OPC Server Research Articles

Разработка цифрового двойника системы управления испытательного стенда для цифровых измерительных трансформаторов

The presented work considers the option of implementing a digital twin of a test bench control system for digital instrument transformers using a universal SCADA system. The basis of the design of the test bench is a hydraulic servo drive using hydrostatic guides. Digital instrument transformers must have a service life of at least 25 years, a verification interval of 8 years or more. To achieve such high performance characteristics, a large number of tests are required for such products. In particular, to check the reliability of operation of this class of devices, it is necessary to conduct tests on a diagnostic vibration stand. The task of creating test benches based on a hydraulic servo drive using hydrostatic guides is an urgent scientific and technical task. The architecture of a digital twin of the test bench control system has been developed. To test the functionality of the application, a simulation of the operation of a digital twin of the control system of a test bench for digital instrument transformers was performed. Aim. Based on an analysis of the operating modes of the test bench and options for implementing digital twins, develop a prototype of a test bench control system for digital instrument transformers using a universal SCADA system. Materials and methods. The posed scientific problems were solved using key methods of digitalization of production, computer and simulation modeling of the interaction of the digital twin with elements of the test bench control system. Results. The main practical result of the research is the development of a digital twin of the test bench control system for digital instrument transformers. It is proposed to use the domestic universal SCADA system when implementing the digital twin in software. Conclusion. Analysis of options for implementing a digital twin showed that the use of universal SCADA systems simplifies the development process. Such software systems provide the ability to control automated technological processes, collect and process data in real time, monitor the condition of equipment and the progress of production processes, as well as quickly respond to any problems. When developing a digital twin, the use of a universal SCADA system is justified. Prototyping of the test bench control system was carried out using a universal domestic SCADA system. An OPC server has been developed for data exchange with a microcontroller of the STM32 family in the Modbus Universal MasterOPC application and a project in the MasterSCADA system. Testing of the application showed the full functionality of the developed project.

Application of Industrial Internet of Things (IIoT) in Crude Oil Production Optimization Using Pump Efficiency Control

The collapse of oil prices in mid-2014 and early 2016 was the biggest in modern history that witnessed more than a 70% drop in the price to around $40 barrel. It prompted companies to think seriously to maintain profitability. Most companies were able to survive partly by simplifying their operations. Price recovery in 2021 is only 70% of its peak value. Companies are focusing on reducing the cost of operations, increasing production simultaneously, and finding new and different strategies to survive. The current scenario is witnessing strong research focusing on the development of process control for oil and gas upstream and downstream to improve the control and preventive maintenance to reduce operating costs and increase production. This paper presents the Industrial Internet of Things (IIoT) practical solution that improves the oil production rate from the well and increases the average pump efficiency (fillage) to 90%. This paper proposes a mechanism for collecting, storing, and analyzing all required parameters to build valuable charts. These charts’ data help optimize the values and parameters for controller setpoints to prevent pump gas lock problems. An artificial lift is required to lift the oil from the well. In this paper, the sucker rod pump is driven by a gas engine fed by the well’s gas. At the same time, SCADAPack 535E remote terminal unit collects all pump and well parameters such as hydraulic pressure, casing pressure, tubing pressure, and pump speed in stroke per minute (SPM). The remote terminal unit sends the data through a wireless network using a 5 GHz antenna to the main control room. The IIoT platform is designed using a visual basic programming language. Microsoft DDE (Dynamic Data Exchange) and Kepware OPC server were used to work on the received data to monitor, generate charts, and apply the controllers.

스마트팩토리 교육을 위한 PLC를 이용한 MES에서 C# 프로그램 구현

In this study, C# codes were implemented in a manufacturing execution system using a programmable logic controller for education of a smart factory. In the existing environment of an aviation campus, when MES education for a smart factory was conducted, HMI or SCADA programs were used as PLC-only software, and the trainees were limited to PLC specialized skills; therefore, MES specialists were nurtured. However, when implementing an OPC server and MS-SQL in PLC equipment by strengthening a smart factory system environment, notably, the control/monitoring function of an MES could be implemented using C# programs without using HMI or SCADA programs as PLC dedicated SW. It is expected that it will be of great help in finding employment by nurturing the MES manpower required in the industrial field, not limited to PLC specialized skills, as it provides trainees with a basic and functional understanding of the MES and C# program education.

Design and Performance Simulation of Computer Control System for Automatic Monitoring of Upper Computer Communication Operation State

The upper computer communication operation state automatic monitoring system is mainly used to remotely monitor the equipment, obtain various parameter indexes in the operation process of remote equipment, realize remote monitoring and fault diagnosis, and improve the management efficiency of decentralized equipment. This paper completes the design of communication, data storage, query, and other subsystems of upper and lower computers. The lower computer establishes a data channel with the OPC server through the MPI protocol and uploads the collected data to the OPC server in real time. The upper computer reads the data through the OPC server and displays the changes of monitored parameters in real time through the monitoring interface, so as to give an alarm under abnormal conditions. In addition, since the default database of Kingview is access, considering that the Microsoft Access database can store up to 2G of content, in order to upgrade and expand the subsequent system, SQL Server database is selected for data query, backup, and saving. The parameter setting method of communication control system is analyzed, the simulation model of industrial boiler control system is established by using Matlab/Simulink, and the interface between host computer software (IBCCS-e) and the model is provided. This paper analyzes the results of communication parameter adjustment. The simulation results show that the industrial boiler computer control system (IBCCS) has stable performance, low cost, convenient operation, and good maintainability. After further improvement, it has certain application value in the operation transformation of new small- and medium-sized boilers and original boilers.

Integration of technology to access the manufacturing plant via remote access system - A part of Industry 4.0

During Covid-19, manufacturing industries have faced problems due to lack of Remote Access system for manufacturing operation whereas IT sector has had a tremendous increase by leveraging the Remote Access system. In this paper, a Remote Access system is formed by integrating the existing technology such as SCADA (Supervisory Control and Data Acquisition), Microcontroller, OPC server, Internet, Sensor, and Actuator which facilitate controlling and monitoring manufacturing operation remotely. Sensor send operation data to Cloud via microcontroller (Arduino). Cloud computing processes the data and provides information to user in analytical form such as chat, graph, table etc., via HMI (Human Machine Interface). Through HMI the user monitors and controls the manufacturing operation by sending signal to actuator via microcontroller. This process integrated Human intelligent with machine capability. Viability of the proposed methodology is validated through simulation model design on Proteus and Wonderware Intouch. To find features and issues of Remote Access system we have done analysis of the simulation model and work done by different author in similar field. From this study, we realise that the Remote Access system is possible but it will not be effective until the infrastructure of IIoT (Industry Internet of Things) is developed.

Development of machine steering with use of PLC as introduction to 4.0 Industry

Article was written in order to make an attempt at developing a simple steering system for numerically controlled machines, with use of virtual modelling environment and an actual driver together with HMI panel. It was made as a response to demand of centralized system for steering a smart factory containing many machines. In the article, creation of a simple single machine steering system was described, which can be upscaled to the entire production hall. Used steering in this case is setting of position in an absolute system, in which only 3 variables X, Y and Z are known, and the operator can perform a correction of location and speed. Obviously, in real conditions these values will be set by a different program - like a post processor generating G-code. Usage of one data communication server can allow integration of devices within one production, and this allow creation of a smart factory suitable for 4.0 industry. In order to obtain such communication, an OPC server was used. Furthermore, the process of creating and connecting machines or programs to it was briefly presented.

Industry Communication Based on TCP/IP Protocol

Abstract The design of control systems needs to ensure communication between multiple PLCs or external IoT devices. Furthermore, there are several ways of communication between them. This article dealt with the PLC communication based on TCP/IP protocol, and compared several communication options between two PLCs of the S7-300 and S7-1200 series connected using Profinet with a solution built in C# connected to the PLC via an OPC server. We used MODBUS TCP, TCON, and PUT/GET program blocks for comparison. We transmitted a digital Boolean data type and an analogue value of the integer data type via Profinet to read data from the S7-300 PLC and send data to the S7-1200. We compared the programming instructions standardly used as a client/server PLC programming with a Windows Forms application, and evaluated the advantages and disadvantages of this solution even when using external IoT devices. The solution was applied and successfully tested for communication between PLC S7-1200 and Nvidia Jetson Nano. We wrote program instructions for PLC in Siemens Tia Portal V15.

Improved control and monitor two different PLC using LabVIEW and NI-OPC server

<span>This paper proposes an improved control and monitors between two different PLCs, the Mitsubishi, and Omron. The main advantage is interoperability and communication between both PLC. The use of NI OPC server as the software interface reached interoperability and communication. There were developed two field applications to test interoperability. Laboratory virtual instrument engineering workbench (LabVIEW) uses as the software application for creating the user interface to control and monitor. This improvement show OPC server technology solves data compatibility issue between different driver controller’s and reducing development cost. Regardless of whether there are more than two different PLCs, it's enough to use the NI OPC server. So the benefit of the NI OPC server is not limited to two types of PLC used right now but can also use the other manufacturers. Besides, the improvement of the previous study is the use of the LabVIEW makes data from the OPC server displayed more realistic. The use of LabVIEW allows additional monitoring functions, one of which is LabVIEW vision. Data utilization becomes more flexible, and so it can use for more complex purposes. It is envisaged that this is very useful for Integrator engineer to implement this method in industrial automation</span>

Transmission Characteristics of a Smart Sensor Based on the OPC Server

In this study, a smart sensor was manufactured to operate on the Internet using an Arduino module. This sensor was programmed to connect to the MQTT broker by connecting to the Internet via Wi-Fi. The OPC server, which is a heterogeneous communication system, was set up to connect to the MQTT broker by connecting to the Internet through a wire. The MQTT broker served to relay data from the smart sensors to the OPC servers and smartphones. The sensor data reaching the OPC server were transmitted to the signal display device. The process by which the data reach the signal display device via the MQTT broker and OPC server is known. However, the transmission characteristics of the data have not been clarified yet. Two experiments were conducted to evaluate the performance of the communication systems connected through the smart sensor, MQTT broker, OPC server, and signal display device. The first experiment was conducted to measure the time taken by the program code of the Arduino module. In the second experiment, five sinusoidal signals were input to the smart sensor, and they were monitored and stored in the signal display device. The experimental results clarified the transmission time and transmission frequency of the smart sensor based on the OPC server.

Implementation of a Pilot Plant for the Integral Development of Remote Laboratories

This article is an integral proposal of remote laboratories that complements the classes and the traditional laboratories of the subjects of Automation at Universidad de Piura. Four control loops have been implemented in the FESTO Compact Workstation pilot plant to remotely manipulate them: level control, flow control, pressure control and temperature control. In each one of them, the students must identify the open-loop process, understand the nature of the process and finally control it in a closed – loop, all this in an automated and remote way through the Internet. EasyPort and DirectLogic06 PLC have been used for module control, DirectSOFT software for PLC programming, FESTO Didactic EzOPC and NI OPC Servers for communication, and mainly LabVIEW for graphic interface and data processing.

Communication between PLC different vendors using OPC server improved with application device

Many industries often use different devices and controllers in automation systems. They all face the same difficulty how to exchange data between all those components. This paper proposed the implementation of OPC Server as software interface on communication between two different controllers, PLC Mitsubishi and PLC Omron. The main advantage of the method is the compatibility and solution for the factory difficulty problem because of using several driver controller. The compatibility among the different platforms of both controller, PLC Mitsubishi and PLC Omron, can be reached by use of KEPServerEx6 (OPC server) as a software interface. To test the compatibility amongst two different controllers, there was developed and implemented two field application devices, bottle unscramble and bottle filling station. This implementation shows OPC Server technology resolving data compatibility issues between different platforms and reducing development costs. It is envisaged that the method can be very useful to realize integration.

Development of a highly automated mobile rig for the Australian CSG market

In Q2 2020, a fully automated rig will enter the coal seam gas fields of Queensland, to work for a major operator. It is expected to be 20–30% faster than current operations. This document describes the upfront iterative design process with local potential users. Following discussions with various contractors and operators it became evident that there was a gap to bridge between operator and contractor targets and in what current operations have to offer. Both strive for the highest safety levels and operational efficiency, reducing the overall time per well, completed by minimising environmental impact. The above fits in the overall industry trend of transformation from mechanised rigs towards fully automated hands-free operated rigs. It was with these ingredients that the basis of a new iterative design process was formed, in which input from the operator field lieutenants, contractor rig crews and the supporting office was translated into a technical design. The target was set to reduce 20–30% of time per well. Key elements were the choice for road legal trailerised loads with no loose items, which resulted in rig moves of 4–6 h. Fully automated sequenced pipe tripping and casing running contributed to big improvements in efficiency and safety level (no people on the floor during standard operations). Performance can be real-time evaluated and optimised by collecting all rig and downhole data on the OPC server. The server also controls the mud system, downhole data and other important systems. This enables through-life time optimisation.

ВИЗНАЧЕННЯ ДИНАМІЧНИХ ПАРАМЕТРІВ ОБ’ЄКТІВ УПРАВЛІННЯ У РЕЖИМІ РЕАЛЬНОГО ЧАСУ ЗА ДОПОМОГОЮ ГРАФОАНАЛІТИЧНИХ МЕТОДІВ ІДЕНТИФІКАЦІЇ

У статті досліджено можливість застосування сучасних апаратних і програмних засобів для автоматизації традиційних способів ідентифікації, з можливістю отримувати значення параметрів об’єктів управління у реальному часі. Проаналізовано відомі графоаналітичні способи ідентифікації об’єктів управління та доведено недоцільність їх використання при ідентифікації у режимі реального часу через необхідність ручного введення експериментальних даних. Для визначення динамічних параметрів типових лінійних об’єктів систем автоматичного управління запропоновано використовувати швидкість зміни вихідного сигналу досліджуваного об’єкту. Доведено, що застосування програмних пакетів Mathcad, Matlab дозволяє безпосередньо вираховувати швидкість зміни вихідного сигналу об’єкта управління, що значно скорочує час обробки даних, а використання пакету Matlab, завдяки вбудованому ОРС серверу, дозволяє обробляти у реальному часі дані процесу, що надходять з датчиків або контролерів по цифровій мережі. Наведено структурну схему системи для дослідження запропонованого способу визначення динамічних характеристик об’єкта управління та блок-схема алгоритму обчислення динамічних параметрів об’єкта управління. Наведено приклад ідентифікації об’єкта управління першого порядку з використанням швидкості зміни вихідного сигналу. Експериментально визначені значення регульованого параметру (температура) зафіксовані датчиком, підключеним до аналогового входу контролера Овен ПЛК63. Дані з контролера по мережі Modbus передавалися через універсальний ОРС-сервер Master OPC на персональний комп’ютер. У якості ОРС-клієнта було використано середовище Matlab, де проводилися розрахунки параметрів динаміки досліджуваного об’єкта. Доведено, що запропонований спосіб дозволяє значно підвищити ефективність відомих графоаналітичних методів ідентифікації. З’ясовано, що шуми, присутні у сигналах датчиків можуть суттєво вплинути на точність визначення параметрів об’єкта управління, тому для зменшення впливу цих шумів необхідно застосовувати фільтри нижніх частот.

Improved predictive functional control for ethylene cracking furnace

The objective of this paper is to show the design and application of pass temperature balance control system using an improved predictive functional control method in eight 800 tone/year USC ethylene cracking furnaces. The advanced pass temperature balance controller is developed using the proposed method and implemented in proprietary APC-ISYS software, which is connected to Yokogawa distributed control system via an OPC server. The advantage of it lies in the fact that the dynamics of pass temperature with nonlinearity and time delay are described by Takagi–Sugeno model and transformed into time-varying extended state space model, and thus, the proposed controller can regulate pass temperature based on the extended state space formulation. In addition, the control law with a linear iterative form, easily applied to industrial process, is derived. The robust analysis for the set point, input disturbance and output disturbance to the output verifies the ability of tracking and disturbance rejection of the proposed method. Application results from an industrial furnace are shown to be markedly better in terms of lower variability in the outlet temperature of both the passes compared to the current proportional–integral–derivative control scheme.

Prediction of PID control model on PLC

PID (Proportional Integral Derivative) is a control algorithm that mostly used in industry. However, users have never known what the PID model that used inside the PLC. By knowing the PID model that used in PLC, users will have more choice in determining the more appropriate tuning algorithm. Also, users can use MATLAB to perform analysis and can implement it to PLC. Through OPC Server (Object Linking and Embedding for Process Control Server) as a software interface, programs on a windows operating system can communicate with industry devices universally. PID model prediction method is done by comparing the output of the plant controlled by PID model in PLC and PID model in SIMULINK MATLAB using OPC Server intermediaries. Based on comparison result in graph and analysis using integral error method, PLC M221 using Parallel PID model and PLC S7-1200 using Ideal PID model.

A real-time event-driven database productivity and maintenance planning tool for continuous surface mining operations

This paper presents a data management application driven by real-time events, which has been developed as a productivity and maintenance planning software application to be used in the surface lignite mines in Northern Greece. The mines operate using a continuous mining system comprised of multiple bucket wheel excavators, belt conveyors, spreaders and stackers. There is a control centre for each mine, comprising of aspect servers, OPC servers and a SCADA system which interfaces with PLCs at each equipment unit in the field. The overall data management infrastructure is installed on the main network system and draws data from the OPC servers at each mine. In order to collect the data, the application is developed using event driven functionality as well as data polls. Data can then be modified by the control tower personnel. The application generates reports on a daily basis for production monitoring, productivity, equipment performance and utilisation as well as various maintenance tasks. The system has been in operation at the surface lignite mines in northern Greece since 2011 and has been embraced by mine personnel for decision making and planning.

System modeling and instability control of wind turbine blade based on hydraulic pitch system and radial basic function neural network proportional–integral–derivative controller

System modeling and aeroservoelastic control for divergent instability of stall-induced composite wind turbine blade modeled as thin-walled symmetric layup beam analysis have been investigated based on hydraulic pitch system and radial basic function neural network control. The blade is modeled as single-cell thin-walled beam structure with the circumferentially asymmetric stiffness design, exhibiting flap/lead-lag bending coupling deformation. The stall flutter and aeroservoelastic control of composite blade are investigated based on dynamic stall Beddoes–Leishman aerodynamic model and radial basic function neural network proportional–integral–derivative controller, with pitch actuator performed by hydraulic system. The system motion equations consist of the aeroelastic equations and the six-order pitch equation. The nonlinear aeroelastic responses, including both flap/lead-lag responses and pitch angle responses under different parameters, are solved by Galerkin method and the nonlinear time integration scheme with nonlinear residual analysis. To verify the effectiveness of the control scheme and realize visualized display of large thin-walled blade in the laboratory, experimental platform based on hardware-in-the-loop simulation is built to realize real-time control and virtual simulation. The platform structure consists of PLC hardware, monitoring interface in configuration software, and simulation environment that is connected by the OPC server with PLC system. The platform lays the foundation for vibrational behavior research on visualization of large wind turbine blade under divergent stall situation and verifies the real-time feasibility of the control algorithm proposed.

Development of automated system based on neural network algorithm for detecting defects on molds installed on casting machines

During the casting of light alloys and ligatures based on aluminum and magnesium, problems of the qualitative distribution of the metal and its crystallization in the mold arise. To monitor the defects of molds on the casting conveyor, a camera with a resolution of 780 x 580 pixels and a shooting rate of 75 frames per second was selected. Images of molds from casting machines were used as input data for neural network algorithm. On the preparation of a digital database and its analytical evaluation stage, the architecture of the convolutional neural network was chosen for the algorithm. The information flow from the local controller is transferred to the OPC server and then to the SCADA system of foundry. After the training, accuracy of neural network defect recognition was about 95.1% on a validation split. After the training, weight coefficients of the neural network were used on testing split and algorithm had identical accuracy with validation images. The proposed technical solutions make it possible to increase the efficiency of the automated process control system in the foundry by expanding the digital database.

The Detection of Spoiled Fruits on a Conveyor Belt Using Image Processing Techniques and OPC Server Software

Quality plays a key role in the marketing of vegetables and fruits. There is a reason that the agricultural products you see in the store usually aren’t rotten. Someone at a sorting facility has already looked over all the products coming in from the fields, and taken out the spoiled ones. This method does not exactly meet the standards of quality and it causes time and labour force loss. Moreover, it has seen that the use of conveyor belt systems are increasing rapidly in today’s industry. These systems, designed to meet the developing needs of the industry, are used to categorize objects with different characteristics. This research was conducted to develop a system for detecting the rottenness on apples on a conveyor belt using image processing techniques, PLC and OPC server. Morphological image processing techniques were used for detecting spots or rottenness emerged on apples and Matlab software was used for image processing. Image processing algorithm developed to detect the characteristics of the apples. Overall conveyor belt system was controlled by PLC. OPC server was used for communication between image processing part and controller part. In this study; image processing algorithm, OPC server and PLC algorithm were tested in real time and results were studied.

Transmitting data over the network using an OPC server

The paper presents the way of transmitting the parameters of operation of a remote installation in a centralized control center of a company. The distance between the computers that collect the data and the data monitoring center is hundreds of kilometers. Data has to be transmitted through multiple physical environments and through multiple networks. This transmission channel must be very stable and secure against external threats to the company network. The monitored installation is comprised of 10 compressors each having a local control cabinet and transmitting data to monitoring computers in the control room. Centralized data in these computers are sent to the beneficiary. This transmission uses a tunneling solution provided by a company together with an OPC Server realized by using that function of the software in which the monitoring application is developed on the industrial computers in the control room of the respective installation. The results obtained in remote data transmission were very good. In conclusion, the configuration and software solutions adopted proved reliability and stability in operation.