Exponentially Great Results Require the Right

1
Exponentially Great Results Require the Right
Box of Tricks

• John Weber - President
• Kevin Rutherford Applications Engineer

2
Agenda
Symbol Factory ArchestrA/Gadget
Wizards Information Integration Solutions Case
Study BHP Hillside/CSS Case Study - Green
IT Case Study - Task Force Tips Summary
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Symbol Factory ArchestrA Overview

• 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!

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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

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Gadget Wizards for Wonderware

• Ideal for InTouch 10 Compact Edition Wonderware
  Panels
• Photorealistic Buttons, Lights, Switches, Meters,
  Sliders, Fills Panels
• Economical - Runtime free licensing

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Data Integration Challenges
Connect to non-Wonderware MES databases
Connect Live OPC Data to Excel
Bridge Data Between OPC Servers?
Log to non- InSQL/ Historian Databases
Move data w/o DCOM?
Monitor Advise if Processes stop or restart
Connect OPC to non-Windows OS?
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Data Integration Solutions
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OPC Data Aggregation Without Data Aggregation

• Multiple Data Sources Clients
• Each Client makes its own connection to each OPC
  Server
• Redundant data flow
• High network utilization, negative impact on
  control network

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OPC DataHub AggregationWith Aggregation

• Reduced Connections
• Common connection for multiple data sources
• Efficient data flow

• 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)

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OPC without TunnellingFull of Challenges

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

I want to connect to you
X
My user name is vernon_koekoemoer and password
is bleddie_lekker
Yes, you are on my list I will grant you access!
Or you might get Han Weg this is a no Vernon
Zone!
Jislaaik, you are so last yearIll check my
access list just now
PC 2 OPC Server
Howzit boet Tell me your login name and password!
OPC Server
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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
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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

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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

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OPC Tunnelling But wait cant 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

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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

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OPC DataHub Email / SMS Notifications

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

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OPC Data HubConnecting Excel to OPC

• Value Quality Timestamp
• Array tag support
• Combine with tunnelling for easy remote data
  access!
• Writes without scripting

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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
• APIs 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?
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Bridging Solutions Moving Data Doesnt 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

OPC Bridging Tool
Control System A (DCS / PLC / Etc.)
Control System B (DCS / PLC / Etc.)
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Bridging Solutions Moving Data Doesnt 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

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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

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Bridging with OPC Data Hub

• Move Data Between Many Different Disparate
  Systems
• Email/SMS Notifications
• Avoid DCOM via Tunnelling

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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
• APIs 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!!!
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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

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OPC Gateway Update Methods

• Multiple Update Methods Available
• On Data Change
• Polled
• Monitored Item Trigger

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OPC Gateway Transformations

• Simple Complex Calculations
• Formulas
• Conversion to Engineering Units
• Scaling
• Test Transform Expressions
• Confirm that your formula has the desired result

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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
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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

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Case Study CSS BHP Billiton
Over 230 PLCs Over 230 000 tags! 1 second scan
rates Entire Hillside facility on TOP Server
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Case Study CSS BHP BillitonSystem Detail
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Case Study CSS BHP Billiton2009 System
Improvements
Problem ZAR 200 000 For non local OPC
connections!
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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!

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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.

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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

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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!
• Cant rewrite the pick program easily
• Must interface it with the ControlLogix
• How????

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Case Study Task Force Tips

• Benefits
• Improved efficiency
• Nearly eliminated downtime

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
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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_at_softwaretoolbox.com
• Kevin Rutherford
• krutherford_at_softwaretoolbox.com
• John Weber
• jweber_at_softwaretoolbox.com
• Order licenses from the Wonderware South Africa
  team!