OPC UA for plastics and rubber machinery

VDMA VDMA

OPC UA for plastics and rubber machineryWolfgang Höglinger, ENGEL Austria Dr. Harald Weber, VDMA Plastics and Rubber Machinery

| Wolfgang Höglinger (ENGEL Austria) & Dr. Harald Weber (VDMA Plastics and Rubber Machinery)

VDMA

The plastics and rubber machinery industry

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| Wolfgang Höglinger (ENGEL Austria) & Dr. Harald Weber (VDMA Plastics and Rubber Machinery) 10 July 2020Page 2 |

VDMA

Time line OPC 40077-Projekt

| Wolfgang Höglinger (ENGEL Austria) & Dr. Harald Weber (VDMA Plastics and Rubber Machinery) 10 July 2020

05/2014 Kick-off OPC UA proposed as basis10/2016 Publication of EUROMAP 77 as Release Candidate

Demonstrator at K 2016 in Düsseldorf03/2017 Start of development superordinated EUROMAP 8301/2018 Plugfest04/2018 2nd Plugfest05/2018 Publication of Release (EUROMAP 77)04/2019 Kick-off Joint Working Group with OPC Foundation06/2020 Publication as OPC 40077

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Chance: From the industry for the industryMembers of EUROMAP 77 working group

Injection moulding machine manufacturers:» ARBURG GmbH + Co KG» ENGEL AUSTRIA GmbH» FANUC Germany/EUROPE» Ferromatik Milacron GmbH» KraussMaffei Technologies GmbH» NEGRI BOSSI S.p.a.» Netstal-Maschinen AG» Sumitomo (SHI) Demag Plastics Machinery GmbH» Wittmann Battenfeld GmbH

Controller manufacturers:» B&R Industrial Automation GmbH» Beckhoff Automation GmbH & Co. KG

MES suppliers:» ARBURG GmbH + Co KG» bfa solutions ltd» BMS bvba» INCLUDIS GmbH» inray Industriesoftware GmbH» MPDV Mikrolab GmbH» ProSeS BDE» RJG Germany» Steinberger Software» Stöckeler Software Services e.U.» TIG – Technische Informationssysteme Ges.m.b.H.

User:» LEGO Systems A/S

Controller manufacturers

Machine manufacturers

MES suppliers

User

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10 July 2020Page 4 || Wolfgang Höglinger (ENGEL Austria) & Dr. Harald Weber (VDMA Plastics and Rubber Machinery)

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Cooperation with international partners


Joint Working Group „OPC UA for plastics and rubber machinery“

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Plugfest for testing of the interface in differentmachine-MES-combinations


It works!

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Motivation


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GEL Increasing complexity of machines

Increasing networking of machinesPage 7 | 10 July 2020

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Industry 4.0 by ENGEL


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Advantages of standardised data exchange

For machine manufacturers» Definition of which data is exchanged in which form No in-house developments necessary Less coordination effort between partners

For plant operators» Simpler combination of machines when components of

different manufacturers are able to communicate with each other Lower integration and configuration effort

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Page 9 | 10 July 2020| Wolfgang Höglinger (ENGEL Austria) & Dr. Harald Weber (VDMA Plastics and Rubber Machinery)

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History of EUROMAP interfaces for plastics and rubber machines

| Wolfgang Höglinger (ENGEL Austria) & Dr. Harald Weber (VDMA Plastics and Rubber Machinery) Page 10 | 10 July 2020

VDMA

History of EUROMAP interfaces for plastics and rubber machines


VDMA

History of EUROMAP interfaces: Data exchange between injection moulding machines and central computers / MES


• 1988• Plug compatible interface• Basis: Bitbus from INTEL

EUROMAP 15

• 2000• Data compatible interface• Basis: Text files

EUROMAP 63

• 2018• Semantic interface• Basis: OPC UA

EUROMAP 77

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Why OPC UA?


Standardized framework for the exchange of data and servicesOpen manufacturer and system independent standardDeveloped by OPC Foundation (non-profit organization)Very good experiences in practical application of membersCost-effective procurement for important programming environments (C++, C#, Java)Fulfils all present requirements withClient/Server-Architecture, Semantic DataDescription, Security

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Challenge: Please no mess of data!


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Change: Structured data - models for specific use cases


BaseObjectType

IMM_MES_InterfaceType

MachineInformation MachineInformationType(Defined in EUROMAP 83)

MachineConfiguration MachineConfigurationType(Defined in EUROMAP 83)

MachineMESConfiguration MachineMESConfigurationType(Defined in EUROMAP 83)

MachineStatus MachineStatusType(Defined in EUROMAP 83)

MachineMESStatus MachineMESStatusType(Defined in EUROMAP 83)

InjectionUnits InjectionUnitsType

Moulds MouldsType(Defined in EUROMAP 83)

PowerUnits PowerUnitsType(Defined in EUROMAP 83)

Jobs JobsType(Defined in EUROMAP 83)

ProductionDatasetManagement ProductionDatasetManagementType(Defined in EUROMAP 83)

0:NodeVersion

InjectionUnit_<Nr> InjectionUnitType

Index

BarrelId

IsPresent

InProduction

ScrewId

ScrewDiameter

ScrewVolume

TemperatureZones TemperatureZonesType(Defined in EUROMAP 83)

DeviceSet(Defined in OPC UA DI)

IMM_<Manufacturer>_<SerialNumber> LogbookEventType

CycleParametersEventType

GeneratesEvent

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Challenge: The injection moulding machine


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Some 10T €

Some Mio. €

One interface for all!

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Challenge: Choosing the right system boundary


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Challenge: Separation between application and interface


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110011010

Which data is generated in the machines?Which data is needed by the machine?Who is responsible for calculations/processing of information?

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Overview Specificationssee www.euromap.org/i40


Released specifications:» OPC 40083: General Type definitions» OPC 40077: Data exchange between injection moulding machines and MES» OPC 40082-1: Peripheral devices: Temperature control devices» OPC 40084 Series: Extrusion

Release Candidates:» OPC 40082-2 and -3: Peripheral devices: Hot runner devices / LSR dosing

Projects under development:» OPC 40079: Interface between Injection Moulding Machine and Handling Device / Robot» OPC 40082-x: Further parts for other peripheral devices» OPC 40084-x: Further components of extrusion lines» OPC 40086: Material Supply Systems

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Structure of OPC UA for Plastics and Rubber Machinery


OPC UA Meta Model

Built-in Information Models

OPC 40083 – Plastics and rubber machinery – General

Vendor Specific Extensions

OPC 40077(IMM –MES)

OPC 40082

(Peripheraldevices)

OPC 40079 (IMM –robot)

OPC 40084 – ExtrusionPart 1: General

Part 2 Part 3 Part 4 …

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OPC 40083 – General Type definitions


Intention: Harmonization of Specifications for different machine types» Currently for plastics and rubber machinery only» Gives input to OPC UA for machinery which is under development

Building blocks for reuse in specifications for several machine types

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OPC 40083 – General Type definitions


» Machine Identification» Machine configuration» Machine status» Error information» Job management» Management of production datasets/programs/recipes» Monitoring/controlling of process values» Energy information» Maintenance information» Diagnostics» …

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Example use of OPC 40083 Types in OPC 40077


0:BaseObjectType


MachineInformation 3:MachineInformationType

MachineConfiguration 3:MachineConfigurationType

MachineMESConfiguration 3:MachineMESConfigurationType

MachineStatus 3:MachineStatusType

MachineMESStatus 3:MachineMESStatusType

InjectionUnits

InjectionUnitsType

Moulds 3:MouldsType

PowerUnits 3:PowerUnitsType

Jobs 3:JobsType

ProductionDatasetManagement 3:ProductionDatasetManagementType

0:NodeVersion

InjectionUnit_<Nr> InjectionUnitType

Index

BarrelId

IsPresent

InProduction

ScrewId

ScrewDiameter

ScrewVolume

TemperatureZones 3:TemperatureZonesType

from OPC 40083

from OPC 40083

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General concept - Use of container objects


» Container objects for objects that can occur several times in the parent object (e.g. several moulds in one machine).

» All instances are collected in one object so that changes can be easily recognized by using a Property NodeVersion and the GeneralModelChangeEvent.

» Within these containers, the child elements have the modelling rule OptionalPlaceholder which allows to add and remove instances of the objects dynamically.

» IsPresent-flag allows to have a fixed number of instances prepared (e.g. if the maximum number of child components is limited by the design of the machine) and to indicate if the component is physically present. Two possibilities: Dynamic creation of instances or fixed number of instances

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Use of container objects - Example


MouldsType

0:NodeVersion

Mould_<Nr> MouldType

Index

Id

Description

TemperatureZones TemperatureZonesType

MouldStatus

IsPresent

0:BaseObjectType


MachineInformation 3:MachineInformationType

MachineConfiguration 3:MachineConfigurationType

MachineMESConfiguration 3:MachineMESConfigurationType

MachineStatus 3:MachineStatusType

MachineMESStatus 3:MachineMESStatusType

Moulds 3:MouldsType

PowerUnits 3:PowerUnitsType

Container

2 approaches possible:1. Dynamic creation and deletion of instances in the server

(notification of client via NodeVersion and GeneralModelChangeEvent)2. Fixed number of instances in the server and setting IsPresent to

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Modelling of process values


3 levels:» Single (actual) value AnalogItemType / AnalogUnitType

» Monitoring with actucal value, set value, tolerances, min/max... MonitoredParameterType

» Changing of set value (and optional control parameters) by client ControlledParameterType

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MonitoredParameterType


MonitoredParameterType ControlledParameterType

0:PropertyType:AutomaticMonitoring

0:AnalogItemType:ActualValue

0:AnalogItemType:SetValue

0:AnalogItemType:SetRampUp

0:AnalogItemType:SetRampDown

0:AnalogItemType:MinValue

0:AnalogItemType:MaxValue

0:AnalogItemType:UpperTolerance

0:AnalogItemType:LowerTolerance

0:MultiStateValueDiscreteType:MonitoringSensitivity

0:MultiStateValueDiscreteType::AlarmSuppression

ResetMonitoring

ClosedLoopControlType

0:Boolean:

AutomaticControllerMode

AutoTuningOn

AutoTuningOff

PIDParametersType:PIDParameters[]

ClosedLoopControl

0:AnalogItemType:SetRampUp

0:AnalogItemType:SetRampDown

0:Boolean:AutoTuningActive

0:AnalogItemType:UpperTolerance2

0:AnalogItemType:LowerTolerance2

Process value

time

Nominal: 190°C UpperTolerance: +10°C

MaxValue: 250°C

LowerTolerance: -8° C

MinValue: 150°C

ActualValue

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OPC 40077 (Released June 2020)Data exchange between injection moulding machines and MES


Information about the injection moulding machine and its configuration» Installed injection unit(s), installed mould(s), current user(s)

Status of productionProcess values

» Temperatures, Pressures, Times

Job management» Current job / job in preparations» How many parts of which products shall be / are produced?

Management of data sets/recipes» Exchange of complete machine setting data between MES and machine

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OPC 40079 (working draft)Data exchange between injection moulding machines and robot


Pairing of IMM and robotStarting of automatic productionCyclic interaction for part handling

» Triggering of robot actions» Position and enable signals to prevent collisions

Part trackingPart quality

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Challenge: Bi-directional real-time communication


Real-time communication necessary for avoiding collisions» Injection moulding machine sends position signals» Robot sends release signals

Pairing of robot(s) and injection moulding machine(s)» n robots can interact with m machines» Position data of machine same for all connected robots» Release signals are only valid for a single machine

Dynamic creation of Dataset» Depending on the application different number of axes needs to be included

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OPC 40082Peripheral devices


Part 1: Temperature control devices (Released June 2020)Part 2: Hot runner (Release Candidate)Part 3: Liquid Silicone Rubber Dosing Systems (Release Candidate)

Information about the device and its condition(Operation status, process values, errors, …)

Writing of set value by connected machine

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OPC 40084 (Released June 2020)Extrusion


Part 1: General Type definitionsPart 2: Extrusion linePart 3: ExtruderPart 4: Haul-offPart 5: Melt PumpPart 6: Filter

Part 7: DiePart 8: PelletizerPart 9: CutterPart 10: CalibratorPart 11: Corrugator Further will follow

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Modular structure which allows single servers and aggregating servers


Main extruder Co extruder Die

Line status

MES

Haul-off

Main extruder with line control Co extruder Die

MES

Haul-off

40084-2

40084-3

40084-3 40084-7

40084-4

Main extruder Co extruder Die

MES

Line control

Haul-off

40084-2 - 40084-x

(40084-3)

(40084-3) (40084-7)

(40084-4)

(40084-4)

(40084-7)(40084-3)

Server ClientData transfer

a)

b)

c)

Legend

Used OPC 40084-x specification for the communication(A number in brackets means that the information between the components may be transferred via OPC UA with the standardized information model but also with other communication technologies)

40084-x

40084-2 - 40084-x

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OPC 40086 (Kick-off June 2020)Material Supply System


Complete path of material from silo to machine

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Challenge: Implementation of the OPC UA interfaces


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Machine

Control systemTraditional,

fixed behaviour

HMITraditional operation

MES 1 MES 2 MES 3

Clientindividual

Clientindividual

Clientindividual

Machine

Control systemChanged behavior,

new functions

HMIAdditional control

elements

OPC UA/EUROMAP

Additional system load,

new error possibilities

One time workImplementation of standard

individualwork ind.

work

individualwork

MES 3OPC UA Client

standardized

MES 1OPC UA Client

standardized

MES 2OPC UA Client

standardized

Easy work via standard

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What have we achieved?

Agreement on OPC UA as preferred communication technology for Industry 4.0 applications

Competitors are working together on common information models for their machines

Verification in plugfests and demonstrators

First machines using Companion Specifications already in the market

Page 36 | 10 July 2020| Wolfgang Höglinger (ENGEL Austria) & Dr. Harald Weber (VDMA Plastics and Rubber Machinery)

VDMA | Wolfgang Höglinger (ENGEL Austria) & Dr. Harald Weber (VDMA Plastics and Rubber Machinery)

Your experts in VDMA

Page 37 | 10 July 2020

Dr. Harald WeberVDMA Plastics and Rubber MachineryPhone: +49 (0)69 6603 - 1833Mail: [email protected]

Marc SchmittVDMA Plastics and Rubber MachineryPhone: +49 (0)69 6603 - 1182Mail: [email protected]

Documents

OPC UA for plastics and rubber machinery