Industrial automation systems use Ethernet application layers technologies like EtherNet/IPTM and Profinet which often have issues related to bandwidth and payload. To overcome these shortcomings, Beckhoff Automation, a German automation company came forward with a Fieldbus system called the Fast Light Bus. This eventually evolved into EtherCAT (Ethernet for Control Automation Technology), which was launched in 2003 by the same company.
EtherCAT works on the basic principle of pass-through reading and combines the benefits of “on the fly processing” and its well-built infrastructure, some of which includes better efficiency and higher speed.
Utthunga’s industry protocol implementation experts understand this new concept of EtherCAT. We integrate the best EtherCAT practices that enhance your hardware and software communication. This in turn, enhances the overall productivity of the automation system.
Beckhoff promoted EtherCAT protocol through the EtherCAT Technology Group or the ETG. It works along with the International Electrotechnical Commission (IEC), which has led to the standardization of EtherCAT over the years.
The EtherCAT standard protocol IEC/PAS6246, which was introduced in 2003, has since then been standardized by IEC to became IEC 61158. One of the main features of EtherCAT is its versatility to work within most of the industrial plant setups. This flexibility allows it to be the fastest Industrial Ethernet technology suitable for both hard and soft real-time requirements in automation technology, in test and measurement and many other applications.
Another feature of EtherCAT is that the EtherCAT master mostly supports various slaves with and without an application controller. This makes the implementation seamless and succesful.
EtherCAT switches are another unique feature of the EtherCAT. Here the switching portfolio refers to all the managed, unmanaged, and configurable switch product lines. An example of the EtherCAT switch is the Fast Track Switching that offers perfect decision-making capabilities even in a mixed communication network under any circumstances. Most of these switches are quite economical to be used in the switch cabinets. They have robust metal housing and support via either VLAN support, IGMP snooping, or other SNMP management features.
To get the best out of the EtherCAT implementation in your industrial plants, you need to have a robust implementation strategy in place. For this matter, we have jotted down the strategies you can use to implement EtherCAT in the following lines:
EtherCAT infrastructure
The EtherCAT infrastructure is quite powerful as it includes various safety and communication protocols and includes multiple profile devices. If we go deep into the architecture, we see that the EtherCAT master uses a standard Ethernet port and network configuration information. The data can be easily fetched from the EtherCAT Network Information file (ENI). The EtherCAT Slave Information files (ESI) that are unique for each device and are provided by the vendor form the basis of these ENI.
If you are working on a load-dependent servo task, the location (Master or Servo Drive) plays a key role in selecting an EtherCAT mode of operation.
EtherCAT Slave & EtherCAT Master devices
EtherCAT slave devices are connected to the master over the Ethernet. Various topologies of EtherCAT can be implemented to connect slaves to the Ethernet Configuration tool. The Ethernet configuration tool is connected to the EtherCAT master via the above mentioned EtherCAT network information file. This configuration tool plays a pivotal role in implementing EtherCAT and connecting the slaves to the master in the right way. The tool generated a network description known as the EtherCAT Network Information file based on the EtherCAT Slave Information files and/or the online information at the EEPROM of the slave devices, including their object dictionaries.
Several EtherCAT slave devices work synchronously with the EtherCAT master devices through various tuning methods. Here the tasks such as setting outputs, reading inputs, copying memory, etc. can be considered, wherein the synchronization between the logical level of the devices plays an imperative role. In order to implement an EtherCAT slave with a master, all you need is an EtherCAT master that works on the lines of a standard Network Interface Controller (NIC, 100 MBit/s Full duplex) protocol. To seamlessly integrate master and slave, a master software with actual run time drives the slaves.
EtherCAT Operation Modes and Network Topology
One of the challenging parts of implementing EtherCAT to your control system is choosing the right operation modes. The reason being, each mode demands differently from the operating system and master. The possible cases of dynamic changes of loads or custom control loop algorithms and the demands of an “on the fly processing system” needs to consider while choosing the operating mode. Here we are going to give you a brief idea of three of the important operating modes that are: CAN over EtherCAT, File over EtherCAT, EtherNet over EtherCAT.
CAN over EtherCAT (CoE)
One of the most widely used communication protocols, the CANopen, is used in this mode. It defines specific profiles for different devices. This operating mode ensures a higher speed EtherCAT network.
File over EtherCAT (FoE)
This operating mode gives you access to data structure or the information files in the device. This enables the uploading of standardized firmware to devices. This does not depend on whether they support other protocols like TCP/IP.
Ethernet over EtherCAT (EoE)
This operating mode allows communication between Windows client applications with an EtherCAT device server program via Ethernet that uses the EtherCAT network. It the simplest way master and slave connect and reduces the overall implementation time.
EtherCAT is one among the many Ethernet based fieldbus protocols but has garnered significant popularity for industrial automation applications. These are optimized for industrial devices like programmable logic controllers (PLCs), I/O, and sensor-level devices. Implementation of EtherCAT offers higher efficiency of the control system, reduction in error, and connect 65,553 nodes in the system with low latency in each slave node.
Utthunga’s services help you to implement EtherCAT in the best possible ways so your industrial automation systems can enjoy the benefits from its versatility to the fullest.
Industrial revolution 4.0 has already set in, and industrial automation is a profound part of it. One of the crucial aspects of implementing a successful automation ecosystem in any industry is seamless communication between devices. For a long time, the traditional field buses like PROFIBUS, HART, FF, Modbus and a few others have been the been the standard communication solution for field layer connectivity.
However, with the ubiquity of Ethernet in the layers above sensors/PLCs and to take advantage of the IT tools and technologies in the OT layer, Ethernet is increasingly being looked as a communication bus in the field layer also. this has led to the idea of the Ethernet Advanced Physical layer (APL).
Ethernet-APL is a subset of the widely used Ethernet standard and it is describes the physical layer of the Ethernet communication specially designed for industrial engineering services. With high communication speeds over long distances and a single, twisted-pair cable for power and communication signal supply, this layer proves to be a robust solution for a better bandwidth communications link between field-level devices and control systems in process automation applications. In simple terms, Ethernet-APL is the upgraded link between Ethernet communication and instrumentation.
Ever since BASF, a German chemical company and the largest chemical producer in the world successfully tested Ethernet APL for the first time in 2019, many companies have successfully implemented the same in various IIoT networks. In February 2020, ABB’s trials proved that Ethernet APL effectively eliminates gateways and protocol conversions at various industrial network levels.
Ethernet-APL makes infrastructure deployment a seamless process as the devices connected over it share the same advanced physical layer. This also indicates that it enables devices in the industrial network to be connected at any time, irrespective of where they are placed in the factory or processing plant.
There are numerous reasons why industries willing to integrate IIoT must consider Ethernet-APL. We have discussed them in the next sections.
Ethernet-APL enables seamless integration of various processes and creates effective communication between the control and plant field devices for long distances process variables, secondary parameters, and asset health feedback and seamlessly communicating them over long distances.
Some of the major benefits of incorporating Ethernet APL in industrial automation applications are:
Improved Plant Availability
In addition to pure process values, modern field devices provide valuable additional data. With Ethernet-APL, plant operators can make the most of the devices in real-time, centrally monitor their components’ status, and identify maintenance requirements early on. This avoids unplanned downtime and increases plant availability significantly.
Cost-Effective Plant Optimization
Ethernet-APL supports the trunk-and-spur technology established in the process industry and is applicable to any industrial Ethernet protocol such as EtherNet/IP,HART-IP, and PROFINET. This simplifies integration for planners, plant designers, and plant operators since existing installations and infrastructures can still be used and investments are protected.
Adds Flexibility to the Plant
IEEE and IEC standards layout communication protocol, testing, and certification of products to implement Ethernet-APL into any plant automated systems in any part of the world. This way, in an industrial environment, devices from different manufacturers, irrespective of their state of origin, can have interoperable communication within the working ecosystem.
Coherent Communication at all levels
Ethernet-APL allows a common communication infrastructure for all levels of process management. This is because field devices can be easily connected to the higher-level system. The high transfer speed of 10Mbit/s and the full-duplex infrastructure make it suitable for data transmission over a length of approximately 1000 m.
APL – For IIoT Applications
The Industrial Internet of Things is undoubtedly an integral part of the industrial automation workspace. Therefore, the high-speed, industrial Ethernet-based Ethernet-APL is touted as the future of industrial communication systems. Many of the leading communication protocol associations like the OPCFoundation, ODVA, PROFIBUS, and PROFINET International are in the process of supporting APL, which makes it compatible with any existing processing system.
It supports 2-WISE (2-wire intrinsically safe Ethernet) and therefore eliminates the need for numerous calculations, which makes it simpler to verify the intrinsic safety of devices within the Ethernet-APL automation network.
Ethernet-APL comes as a blessing for the manufacturing and process industry in particular, as they lacked a standard network capable of high-speed transfer of data within field devices irrespective of their implementation level in the Industry 4.0 architecture.
How APL is Serving the Special Requirements of Process Industries
Ethernet-APL is specially crafted for process industries. Since these industries involve works at hazardous and explosive areas, deployment of industrial Ethernet seemed like a far thought for quite long. However, with the introduction of an advanced physical layer into the Ethernet, 2-WISE became a reality.
The 2-WISE infrastructure makes it safe to be deployed in such hazardous areas. This improved the overall plant availability and brought remote access to many devices in the process industry 4.0.
Conclusion
Advanced Physical Layer or APL has brought in a new ray of hope for effective adoption and implementation of IIoT in the industries. Utthunga’s innovation-driven team is ready to support you in your APL plans. Get in touch with us and get the best industrial engineering services that elevate the efficiency of your plant and plant assets for increased ROI.
The term “simulator” means “imitator of a situation or a process”. In the digital sense, we can say that a protocol simulator or a network simulator is a computer-generated simulation of a protocol before bringing the product to the market.
There is a paradigm shift in industries like industrial OEMs, discrete, power, and process utilities to move towards automation. This implies more interconnected devices over the internet with interlinked communication between the devices. In order to carry out a reliable and seamless automated working ecosystem in IIoT, many foundations like OPC, ETG, PI and others have laid down certain industrial protocols that a product must follow.
Protocol testing is a crucial element that product engineering companies like Utthunga take care of. It is imperative as it checks the alignment of the hardware or software product with the industrial protocol standards. This helps to address an issue, be it a design glitch, or points out the challenges in implementing it. Protocol simulation is a part of product testing and it helps to check if a hardware or software is working as per the communication protocol standard and purpose.
Protocol simulation is mainly carried out for checking the accuracy and latency of the communications over the wire. It is done by creating scenarios that are similar to the real-time use cases. These mimic the exact situations that are similar to the real-time use cases and help you evaluate the possible risks and challenges associated with the product. Knowing these before its release helps you create a product that stands apart in quality among your competitors.
How Simulation Can Save Your Product Development Time And Cost?
Simulation can be carried out in various ways, it all depends on your ultimate goal. If a reduced product development time and cost is on your checklist, then you can use the simulation approaches that we have listed down:
Protocol simulation to test for design reliability
In industries, especially in the current automated ecosystem, the device which you manufacture must be in compliance with the industry standards. When you create a device prototype and simulate it to test the design capabilities, you get to interact with the unknown design features and may discover some loopholes as well. This saves you product development time, as you optimize your product before it reaches the market. This way you can fix the glitches and then move on mass production.
Finite element analysis
Industrial devices are subjected to a lot of unpredictable scenarios and stresses that requires your product to be robust enough to handle such unforeseen situations. The finite element analysis helps you to validate your product in this context. It ensures your product can endure unpredictable stresses (in the connectivity/communications context) up to a certain limit. You can carry out FEA even in the design stage, to get a real idea as to what to expect from your product and the areas which need improvements.
It helps to improve the reliability of the product before an untested product reaches your customers and ruins your brand image. It also makes manual testing a lot easier.
APIs in protocol simulation allow easy integration of your product to various software frameworks. This means test engineers can leverage better test automation solutions to carry out protocol simulations with high precision. Utthunga’s protocol simulators are configurable as a server-side application in your industrial devices. So, it enables remote control of the devices through various programming languages like Python, Java, C++, and others.
Industries have complex systems. Protocol simulators like master simulators and slave simulators when used in the product development cycle, help them to create a reliable product.
Since such a simulator is capable of providing practical feedback at the designing stages itself, it comes across as a time and cost saver. It also empowers design engineers to understand the possible glitches in the design and create an optimum layout for the same.
These allow simulation of the required prototype at the luxury of the lab, or during R&D or engineering. The control systems can be built to test the devices in various load and real-time scenarios. These can run on a desktop and be integrated with the control systems and another master systems that communicates with these field devices. Therefore the overall infrastructure, cost to procure, deploy and maintain the devices can be considerably reduced.
In research and development, these protocol simulators act like a perfect aid to train the operational personnel and get an in-depth knowledge of the functionalities of the product. It also helps the R&D department to come with innovative ideas for creating a better product that matches the growing demands of the users.
Conclusion
A protocol simulator helps create a virtual representation of the product even in its design stage. It helps design and product engineers understand the dynamics of the device’s operation at each phase of the production cycle.Choosing the protocol simulator, therefore, should be a well-thought decision, if you are keen on creating error-free, top-quality devices. Utthunga’s protocol simulator is carefully created by our panel of experts who have gained years of experience in this field. Get in touch with our team, to know more about our exceptional services tailored to get you Industrie 4.0 ready. Utthunga has deep capabilities in industrial protocols, and our protocol simulators are an extension of Utthunga’s rich and deep protocol expertise. All our protocol simulators are built on top of our uSimulate framework – tried and tested in the field for years. We support several protocols like Modbus, EtherCAT, IEC-104, GE-GSM and others. Adding a new protocol (legacy or proprietary) to the simulator family is fairly easy as well.
The current wave of the industrial revolution, also known as the Industrie 4.0, has proven to improve the production process in various aspects. To realize the promised benefits, a strong communication protocol that allows semantic interoperability among interconnected devices is needed. In manufacturing industries where processes are greatly dependent on the industrial sensors and actuators, there are a few challenges that hinder seamless plant floor communication.
Take for example, the use of 4-20mA analog signals for communication between proximity switches and sensors. Although this produced satisfactory results, it did not provide any scope for diagnostics. So, the issues in the process go unnoticed until the whole system comes to a standstill. The combination of digital and analog devices also requires multiple cable and hence a tedious installation and maintenance process.
To overcome such challenges, the IO-Link Consortium Community, an organization in which key user companies from various industries and leading automation suppliers join forces to support, promote and advance the IO-Link technology. With over 120 members and strong support in Europe, Asia and the Americas, IO-Link has become the leading sensor and actuator interface in the world. The common goal of these companies is to develop and promote a unified and bi-directional communication architecture that involved an easy implementation process and the ability to diagnose the errors at the right time. The IO-Link protocol thus came as a knight in shining armor for the industries to help them gain the best of the Industrie 4.0.
IO-Link is a robust; point-to-point communication protocol specifically designed for devices like actuators and sensors. The IO-Link client is independent of the control network and communicates with an IO-Link master port. This port is placed on a gateway and transfers the data and or signals to the control system for further operations.
IO-Link proves to be beneficial for the factory automation processes especially in the digital era of Industrial Automation. With embedded software systems now becoming an inevitable part of industries, more IO-Links help them to leverage the power of Industrial automation and IIoT.
To get a gist of the benefits you can expect through the proper implementation of IO-Links, read the entire blog.
IO-Link Wired setup enhances factory automation communication for Industry 4.0 applications
Incorporating automation processes into an existing manual based manufacturing end processes are a primary challenge that IR4.0 possesses. To overcome this, many factory communication protocols have been introduced by various institutions.
For the device level, the communication IO-Link protocol is the most viable options to choose from. The reason being many, that we shall discuss in the next section. On the factory floor, IO-Link has long been seen as a wired communication network.
A basic IO-Link communication cycle involves:
A request from the master device
Waiting Time- for the request to reach the client device
Processing time of the request from the client device
Answer from the device to the master.
Waiting Time- for the answer to reaching the master.
In general, factory automation units have wired IO-Links that offer high flexibility and enhances the communication systems between the controllers and the system actuators and sensors. However, with the advent of reliable wireless networks, industries are now adopting wireless IO-Link set up these days.
The popularity of the IO-Link for the communication between sensors, actuators, and the control level is steadily increasing with each passing year. In a wireless setup, an approximate 5ms maximum cycle is achievable with high probability. In addition to this, it also provides the required flexibility in automation solutions and opens door to the possibility of using battery-powered or energy-harvesting sensors as well.
As already mentioned, IO-Link be it wired or wireless creates ripples of benefits for OEMs and ends users.As already mentioned, IO-Link be it wired or wireless creates ripples of benefits for OEMs and ends users. One of the advantages of IO-Link is that by incorporating the smart sensors with IO-Link, you can optimize your smart factory with powerful data and diagnostics and prepare them for the future – to increase your uptime and productivity. Along with faster time to market and lower total cost of ownership, OEMs and end usersalso benefit from improved asset utilization and risk management.
Typically a smart sensor functions as a regular sensor unless it’s connected to an IO-Link master. When connected, you can leverage all the advanced configuration data capabilities that IO-Link has to offer.
Let us have a look into some of the key advantages of implementing IO-Link for OEMs and end users.
Enables better maintenance
One of the main reason behind the popularity of the IO-Link is its diagnostic capabilities. It means the servers are informed well in advance about any forthcoming issues. This makes them ready for need-oriented maintenance and a better factory automation system.
Efficient operation
As IO-Link sensors are independent of the control network and their accessibility no longer plays a role in automation, you can place them directly at the point of operation. This means the machining process can be optimized to operate at maximum efficiency in the minimum time frame.
Consistent Network
The IO-Link being a standard communication protocol between IO sensors/actuators and the control network brings consistency in your automation network. So you get to integrate more devices into your IO-Link protocol network and introduce flexibility to your network.
Makes your system versatile and future proof
IO-Link sensors and actuators do more than just process and transmitting data to and from the control network. IO-Link protocol integration facilitates reliable and efficient communication between devices. Having IO-Link devices means your system has access to integrated diagnostics and parameterization which also reduces the commissioning time to a great extent. Overall it imbibes versatility to your system and makes it ready for the future of IIoT.
Enables processing of three types of data
With the IO-Link, you can access and process three types of data namely process data, service data, and event data.
Process data includes data such as temperature, the pressure that is transmitted by the sensors or actuators upon request from the IO-Link master request.
Service data refers to the one related to the product and not process and includes manufacturer name, product model number, and the like.
Event data usually comes from sensors when any event notification has to be raised like an increase in pressure.
Provides IODD for each IO device
IO-Link protocol integration assigns each IO device with an IODD or IO Device Description such that the master manufacturers display the same IODD for each of their devices. This way, the operability of all the IO-Links is uniform irrespective of the manufacturer.
Reduces or eliminates wired networks
Since IO-Link protocol integration allows uniformity among the sensors, actuators, and control system, there is no need for separate wires. This way the number of wires can be reduced to a great extent. As wireless networks reign the IIoT arena, the concept of wireless IO-Link protocol integration is also gaining popularity.
Increases machine availability
With IO-Link protocol porting, you can enjoy an errorless and fast data exchange between sensors, actuators, and the control system. This increases the operation speed and reduces the downtime and improves the commissioning processes. Overall the machine errors are reduced thereby giving you more out of the machines.
The 21st century has paved the way to better industrial processes through the advent of industrial automation or the IR4.0. IO-Link protocol porting and IO-Link protocol integration has greatly helped OEMs and end-users alike, in making their production process in compliance with the IIoT set up. If you are looking for a reliable and flexible IO protocol integration for your plant, we at Utthunga have the state of the art technologies.
Open Process AutomationTM Standard (O-PASTM Standard) or “Standard of Standards” as it’s popularly known is an initiative to create a new age automation system with a different architecture than the existing process automation systems that uses Distributed Control Systems (DCS) and Programmable Logic Controllers (PLCs). As automation applications require ultra-high availability and real-time performance, process automation systems have always been highly proprietary. The reason behind developing this standard is to transform from a closed, proprietary, distributed control systems towards a standards-based open, secure and interoperable process automation architecture.
In 2016, The Open Group launched the Open Process AutomationTM Forum (OPAF) to create an open, secure and interoperable process control architecture to:
Facilitate access to leading-edge capacity
Safeguard asset owner’s application software
Easy integration of high-grade components
Use an adaptive intrinsic security model
Facilitate innovation value creation
This blog aims to show why and how OPC UA can be applied to realize the Open Process AutomationTM Standard. Before that, let us be familiar with the Open Process AutomationTM Forum. In simple terms, The Open Group Open Process Automation™ Forum is an international forum that comprises users, system integrators, suppliers, academia, and organizations.
These stakeholders work together to develop a standards-based, open, secure, and interoperable process control architecture called Open Process AutomationTM Standard or O-PASTM. In version 1 of O-PASTM, published in 2019, the critical quality attribute of interoperability was addressed. In version 2, published in January 2020, the O-PASTM Standard addressed configuration portability, and version 3.0 will be addressing application portability.
Version 1.0 of the O-PASTM Standard unlocks the potential of emerging data communications technology. Version 1.0 was created with significant information from three existing standards:
The seven parts that makeup the latest preliminary 2.1 version of O-PASTM Standard are:
Part 1 – Technical Architecture Overview
Part 2 – Security (informative)
Part 3 – Profiles
Part 4 – Connectivity Framework (OCF)
Part 5 – System Management
Part 6 – Information Models based on OPC UA (Multipart specification ranging from 6.1 to 6.6)
Part 7 – Physical Platform
Part 1 – Technical Architecture Overview
This informative part demonstrates an OPAS-conformant system through a set of interfaces to the components.
Part 2 – Security
This part addresses the cybersecurity functionality of components that should be conformant to O-PASTM. This part of the standard also explains the security principles and guidelines incorporated into the interfaces.
Part 3 – Profiles
This part of the version defines the hardware and software interfaces for which OPAF needs to develop conformance tests and ensure the interoperability of the products. A profile describes the set of discrete functionalities or technologies available for each DCN. They may be composed of other profiles, facets, as well as individual conformance requirements.
Part 4 – O-PASTM Connectivity Framework (OCF)
This part forms the interoperable core of the system, and OCF is more than a network. OCF is the underlying structure that enables disparate elements to interoperate as a system. This is based on the OPC UA connectivity framework.
Part 5 – System Management
This part covers the basic functionality and interface standards that allow the management and monitoring of functions using a standard interface. The system management addresses the hardware, operating systems, and platform software, applications, and networks.
Part 6 – Information and Exchange Models
This part defines the common services and the common information exchange structure that enable the portability of applications such as function blocks, alarm applications, IEC 61131-3 programs, and IEC 61499-1 applications among others.
Part 7 – Physical Platform
This part defines the Distributed Control Platform (DCP) and the associated I/O subsystem required to support O-PASTM conformant components. It defines the physical equipment used to embody control and I/O functionality.
The O-PASTM Standard supports communication interactions within a service-oriented architecture. In automation systems, it outlines the specific interfaces of the hardware and software components used to architect, build, and start-up automation systems for end-users. The vision for the O-PASTM Standard V2.0 addressed configuration portability and can be used in an unlimited number of architectures. Meaning, every process automation system needs to be “fit for a reason” to meet specific objectives.
Why OPC UA is important for Open Process AutomationTM Forum
The lower L1, L2 layers of the automation pyramid is heavily proprietary with a tight vendor control over the devices where the PLC’s, DCS, sensors, actuators and IO devices operate. This is where the vendors have strong hold over the end-users. As a revenue generating path, they are reluctant to lose this advantage. Additionally, this poses interoperability, security and connectivity issues causing significant lifecycle and capital costs for the stakeholders.
This inherent lack of standardization in the lower OT layers is a constant pressure point for the automation industry. O-PASTM Standard solves this standardization & connectivity issue and uses OPC UA as one of the foundation for developing this standard. This de-facto standard is used for open process automation integrating controls, data, enterprise systems and serves as a fundamental enabler for manufacturers.
Building the basic components of this standard (like DCN, gateways, OCI interfaces, OCF) using OPC UA helps them achieve secure data integration and interoperability at all levels of the IT/OT integration. This involves leveraging the OPC UA connectivity (Part 4 of O-PASTM and information modeling capabilities (Part 6 of O-PASTM) which play a key role in the O-PAS™ reference architecture.
How O-PASTM leverages OPC UA
From the below architecture diagram it’s evident that a Distributed Control Node (DCN) is the heart of the OPAF architecture. Here a single DCN is similar to a small machine capable of control, running applications, and other functions for seamless data exchange with the higher Advanced Computing Platform (ACP) layers. This component interfaces with the O-PASTM Connectivity Framework (OCF) layer that is based on the OPC UA connectivity framework.
The connectivity framework allows interoperability for process-related data between instances of DCNs. It also defines the mechanisms for handling the information flow between the DCN instances. The framework defines the run-time environments used to communicate data.
Basically each DCN has a profile which describes a set of full-featured definition of functionalities or technologies. For example:
The DCNs (i.e. O-PAS conformant components) are built conforming to anyone of the primary profiles specified in the O-PASTM:
OBC
O-PAS Basic Configuration
OCF
O-PAS Connectivity Framework (OPC UA Client/server, OPC UA PubSub profiles)
OSM
O-PAS System Management
NET
Network Stack
CMI
Configuration Management Interface
SEC
Security
DCP
Distributed Control Platform (Physical hardware)
The OPC UA information model capability is used to define and build these DCN profiles. Part 6 of the O-PASTM and its subparts defines related set of information and exchange models, such as basic configuration, alarm models, or function block models. This provides a standard format used for the exchange of import/export information across management applications. It also provides standard services used for the download/upload of information to O-PASTM conformant components.
According to the report OPC UA Momentum Continues to Build published by the ARC Advisory Group and endorsed by the OPC Foundation, it provides timely insights into what makes OPC UA the global standard of choice for industrial data communications in process and discrete manufacturing industries. From an IIoT and Industry 4.0 perspective, the report examines how the OPC UA technology is the standard that solves the interoperability challenges.
Key take-away from the report that help maximize OPC UA adoption include:
OPC UA standard is open and vendor agnostic, and the standard and Companion Specifications are freely available to everyone.
OPC UA is an enabler for next-generation automation standards that will, potentially change the industry structure of process automation e.g. Ethernet Advanced Physical Layer (Ethernet APL), NAMUR Open Architecture, and the Open Process Automation Forum (OPAF)
OPC UA is arguably the most extensive ecosystem for secured industrial interoperability
OPC UA is independent of underlying transport layers. As such, it uses the most suitable transports for the right applications (ex. TCP, UDP, MQTT, and 5G)
OPC UA is highly extensible via its Information Modeling (IM) capabilities. This makes OPC UA an excellent fit for use by automation vendors and other standards organizations wishing to express and share semantic data seamlessly across all verticals.
The OPC Foundation Field Level Communications (FLC) Initiative is defining a new OPC UA Field eXchange (OPC UA FX) standard that is supported by virtually all leading process automation suppliers.
OPC UA FX will extend OPC UA to the field level to enable open, unified, and standards-based communications between sensors, actuators, controllers, and the cloud.
Forward-looking companies should make OPC UA a crucial part of their long-term strategies today because the changes this technology brings will become a necessity faster than most people anticipate
OPAF is making outstanding records in creating a comprehensive, open process automation standard. Since it is partially built on other established industry standards like OPC UA, the O-PASTM Standard can improve interoperability in industrial automation systems and components.
OPAF fulfills its mission to deliver effective process automation solutions with the collaborative efforts of the OPC Foundation. Utthunga’s expertise in OPC UA standard and by adopting our OPC related products and solutions, businesses can benefit from low implementation and support costs for end-users and enable vendors to experiment around an open standard.
Get in touch with our OPAF experts to experience a new-age open, secure by design and interoperable process automation ecosystem.
Industrial revolution 4.0 has already started to show signs of significant change in various industrial operations. From manufacturing, to automotive, finance and production, every business process is being explored to unveil the potential of automating them.
Industries are thriving hard to stay in tune with the latest technological advancements and be relevant in the digital era. The popularity of software-based automation for industrial units therefore has seen a sharp rise. According to a survey, the industrial control and factory automation market are expected to reach USD 229.3 billion by 2025 from USD 151.8 billion in 2020, at a CAGR of 8.6%.
The I4.0 brings in a lot of improvements in the manufacturing industry. OEMs, in particular, are embracing the rapidly changing technology, and are implementing software that needs timely up-gradation with the inclusion of new features.
Even though the changes work for the betterment of the system, it may also bring unwanted alteration to the existing features. Hence, proper regression testing is required to check if the changes does not alter the intended purpose of the system.
Regression testing uses the requirement specifications as basis for creating test cases and looks for any bugs or fault in the software system. As more and more OEMs and factory process are drifting towards remote functions and software implementation, this testing helps them to improve the overall quality of the software.
Improve efficiency: An OEM with an error-free software ensures precision in its operation. Regression testing constantly checks for deviations in the software each time a modification is made.
Better monitoring and decision-making process: In some cases, especially when dealing with a complex software, OEM tends to lose track of the code modification. Regression testing makes it easier, as it keeps a record of all the changes made. This in turn aids in proper monitoring of the changes and decision-making process related to the deployment of the final software.
Reduces unnecessary manufacturing costs: Regression testing identifies the errors and notifies the OEMs to fix them in the early stages itself. A bug fix in the production/manufacturing stage of the product life cycle will result in huge manufacturing costs. Regression testing ensures the final product will be error-free.
Continuous operation: A crucial aspect in the successful deployment of I4.0 is the assuring the interconnectivity and automation of the devices. Regression testing ensures the bugs are fixed and all the interconnected devices work together seamlessly.
There are different ways regression testing can be carried out. Based on your requirements and the complexity of the software, a proper regression mechanism is chosen.
In industrial automation, devices need to be connected together. Here, with every additional device, the software may need changes in its code or features. The testing here ensures that the introduction of the new device or an upgrade does not alter the functions of an existing setup.
In an OEM unit, regression tests are mostly executed at the design stage to find the immediate bugs and at the production stage to decide whether the quality of the product matched the specification of the customer.
If there needs to be a functional change in any of the devices, corresponding codes need to be changed, Here the regression testing helps in producing the desired outcome.
To keep up with an evolving market, the manufacturing industries and industrial automation in particular are working in an agile environment. The DevOps culture is being widely accepted by the industrial automation companies for on-time and efficient deployment of new software technologies.
The constant upgrades and features introduced by OEMs can change the way the whole system works. This brings in an agile environment where continuous change comes with a high amount of risk.
Risks involve fatal bugs, repeated errors, duplicate entries, etc. These all culminate to either non-delivery of the product or a delay in deployment. Both these cases can be avoided by continuously keeping a check on the code source and its impact, through regression testing.
Benefits of Regression Testing In Agile Environments
OEMs and factory processes are focusing to blend in an agile environment to build a better technology-enabled workspace. This along with the current DevOps culture has helped industrial automation to create a digital identity of its own even in the times of cutthroat competition.
Regression testing helps OEMs to manufacture more reliable products and provide better services. Apart from this obvious benefit, some of the crucial ones are listed below:
Since the software testing and development team can easily identify the bugs, they are motivated to deliver high-end bug-free device
Each case is handled and verified differently, therefore, it ensures a seamless functional process
It ensures the bugs are fixed and the products are ready to be launched in the market.
A bug free software ensures better communication between the interconnected devices in an automation system
Conclusion
The future of industrial automation belongs to agile environment and DevOps. These not only offer a better coping mechanism to the changing scenarios but also are crucial in delivering services with utmost precision. With big data and artificial intelligence seeing new heights, industries are sure to leverage them in software testing to bring the best out of the agile and DevOps culture.Catch up with the most effective testing solutions offered by Utthunga. Contact us to know more.
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