortlessly without incurring additional expenses. The OPC interface is advantageous because it does not have any limitations on specific manufacturers, products, or hardware.


The technology efficiently handles various tasks such as clearly distinguishing between server and client applications, seamlessly integrating product-specific features, and allowing for smooth upgrades or replacements with newer or different products. OPC communication between components running different operating systems and via the Internet can be achieved easily, thanks to its independence from the platform.


The OPC standard is limited to the Windows operating system because it relies on the DCOM technology. It's worth noting that the success of OPC was heavily influenced by DCOM.


OPC technology has quickly gained popularity in recent years, thanks to the widespread use of Windows computers as automation components. Due to its growing usage, the OPC standard must adapt to meet new requirements set by emerging application fields. This is in line with the overall trend towards Web technologies.


The groundbreaking application harnesses the power of OPC-UA (Unified Architecture) technology, which undoubtedly represents the pinnacle of OPC technology's evolution. This next generation technology is revolutionizing the way data is exchanged and communicated within industrial automation systems, setting new standards for efficiency and interoperability. It offers an incredibly secure, open, and highly reliable method for seamlessly transferring critical information between servers and clients. OPC-UA unquestionably provides a multitude of significant advantages over the outdated OPC Classic protocol. The latest advancements in transportation technology have brought about a range of new and improved options for travel. These include highly efficient and environmentally-friendly open transports that are revolutionizing the way we commute.


Additionally, there have been significant enhancements in security measures, ensuring that passengers can feel confident and protected throughout their journey. Finally, a comprehensive information model has been implemented to provide travelers with all the necessary details they need for a seamless experience. OPC-UA presents the ideal, flawless solution for seamlessly and efficiently transferring data between various enterprise systems, controls, monitoring devices, and sensors. Its robust capabilities ensure that information is relayed effortlessly and without any disruptions or delays. With OPC-UA in place, organizations can enjoy uninterrupted data exchange and achieve unparalleled levels of integration and connectivity within their operations. The mechanism of this exceptional product is not only incredibly flexible and adaptable, but it also ensures a seamless and effortless interaction with real-world data. Its innovative design guarantees a flawless integration with your existing systems, allowing for a dynamic and efficient utilization of the vast amounts of data at your disposal.


OPC-UA is significantly more complex compared to previous OPC specifications and has been designed to:

- Opt for cross-platform capable communication rather than relying on Windows DCOM.

- Combine the OPC DA, AE, and HDA functionality into a single set of services.

- Modeling complex data structures for collaboration with other standards organizations is essential. It ensures effective communication and seamless integration between different entities.

- It is important for the solution to be able to work on various platforms, ranging from embedded systems to enterprise systems.


OPC-UA servers do not have standardized functionality, performance, or device types. They initiate communication sessions and provide data to OPC-UA client endpoints. Devices of various sizes, from small sensors to large computers, can represent OPC-UA servers.

Servers possess an exceptional capability to effortlessly host an extensive range of data points, spanning from a mere few to an astounding number that can reach into the thousands. Some OPC-UA servers make it a top priority to prioritize high security measures over performance, and they achieve this by implementing XML mappings. This ensures that the servers are fortified with robust security measures, providing an extra layer of protection against potential threats.


However, it is absolutely crucial to note that there are still a concerning number of servers that persist in communicating without any proper security measures in place whatsoever. However, it is important to note that they not only make use of high-performance OPC-UA Binary Encoding, but they do so with unparalleled efficiency and effectiveness. Servers, without a doubt, offer clients the invaluable capability to effortlessly configure data model views, alarms, and events. However, it is worth noting that certain servers may unfortunately lack some much-needed configuration options.


OPC-UA is a superior network that provides clients with unparalleled flexibility. Here are the key benefits it offers:

  • You can easily search for and identify OPC-UA servers, determine their communication method, understand their capabilities, and configure them to provide the specific data you need.


OPC-UA clients typically support various protocol mappings to enable communication with different types of servers.


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