Process Control Systems

Any installation, whether it is a factory, a large infrastructure, a city or a large building, has a set of physical equipment deployed – typically PLCs or RTUs – in charge of controlling and automating the production process or guaranteeing its correct operation – comfort states, various consumptions, maintenance data, … -. These controllers in turn report this information to the higher control systems – SCADAs, GMAOs, MES systems, BBDDs, … – which vary according to the needs of the installation itself.

Currently, we are at a time where it is necessary to open that controller + system architecture to integrate it with other components of the installation. And it is not always easy. OPC Router is a connectivity solution designed and developed to facilitate this exchange of information. In this entry of the series ‘We can integrate everything’ we will discuss the use and value of this solution. We will see how to open the classic components in charge of the control and monitoring of an installation to the other systems in a simple and effective way.

The PLC/RTU + SCADA integration – or other system – has been resolved for years thanks to the OPC Servers. OPC Router as such, is not a solution that has connectivity drivers for field devices, it does not ‘speak’ Siemens, Allen-Bradley, Modbus, or DNP3 protocol, etc. But it does communicate via OPC DA and OPC UA, that is, OPC Router together with a market OPC Server is already capable of communicating with all PLCs on the market.

OPC is an optimal technology for this architecture, but it falls short with other needs. That’s where OPC Router fits in very well. Let’s see it with real examples where OPC Router is already being used to improve the control, traceability and automation of process data.

I Integrate Printers to the SCADA

Example architecture: SQL/OPC plugin + Domino/Zebra/Videjet/Generic plugin

Although they are an important part of the production process of many factories, it is not easy to communicate industrial printers with SCADA systems. At most, they have some APIs to integrate with MES or ERP systems. Everything else requires custom integrations. Through the different plugins for printers, OPC Router will be able to send and receive information from them and send them to an intermediate database or to an OPC Server, for example, so that the SCADA is able to acquire information or send commands to the printers in a simple and scalable way.

I Integrate Barcode Readers with PLCs

Example architecture: OPC plugin + Barcode-Scanner plugin

Barcodes are another part of the process that is widely used but also very isolated from the rest. In a batch production process, PLCs must execute one programming or another depending on the specific batch. It is very common to want the PLC to check if the type of batch that is entering its process line corresponds to the type of programming that they have ordered it to do. Currently, the communication between the PLC and the barcode reader is not usually direct, but requires intermediate elements – databases, going through the ERP, … -, which makes it difficult to have a quick or accurate verification. In this case, OPC Router is the bridge between the barcode reader and the OPC Server connected to the PLC.

I Integrate Barcode Readers with the SCADA or the ERP

Example architecture: SQL/OPC/SAP/Webservices plugin + Barcode-Scanner plugin

If you want to put a barcode reader at the end of the line to ensure that the labeler and the traceability system are synchronized, the solution often involves a custom development. With OPC Router, once again, we will be able to integrate both systems by reading directly from the source and sending it to the SCADA or the ERP – be it SAP or any other – in a transparent way.

I Integrate RFID Readers with the SCADA

Example architecture: OPC/SQL plugin + RFID plugin

Once again, current SCADAs do not have native drivers to connect with RFID readers, but their use is increasing in installations, whether for labeling, stock management or for access control, for example. In the same way as in the previous cases, the use of OPC Router allows integrating these systems with the rest of field and process information.

I Integrate PLCs with Historization Systems

Example architecture: OPC plugin + SQL/InfluxDB/MongoDB plugin

The use of databases for historical records is growing very rapidly in the industry. The reason is simple, they are databases that work better for dealing with large volumes of data based on time, that is, they fit much better with analytics and big data systems. If you want to integrate the information coming directly from the process, OPC Router has a large set of drivers focused on connectivity with databases, including a specific plugin for InfluxDB the database for time series that is growing the most currently.

I Integrate the SCADA with other non-SCADA Systems

Example architecture: OPC plugin + SQL/Webservices/SAP/MQTT plugin

Currently, projects are rapidly increasing where it is necessary to connect the PLC or the SCADA with other systems, such as the CMMS or predictive maintenance, air conditioning systems, warehouse management, cloud systems or the ERP among others. These solutions do not usually have native drivers to communicate with each other unless they are from the same manufacturer – and sometimes not even then -, but they are frequently from different brands. OPC Router allows integrating all these tools in a scalable and productivized way through its own plugins.

Without a doubt, there will be more use cases. What we intend to teach in this article is that the exchange of information between PLCs/RTUs and SCADAs is no longer sufficient, but new communication needs are appearing with other systems. OPC Router is the solution that will allow you to carry out these integrations without the need to carry out custom developments.

If you have a case like the ones we have raised or you have others to solve, do not hesitate to contact us or take a deeper look at the solution.

You can consult all the posts in this series:

https://www.comunicacionesindustrialeslogitek.com/opc-router-podemos-integrarlo-todo-ii/

https://www.comunicacionesindustrialeslogitek.com/opc-router-podemos-integrarlo-todo-iii/

https://www.comunicacionesindustrialeslogitek.com/opc-router-podemos-integrarlo-todo-iv/

https://www.comunicacionesindustrialeslogitek.com/opc-router-podemos-integrarlo-todo-v/