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Automation Technologies 4/2015

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Automation Technologies 4/2015

INDUSTRIAL COMMUNICATION

INDUSTRIAL COMMUNICATION Integrating S5 and S7 controllers in the OPC UA world The basic objective of Industry 4.0 is to make manufacturing more competitive by utilising the information and communication technology (ICT). In order to implement this technology efficiently and as quickly as possible, modularization and standardization are important. Both these factors reduce the complexity and increase the flexibility of the system. In this context, OPC UA has proven to be the pioneering communication standard. With OPC UA the industry 4.0 requirements for minimum dependence on the manufacturer and companycommunication-systems are fulfilled. OPC UA is basically an industrial machine to machine communication protocol for interoperability. It is a platform independent, service orient ed architecture specification that integrates all the functionalities from existing OPC specifications. Not only does it transfer the machine data such as process values and measured values, but because it allows for describing or expressing the meaning of the data with semantic descriptions, OPC UA is becoming increasingly important to transfer machine data to higher level controller systems. But how is the process data from Simatic controllers integrated into the OPC UA ? The solution to this is the IBH Link UA. The IBH Link UA, OPC UA server/client module with in-built firewall, connects the simatic controllers S5, S7-200, AUTOMATION TECHNOLOGIES 4/2015

INDUSTRIAL COMMUNICATION next page S7-300, S7-400, S7-1200 and S7-1500 into the OPC UA communication. It is compact in size and is well suited for DIN rail mounting. It consists of 4 ethernet ports and requires a 24V power supply. To configure the IBH Link UA, no special software is required and can be done by using Siemens Step-7 or the TIA ( totally integrated automation) portal. This allows total integration into the project. The definitions of the variables are transferred by the programming software via ethernet into the IBH Link UA. The variable attributes are directly defined within the PLC project. Thus a symbolic access to variables and data block structures is possible. To communicate with Siemens series of PLC, the ethernet port is utilised. If the PLC has no ethernet port then the IBH Link S7++ or S5++ gateways are used. Out of the 4 Ethernet ports 3 of them are assigned to machine level on the IBH Link UA and 1 is assigned for supervision level where only the OPC access is possible. An integrated firewall between these 2 levels prevents any possible manipulation from the supervisory level. the HMI. Earlier, a custon driver that translated the data between the source and sink was required. With OPC DA it is now possible to transfer data directly hence reducing the cost and providing the real time data. Since the IBH Link UA can be accessed by multiple OPC clients, this makes the data source for any OPC UA compliant application like the SAP, MES and ERP systems available. Historical Data OPC Data Access allows the access to data in real time, but not the archived data. OPC Historical Data Access, called OPC HDA provides access to already stored data. From simple data logging systems to complex Scada system’s historical data can be queried in standardized manner. Stepwise configuration Configuration is done as follows: n At first a PC station is created by the user. n The OPC server (SW8.2) is inserted into slot 1. n In slot 2, the Ethernet interface (IE General SW8.2) is inserted n Next the S7 connection to the required controls are established n In the properties of the OPC server, the variables are now easily configured n Subsequently the configuration is transferred via Ethernet into the IBH Link UA. The IBH Link UA then immediately knows the access paths to the controls and puts the required variables in the OPC client. All done! OPC Data Access OPC Data Access, also known as OPC DA, is a specification that defines how real-time data can be transferred between a data source and a data sink without either of them knowing each other’s native protocol. For example, source being the PLC and sink being The activation of historical data can be done using the web browser Safety The device has a certificate management for secure communication. The configuration of the security levels and the certificate management is easily accomplished via a web browser with help of an AUTOMATION TECHNOLOGIES 4/2015

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