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Open communication standards such as OPC UA, POWERLINK and openSAFETY are key to success for Industry 4.0
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Open communication standards
Key to success for Industry 4.0
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Stéphane POTIER Technology Marketing Manager
B&R Automation
Perfection in Automation www.br-automation.com
First industrial revolution
Mechanization of production using water and steam power
Second industrial revolution
Mass production with the help of electric power
Third industrial revolution
Digital communication technologies to automate production
Fourth industrial evolution
Interconnected systems for smart production
Fourth industrial evolution
Industry 4.0
Smart Manufacturing
The Connected Machine©
The Industrial Internet
One concept, several initiatives worldwide
Industry 4.0
The goal of Industry 4.0 is the smart and connected factory with
Internet of Things and Cyber Physical Systems as technology basis.
Internet of Things (IoT) is the Interconnection of uniquely
identifiable embedded computing devices (smart objects) within the
Internet infrastructure.
Cyber Physical Systems (CPS) are systems using computations
and communication deeply embedded in and interacting with
physical processes.
Computerization of the manufacturing industry
Industry 4.0
Concept of Industry 4.0 is to interconnect machinery, sensors and
control systems together via intelligent networks to achieve:
• Dynamic response to product demands, enable rapid manufacturing
of new products.
• Real-time optimization of manufacturing production and supply chain
networks, highly flexible production.
• Strong customization of products, mass customization.
• Self-optimization, self-configuration and self-diagnosis.
• Active support of the manufacturing process by smart products
themselves
Connecting machines with intelligent networks
Networked Manufacturing
Horizontal value network
Industry 4.0 Working Group
Industry 4.0 will involve networking
and integration of several different
companies through value networks.
This collaborative partnership will only
be possible if a single set of common
standards is developed.
Standardization as a prerequisite for Industry 4.0
http://www.forschungsunion.de/p
df/industrie_4_0_final_report.pdf
Distributed intelligence based on standards
Networks incorporate entire manufacturing process
Connecting ERP, MES, SCADA and PLCs
• Interoperability standard
developed by the OPC Foundation
• Manufacturer-independent
standard for exchanging data
• Multi-platform service-oriented
architecture
• Scalable from smart
sensors/actuators to mainframes
• International standard IEC 62541
OPC Unified Architecture (OPC UA)
OPC UA in PLC
• OPC UA Server in PLC for vertical
communication to SCADA, MES
and ERP
• OPC UA Client in PLC enables
vendor-independent horizontal
communication from PLC to PLC
• PLCopen-compliant function blocks
• Guaranteed semantic
interoperability
OPC UA Client / Server in the PLC
Distributed intelligence based on standards
OPC UA standard for ERP, MES, SCADA and PLCs
Distributed intelligence based on standards
Standard for real-time field network
Connecting sensors and actuators
A real-time standard for the field network
• OPC UA is based on TCP/UDP/IP
• Not suitable for real-time data
exchange
• Field network usually require
high level of determinism
• POWERLINK fulfills perfectly
requirements for real-time field
network
Why POWERLINK
• Maximum performance
• Absolute openness
• Based on Standard Ethernet
• Designed for Integrated Automation
• International standard IEC 61158-13
Worldwide market leader
• Worldwide leader for real-time Ethernet solutions
• 3,100 OEMs trust in POWERLINK
• More than 900,000 POWERLINK systems installed
An 100% open standard
• POWERLINK is completely free of patents and without licenses
• POWERLINK is open source – downloadable on sourceforge.net
27.000
Designed for integrated automation
Remote
I/Os Safety Motion
Vision
Robotics
Pneumatic
Integrated Automation
Controller
Visualization
Decentralized
controller Sensors Encoder
Distributed intelligence based on standards
POWERLINK standard for field level networks
OPC UA down to the sensors
• Deterministic data are exchanged in the POWERLINK isochronous
phase
• With POWERLINK a dedicated bandwidth is reserved for non real-time
data exchange, can not degrade real-time data exchange
Combining OPC UA and determinism of field network
OPC UA down to the sensors
Efficient non real-time data exchange with POWERLINK
OPC UA down to the sensors
OPC UA client/server down to the sensors
Distributed intelligence based on standards
POWERLINK standard for field level networks
Integrated safety
The Industry 4.0 Working Group has stated:
• Safety is the first priority area for Industry 4.0
• Safety strategies must be designed for open collaborative
subsystems belonging to different manufacturers and operators
• Industry 4.0 will require the deployment of integrated safety
• openSAFETY is ideal solution for integrated safety in an open multi-
vendor environment
Critical factor for the success of Industry 4.0
openSAFETY is open and independent
• The world’s first 100% open safety protocol
• Totally independent from technical and legal aspects
• Supported by the international user organization EPSG
One safety standard for all networks
TCP/IP
EtherCAT POWERLINK PROFINET
Distributed intelligence based on standards
Standard for integrated safety
Distributed intelligence based on standards
OPC UA – POWERLINK - openSAFETY
Open standards for Industry 4.0
OPC UA – POWERLINK - openSAFETY
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