Advanced Automation Appliances 6.21.09

© 2008 Online Development Inc. All Rights Reserved.

Advanced Automation Appliances

Mark Knebusch: Business Development

Laurie Wilson: Product Management

© 2008 Online Development Inc. All Rights Reserved.

Online Development Inc. (OLDI)

• Headquartered in Knoxville, TN USA with North

American and European locations.

• Develop and produce factory automation hardware

and software for companies such as Rockwell

Automation and ProSoft Technology.

• Core Competence: Computing and communications

platforms

IBMBusiness Partner

© 2008 Online Development Inc. All Rights Reserved.

Topics

• What is an Automation Appliance?

• Latest Developments

• cATM

• eATM

• eATM tManager

• Connectivity

• Configuration/Operation

• Takeaways

© 2008 Online Development Inc. All Rights Reserved.

Appliance: What is it?

• An Automation Appliance does just one

thing and does it well…transfer data to

and from one Application/System to

another Application/ System

© 2008 Online Development Inc. All Rights Reserved.

Appliance: Operation

• Configure and go –

• No….

…..code to write

…...command prompt

…...installable or updateable code – updates as

full firmware images only

……installation services

Reduces installation and maintenance costs

© 2008 Online Development Inc. All Rights Reserved.

An Automation Appliance is….

NOT a general purpose Industrial Computer

© 2008 Online Development Inc. All Rights Reserved.

Appliances:

Representative Applications

• Recipe Material and Controller

Setup Downloads

• Weighing Data Collection

• Build to Order Requirements

• Statistical Process/Quality Control

• Dynamic Palletizing and

Warehousing

• Sensor Data Reporting

• Product Tracking and Tracing

• Alarms and Event Notifications

© 2008 Online Development Inc. All Rights Reserved.

Customer base

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Appliance Transaction Modules

• OLDI’s Appliance Transaction Modules…ATMs

• Controller to Controller…cATM

• Controller to Enterprise…eATM®

• Typically mount in ControlLogix® chassis

• Communicate

• Via CLX backplane to controller

• Via Ethernet externally

• Designed and tested to PAC/PLC environmental

specifications and certifications

Tightly integrated and physically robust

© 2008 Online Development Inc. All Rights Reserved.

Controller-to-Controller &

Enterprise-to-Controller Connections

General Purpose Computing

Enterprise/Division IT Plant Floor Systems

Controllers Controllers

Controllers

cATM

eATM

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Business Planning &

LogisticsPlant Production Scheduling,

Operational Management, etc.

Manufacturing Operations

ManagementDispatching Production, Detailed

Production Scheduling,

Reliability Assurance

Discrete

Control

Batch

Control

Continuous

Control

Level 4

Level 1

Level 3

Level 2

Sensing; manipulating production process

Monitoring, supervisory control and automated control

of production process

Time frame: Hours, minutes, seconds, subseconds

Workflow/recipe control; Maintaining records;

Optimizing production process

Time frame: Days, shifts, hours, minutes, seconds

Plant schedule: production, material use, delivery

shipping; Determining inventory levels

Time frame: Months, weeks, days

eAT

McATM

eAT

M

Relationships to

Enterprise/Plant Systems

© 2008 Online Development Inc. All Rights Reserved.

Controller-to-Controller: cATM Bailey

• Migrate ABB Bailey Infi 90 or Network 90

Legacy DCS to ControlLogix PACs

• Flexible Data Handling

– Supports DCS Block functions:

– System status monitoring

– No hard tag limits

• ABB Bailey Database Conversion Tool

– Available from Rockwell Automation.

– Converts Bailey tag database into CSV for import

into the cATM-BLY90 appliance and RSLogix 5000

programming software.

Once configured, use with applications such as

FactoryTalk View® SE for visualization, alarming, etc.

cATM

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Controller-to-Controller: cATM Kepware

• Connect ControlLogix to other systems/devices via any

Kepware driver suite…including…– Fisher ROC

– GE Fanuc

– Honeywell UDC

– Mitsubishi FX

– Omron Host Link

– Siemens S5

– Triconex Ethernet

– Yaskawa MP Ethernet

– Yokogawa CX

• Base price includes one suite; can run multiple suites

Use any of Kepware’s driver suites in an in-chassis

ControlLogix module to migrate legacy systems

cATM

© 2008 Online Development Inc. All Rights Reserved.

Enterprise-to-Controller: eATM tManager ®

Simplifies Transaction Handling between

Business/Plant Applications and ControlLogix® PACs

eAT

M

• Enables SOA, ERP and MES

applications

• Bidirectional transactions

configured – not programmed

• Supports…

– Middleware

– Databases

– Controller Protocols

– TCP/IP, UDP, e-mail, FTP

© 2008 Online Development Inc. All Rights Reserved.

Advanced Appliance Architectures:

Appliance Transaction Modules (ATMs)

© 2008 Online Development Inc. All Rights Reserved.

Transaction vs Data Server-based designs

•Java Message Service (JMS)• Is a form of enterprise messaging, or Messaging Oriented

Middleware (MOM)

• A tool for building enterprise applications.

• Provides a reliable, flexible service for the asynchronous

exchange of critical business data and events throughout an

enterprise

© 2008 Online Development Inc. All Rights Reserved.

SLC™

PLC-5®

Allen-Bradley®

ControlLogix® PAC

eATM™ tManager Module

ControlLogix®

MicroLogix™

CompactLogix™

FlexLogix™

Local Rack

ControlNet

Ethernet

ControlNet

Ethernet

DH485

DH+

Ethernet

DH485

Ethernet

ControlNet

Ethernet

DH+

Ethernet

Ethernet RA Bridges

Enterprise

Applications

eATM tManager Connectivity

© 2008 Online Development Inc. All Rights Reserved.

eATM tManager Connectivity:

ControlLogix Backplane

• ControlLogix

• CompactLogix

• FlexLogix

• MicroLogix

• SLC 500

• PLC-5

Automatically connects via RA bridges for

legacy protocols (DH+, DH485)

© 2008 Online Development Inc. All Rights Reserved.

eATM tManager Connectivity:

Ethernet

• RA controllers: EtherNet/IP

– ControlLogix

– CompactLogix

– FlexLogix

– MicroLogix

– SLC 500

– PLC-5

• Siemens SIMATIC S7: TCP/IP

• Schneider: Modbus/TCP

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eATM tManager Appliance Block Diagram

Operating System

CPU

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Database Adapters

• IBM DB2 (System i only)

• MS MSSQL

• Oracle

– Oracle database

– MySQL

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Computer Adapters

• JEE Application Server JMS

– IBM WAS (default provider)

– JBOSS

• Community Edition (JBossMQ provider)

• Red Hat 4.3 (JBoss Messaging provider)

• IBM WMQ

• eMail (requires external POP3

and SMTP servers)

• FTP (requires external FTP server)

• TCP sockets

• UDP sockets

• MS Excel & Access

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Schemas

• Types

– PAC & PLC tag lists

– Database (metadata)

– Subset of XSD (XML)

– Flat files

• Source

– Automatic

• Database

– Imported

• Manual (via GUI)

– XSD

– ASCII Fixed-format flat file

– ASCII Delimited-format flat file

– Binary Fixed-format flat file

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eATM tManager Appliance Basic Operation

TriggerServer Mapper

Store &ForwardHandler

Store &ForwardQueues

EndpointAdapter

InputAdapter

eATM

Runtime

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eATM Project Editor

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Input Adapter (aka Automation Adapter)

InputAdapter

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eATM Project Editor:

Endpoint (Computer Adapter)

EndpointAdapter

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eATM Project Editor:

Map; Trigger; Message Path

TriggerServer

Mapper

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eATM tManager: Organization

Transaction Configuration Options

• Store & Forward - if the incoming message cannot be

processed immediately, it can optionally be stored in an

onboard store and forward queue

• Transaction Log - optionally all transactions to/from IT logged

to later prove receipt or absence of successful receipt

• Failover - two or more redundant adapters can be specified. If

the currently active one does not respond, the next one in the

chain is tried. Reset of the failover sequence is manual.

© 2008 Online Development Inc. All Rights Reserved.

Feedback/Handshaking to Controller

• ControlLogix profile support

• Control

• Status

• Automation Flow Control

• Handshaking

• When data acquired from Input

• When placed in queue for Endpoint

• When message accepted by Endpoint

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Status Reporting & Logging

• Status Reporting

– CLX profile bits

– Status tags

– Module front panel display

– Email

– FTP log export

• Logging

– Error logging

– Transaction logging

© 2008 Online Development Inc. All Rights Reserved.

Takeaways

• OLDI Appliance Transaction Module line-up is

expanding

• cATMs added Bailey DCS and Kepware driver modules

• eATMs move beyond just database connections to message

oriented adapters e.g. JMS

• Connectivity includes all major Rockwell

Automation controllers plus Siemens S7 and

Modicon Modbus TCP

• Configuration is drag and drop

• Operation is secure

© 2008 Online Development Inc. All Rights Reserved.

Topics

• What is an Automation Appliance?

• Latest Developments

• cATM

• eATM

• eATM tManager

• Connectivity

• Configuration/Operation

• Takeaways