This document discusses building large, collaborative automation systems by extending OPC-UA through architecture flexibility, performance, and scalability. It addresses the need for choices in architecture, topologies, and integration patterns to accommodate diverse system requirements. Performance and scalability are also critical to address as systems increase in size and complexity. The Real-Time Automation Message Bus is presented as a solution that provides flexibility through peer-to-peer connectivity, global data access, publish/subscribe capabilities, and other features to enable performance at scale across disparate systems.

1. Your systems. Working as one.
Extending OPC-UA through
Architecture Flexibility, Performance, and Scalability
Building Large, Disparate Systems
Dave Scheibenhoffer
Real-Time Innovations

2. Industry Checkpoint

3. Collaboration
Business Centric Decade
Shift from enabling technology
to using
Available and proven Technology
to improve Business Performance
Operational Efficiency

4. Business Centric
• Business Goals • Business Benefits
– Return on Assets – Operational Effectiveness
– Continuous Improvement – Asset Utilization
– Flawless Execution – Minimize Variable Costs
– Automate – Reduce Downtime
– Total Cost of Ownership – Preserve Capital Assets
– Common Infrastructure
– Barriers to Information

5. System Requirements
• Collaborative Automation Systems
– Guiding Principles
• Extensible
• Common Data Model
• Adaptable through Configuration
• Single Version of the Truth
• Interoperable
• Standards Adoption
• Multi-supplier Support
• Security and Reliability
• Actionable Context Support
• Knowledge Workplace Support

6. Problem Statement

7. The Systems Engineering Challenge
• Systems
– Built from components
Must ease integration complexity
• System of Systems
Integration (time & cost)
– Convergence of disparate systems
• Small Systems
– Integration is challenging
• Large Systems
– Integration costs dominate System Scale

8. Four Key Factors in Distributing Data
• Number of Devices
– Ever expanding and many disparate types
• Volume of Information
– Only send pertinent data
• Density of Pipe
– Limited bandwidth which must be used wisely
• Timeliness
– Making data available when it is needed
Need for Scalability, Reliability, Performance

9. Industrial Automation
(Continuous / Hybrid / Discrete)

10. Historical View
CRM FRM HRM PLM SCM
4-Business
Database
ERP
B2MML
ISA-95
Enterprise
LIM
WMS
CCM
3-Execution
Schedule/ Simulation/ Supervisory
MES Dispatch Analysis Display Database
Electric
2-Supervisory
OPC
DAQ &Control Alarms HMI IEC-61850
Windows
Mobile Historian
SCADA Devices
IEC-104
DNP3
Redundant LAN C37.118
ISA-88
OPC
0-Device / 1-Control
DCS PAC PLC
Embedded RTOS
Examples
I/O Ethernet I/P
DCS/PLC EtherCAT
PROFINET
Fieldbus Modbus TCP

11. System of Systems
Workflow-Driven Services
•IT systems respond to human
> 1s
ERP intention on demand
Timeliness of Response
•Focus on access to stored data
•Consistency is mission-critical
10ms–1s
MES/SCADA Combination of Both
Event-Driven Services
10μs–10ms
•Detect change and respond automatically
SCADA/DCS •Focus on processing data as it changes
•Availability is mission-critical

12. Modern View
CRM FRM HRM PLM SCM Database
Information
Technology
Systems
Business Message Bus
(IT)
MES SCADA
Operational
Technology Automation Network
Systems
(OT)
DCS PAC PLC
© 2012 RTI • COMPANY CONFIDENTIAL 12

13. OPC-UA
• Addressing Interoperability via
– Layered Architecture
• Information Model (PIM)
• Services
• Mappings (PSM)
OPC-UA Architecture
Standard Information Models
Base Information Models
Services
Mappings Meta Model
Network

14. Modern View with OPC-UA
ERP
UA Client/Server
HMI
HMI
MES MES DAQ & Control Alarm HMI
Historian HMI
Server Server Server Server
UA Client UA Server UA Client UA Client UA Client UA Client
Bridge Bridge
Gateway Gateway
TCP/IP Adapter TCP Adapter Web Services
UA Server
UA Server
UA Server
DCS PAC PLC
I/O
Fieldbus

15. More Typical…
ERP
JMS
HMI
HMI
MES MES DAQ & Control Alarm HMI
Historian HMI
Server Server Server Server
UA Client Custom UA Client UA Client OPC-HDA HTML5
Bridge Bridge
Gateway Gateway
TCP/IP Adapter TCP Adapter Web Services
Simulation R&D
OPC-DA Modbus TCP
UA Server
Application Specific
Devices DCS PAC PLC
I/O
Fieldbus

16. More is Needed

17. Disparate System Requirements
• Large-Scale Heterogeneous Systems
– Architecture
– Interoperability
– Performance
– Scalability
Collaborative Automation Systems

18. Architecture & Interoperability

19. Architecture & Interoperability
Point-to-Point Client/Server Publish/Subscribe Data-Centric
Pub/Sub Messaging
Brokered
ESB
Daemon
Data-Centric
Publish/Subscribe (DCPS)

20. Architecture & Interoperability
• Design Patterns • Topologies
– Point-to-Point – Flat
– Client/Server – Hierarchical
• Request/Reply – Federated
• Command/Response
– Combination
– Publish/Subscribe
• One-to-Many
• Many-to-One
– Combination
Need Choices – Not One Size Fits All

21. Performance & Scalability

22. Performance & Scalability
• Performance • Scalability
– Latency – Number of devices
– Throughput – Number of applications
– Bandwidth Management – Disparate systems
– Quality of Service
Performance at Scale

23. Flexibility

24. Flexibility
Real-Time Automation Message Bus
Capabilities Performance Services
• Peer-to-Peer • usec Latency • Record/Playback
• Discovery • 1M+ msg/sec • Persistence
• Transparency • UDP w/ Multicast • System Monitor
• Reliability • QoS • Distributed Logging

25. Flexibility – OneBus
CRM FRM HRM PLM SCM Database
Business Message Bus
Real-Time Automation Message Bus
UA Client UA Client/Server UA Client UA Client
UA Client UA Server
DAQ & Control Alarm
MES MES HMI Historian
Simulation Server Server
Server Server
UA Client UA Server
Application Specific
Devices PAC PLC
I/O
Fieldbus

26. Flexibility – Disparate
CRM FRM HRM PLM SCM Database
Business Message Bus
UA Client/Server JMS / Web Service / Etc.
Real-Time Automation Message Bus
UA Client UA Server UA Client/Server
DAQ & Control Alarm
MES MES HMI Historian
Simulation Server Server
Server Server
UA Client UA Server
Application Specific
Devices PAC PLC
I/O
Fieldbus

27. Performance at Scale

28. RTI – Real-Time Automation Bus
Information Technology (IT)
Mobile
Devices Plant Business Operations
Gartner
Traditional ESB
Convergence
Alignment
Integration
RTI Connext – Common Data Infrastructure
Process Automation Systems
Production Management
HMI Data/Conf ig Control Alarms I/O
Operational Technology (OT)
SOA Architecture Peer-to-Peer Global Data Access Reliable Multicast Tools
Dynamic Discovery Publish/Subscribe Full Redundancy Quality of Service
Making Data Available to meet your Business Objectives

29. Download Your systems. Working as one.
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30. Thank You
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