Exponentially Great Results Require the Right “Box of Tricks”

John Weber - PresidentKevin Rutherford – Applications Engineer

Agenda

Symbol Factory ArchestrA/Gadget Wizards

Information Integration Solutions

Case Study – BHP Hillside/CSS

Case Study - Green IT

Case Study - Task Force Tips

Summary

► Over 4,000 ArchestrA Symbols for InTouch 10

► Vector Graphics!► Resolution

Independent► Deployable► Embeddable► Vertical Industries► Easily joined pipe

pieces► Over 60 categories ► Let us focus on

graphics, you focus on your system!

Symbol Factory ArchestrA Overview

Symbol Factory for ArchestrA Licensing

► Runtime Free Distribution - Licenses Only Needed for InTouch 10 Development Workstations

► Works with▪ InTouch10 Managed▪ InTouch10 Managed with System Platform

► No Licenses needed for deployment!► Catalog of Symbols on DVD you can pick

up at our stand at the Expo► Come by Expo Stand for a 1-to-1 demo

Benefits

• Reduced Engineering Time

• Improved graphics quality

Benefits

• Reduced Engineering Time

• Improved graphics quality

Gadget Wizards for Wonderware► Ideal for InTouch 10 Compact Edition & Wonderware

Panels► Photorealistic Buttons, Lights, Switches, Meters, Sliders,

Fills & Panels► Economical - Runtime free licensing

Data Integration Challenges

Move data w/o DCOM?

Monitor & Advise if

Processes stop or restart

Connect OPC to non-

Windows OS?

Log to non- InSQL/

Historian Databases

Bridge Data Between

OPC Servers?

Connect Live OPC Data to

Excel

Connect to non-Wonderware

MES databases

Is this you daring to face your challenges without the proper tools?

Data Integration Solutions

The Swiss Army Knife of OPC!The Perfect Tool to Leverage Your ArchestrA Investments

OPC Data Aggregation Without Data Aggregation…

OPC Clients

Multiple & Varied

Data Sources

► Multiple Data Sources & Clients► Each Client makes it’s own connection to each OPC Server► Redundant data flow► High network utilization, negative impact on control network

OPC DataHub AggregationWith Aggregation

► Reduced # Connections► Common connection for multiple data

sources► Efficient data flow

OPC Clients

Multiple & Varied

Data Sources

OPC

DataHub

Benefits:• Unified data • Controllable update rates• Isolate control network from unruly client applications• Limit # of OPC connections• Common tag naming from projects• Reduce network traffic• Improve system performance• Overcome OPC server or client limitations• Single separable point of troubleshooting for clients• Save money on OPC client & server licensing (Hint – ABB robotics)

Benefits:• Unified data • Controllable update rates• Isolate control network from unruly client applications• Limit # of OPC connections• Common tag naming from projects• Reduce network traffic• Improve system performance• Overcome OPC server or client limitations• Single separable point of troubleshooting for clients• Save money on OPC client & server licensing (Hint – ABB robotics)

OPC without TunnellingFull of Challenges

PC – 1 OPC Client

COM run-time

Security Provider

OPC Client

PC – 2 OPC Server

COM run-time

Security Provider

OPC Server

I want to connect to you

I want to connect to you

Howzit boet: Tell me your login

name and password!

My user name is “vernon_koekoemoer”

and password is “bleddie_lekker”

My user name is “vernon_koekoemoer”

and password is “bleddie_lekker”

Jislaaik, you are so last year…I’ll

check my access list just now

Yes, you are on my list… I will

grant you access!

► OPC remote connections without tunneling► Many points of failure► Forget working through firewalls► Does not recover well from network issues

Or you might get: Han Weg – this is

a no Vernon Zone!

X

3 Steps to Tunnelling with OPC DataHub

► Step 1: Connect Master to OPC Server► Step 2: Connect Master to Slave► Step 3: Connect OPC Client to Slave

Or… Windows NT, 2000, XP, Vista, or 2008

Or… Windows NT, 2000, Vista, 2003, or 2008

OPC TunnellingWhy Tunnel with DataHub?

► Clean Network Interruption Handling▪ Heartbeat and reconnect settings▪ OPC transactions all local

► Reduce Network Traffic for Low Bandwidth Connections▪ No polling – event driven transfers▪ Single connection for multiple tunnels

► Improve System Performance & Reliability▪ Mirrors data – both side share data

• Clients connected to OPC DataHub always get an answer

▪ Non-blocking calls

OPC Tunnelling Why Tunnel with DataHub?

► Increase Data security (passwords & SSL)► Connecting to Non-Windows Systems► Multiple clients on same PC,

▪ One remote connection to remote OPC sources, managed by OPC DataHub

▪ Competing solutions N clients = N connections► Connect from NT forward to any current

Windows OS► OPC DataHub tunnels DATA

▪ Any data source – OPC DA, DDE, ODBC▪ Any data that DataHub can read▪ Competing solutions tunnel only OPC

OPC Server

DatabaseServer

TCP/IPTunnel

OPC Tunnelling But wait – can’t I use these…

► VPN - Does not solve problems of▪ DCOM, Network stability, bandwidth and

crossing domains – only provides security► OPC XML/DA

▪ Not secure, more overhead, not for high speed, limited products, OPC UA replaces XML/DA

► OPC UA▪ Requires all products involved to support it▪ Only tunnels OPC▪ You can use DataHub TODAY! and it will be

adding OPC UA to give you more choices

Benefits of OPC DataHub Tunnelling• Tunnel any type of data• Recover from network issues easily• All other features of DataHub included free• Fast – 30 to 50k points/sec in field, have done

100k in test• Less time on DCOM = More time on things that

generate profits

Benefits of OPC DataHub Tunnelling• Tunnel any type of data• Recover from network issues easily• All other features of DataHub included free• Fast – 30 to 50k points/sec in field, have done

100k in test• Less time on DCOM = More time on things that

generate profits

OPC DataHubSystem Monitor Function► Monitors any windows performance monitor

counter & makes it available via OPC, web, & can alarm/notify off of it

► Combine with tunnelling to monitor remote systems

OPC DataHub Email / SMS Notifications

► Easy to configure► Flexible► Get data from almost any source

Multiple & Varied

Data Sources

Send message based on Conditions and Triggers from any

source

OPC

DataHub

OPC Data HubConnecting Excel to OPC

► Value – Quality – Timestamp► Array tag support► Combine with tunnelling for easy remote

data access!► Writes without scripting

Anyone’s Desktop PC

Drag & Drop DDE Connections to OPC

DataHub

DataHub ConnectorsMore Sources = More Solutions► OPC DA

▪ Acts and OPC Server and OPC Client

► DDE▪ Acts as a Local DDE Client or Server

► ODBC▪ Can write to ODBC systems or Read from using scripting

► API’s – lets you make TCP connections ▪ C++ - Windows or Linux▪ JAVA – support web browser applications▪ .NET – C#, but works with any

► TCP Socket connection with DataHub protocol► Linux/QNX via Cascade Data Hub► Connect to your custom application

Now that we have all this data into the DataHub – what if we want to move it between systems?

Now that we have all this data into the DataHub – what if we want to move it between systems?

Bridging Solutions: Moving Data Doesn’t Have to Be Like Mountains

► What Can Bridging Mean?▪ Simple Data Exchange

Between Control Systems▪ Data Exchange and

Manipulation Between Systems

▪ Timed or Triggered Data Exchange between Control Systems

▪ Data Exchange Between HMI Systems

Control System A

(DCS / PLC / Etc.)

DA Server

XOPC

Bridging Tool

Control System B

(DCS / PLC / Etc.)

DA Server

Bridging Solutions: Moving Data Doesn’t Have to Be Like Mountains

►Traditional Solutions▪ Scripting in the SCADA/HMI

• Read from one system

• Write to the other system

• Scripted calculations or formulas to modify the data

▪ Custom Application• Development Expertise

• Scripting

Resulting in:• More Time• More Money

Resulting in:• More Time• More Money

Bridging Data Made Easy

►Software Toolbox Solutions▪ OPC Data Hub

• On Change Transfers Only (without scripting)

• Checkbox Configuration for Forward/Inverse Transfers

• Simple Linear Transformations (Multiply/Add)

▪ OPC Gateway• On Change/Polled/Triggered Data Transfer

• Complex Calculations/Transformations on Source Values

Bridging with OPC Data Hub

► Move Data Between Many Different Disparate Systems

► Email/SMS Notifications

► Avoid DCOM via Tunnelling

OPC DataHub: Diversity of Connection Types► OPC DA

▪ Acts and OPC Server and OPC Client

► DDE▪ Acts as a Local DDE Client or Server

► ODBC▪ Can write to ODBC systems or Read from using scripting

► API’s – lets you make TCP connections ▪ C++ - Windows or Linux▪ JAVA – support web browser applications▪ .NET – C#, but works with any

► TCP Socket connection with DataHub protocol► Linux/QNX via Cascade Data Hub

Bottomline:Once you get the data into OPC Data Hub – You can move it ANYWHERE!!!

Bottomline:Once you get the data into OPC Data Hub – You can move it ANYWHERE!!!

Bridging Solutions: OPC Gateway

► OPC-to-OPC Bridging► Data Transfers via:

▪ Data Change Events▪ Specified Polling Period▪ Monitored Item Condition

► Data Transformations▪ Simple & Complex▪ Wide range of

Mathematical Operators to use for calculations

▪ Transform data values prior to transfer

OPC Gateway: Update Methods

► Multiple Update Methods Available▪ On Data Change▪ Polled▪ Monitored Item Trigger

OPC Gateway: Transformations

► Simple & Complex Calculations▪ Formulas▪ Conversion to

Engineering Units▪ Scaling

► Test Transform Expressions▪ Confirm that your

formula has the desired result

OPC Data Hub & OPC Gateway: How to Choose

Exchange type OPC Gateway OPC Data Hub

Simple data exchange (Source Value to Target Value Transfer Only)

Yes Yes

Exchange between HMI systems (as OPC Servers)

Yes Yes

Data Exchange and Transformation Yes Yes (Scripting)

Triggered or Polled exchange Yes Yes (Scripting)

Data Exchange between Non-OPC Systems

Yes

Exchange over different Networks – No DCOM

Yes

Case Study – CSS & BHP Billiton Hillside

► Cast first metal June 1995.► 685 000 tons per annum. ► Largest smelter in the southern hemisphere► One of the world's most advanced and

efficient smelters► Major Wonderware User

Case Study – CSS & BHP Billiton

GTC’s40 PLC’s25K I/O

Logistics30 PLC’s13K I/O

Reduction10 PLC’s20K I/O

FTC’s4 PLC’s15K I/O

Treatment&

Logistics

Substation10 PLC’s30K I/O

ICM10 PLC’s20K I/O

HDC10 PLC’s20K I/O

Casthouse

Rodding Shop

34 PLC’s20K I/O

Handling & Storage21 PLC’s15K I/O

PastePlant 2

10 PLC’s20K I/O

PastePlant 1

10 PLC’s20K I/O

Carbon

Over 230 PLCsOver 230 000 tags!1 second scan ratesEntire Hillside facility on TOP Server

Over 230 PLCsOver 230 000 tags!1 second scan ratesEntire Hillside facility on TOP Server

GTC’s40 PLC’s25K I/O

Logistics30 PLC’s13K I/O

Reduction10 PLC’s20K I/O

FTC’s4 PLC’s15K I/O

Treatment&

Logistics

Case Study – CSS & BHP BillitonSystem Detail

InTouch View Nodes

Redundant I/O ServersTopserver

Redundant Historian Servers

Mass Auto Save Server

Case Study – CSS & BHP Billiton2009 System Improvements

• Data needed:• Position• Status• Sequence• Fault Status

• 4 systems/line, 5 lines• Skimmer• Stacker• Label Applicator• Gantry

• Used in Paste Plant for anode production• Adjusts setpoints to adapt process• Need data on control status, setpoints, process

variables, and fault indications

TOP Server OPC Client Driver TOP Server OPC Client Driver

Problem – ZAR 200 000For non local OPC

connections!

Case Study – CSS & BHP Billiton2009 System Improvements

► Added OPC DataHub to do notifications directly from TOP Server AB Suite

► Monitoring about 100 points► Plans for same in other 3 plant areas► Future: Direct connect to Oracle DB for existing

plant MES system – no added cost!

ICM10 PLC’s20K I/O

HDC10 PLC’s20K I/O

Casthouse

Send messages & reports based on Conditions and

Triggers from any source OPC

DataHubODBC

Green IT - Monitoring Data Center HVAC Systems

► System Integrator► Industry – IT Data Center Management► Background

▪ Data centers accounted for 1.2% of energy used by the United States in 2005 and is expected to be 2.5% by 2011.

▪ Objective • Minimize cost of running Data Centers.

▪ Key requirements• Allow operators to view a graphical interface with real-time

data.

Green IT - Monitoring Data Center HVAC Systems

► Lower Energy Cost with Real-time Data

▪ Operating at higher temperatures ▪ Controlling air flow between server rack

aisles▪ Using cold outside air for cooling Visio

Data Shapes

Case Study – Task Force Tips

► Problem▪ Robotic picker

• Controlled by COBOL program on a Linux system

• Slow response times

• High downtime

► Solution – revamp the robot▪ AB ControlLogix PLC & Servos

► Challenge!▪ Can’t rewrite the pick program easily ▪ Must interface it with the ControlLogix

► How????

Case Study – Task Force Tips

“It is magical what this has done for our application. The OPC DataHub and TOP Server allow the PLC to share any data point. The possibilities that this opens up for real-time connections between PLCs and corporate data processing systems will bend your imagination. It is so much faster than what we had before! Now we are trying to find other problems to solve. This solution has been VERY effective for our business results.”

Stuart MacMillan – President, Task Force Tips

“It is magical what this has done for our application. The OPC DataHub and TOP Server allow the PLC to share any data point. The possibilities that this opens up for real-time connections between PLCs and corporate data processing systems will bend your imagination. It is so much faster than what we had before! Now we are trying to find other problems to solve. This solution has been VERY effective for our business results.”

Stuart MacMillan – President, Task Force Tips

Benefits

• Improved efficiency

• Nearly eliminated downtime

Benefits

• Improved efficiency

• Nearly eliminated downtime

Dankie - Thank You!

► Visit our stand at Expo▪ Free demo DVD with training videos & trial

software▪ Discuss your integration challenges

► Contact us to discuss your challenges▪ support@softwaretoolbox.com▪ Kevin Rutherford

• krutherford@softwaretoolbox.com

▪ John Weber• jweber@softwaretoolbox.com

► Order licenses from the Wonderware South Africa team!