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Software Architecture in Process Automation: UML & the "Smart Factory"

Heiko Koziolek
Heiko Koziolek

The document details a guest lecture on software architecture in process automation by Dr.-Ing. Heiko Koziolek, emphasizing the role of Unified Modeling Language (UML) in modeling industrial IoT systems for automation. It outlines ABB's mission in architecting sustainable automation products and highlights the need for self-commissioning field devices within the context of Industry 4.0. The presentation also discusses various methods and tools for software architecture and emphasizes the potential competitive advantages achievable through effective software engineering practices.

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GUEST LECTURE, UNIVERSITY OF HEIDELBERG, 2018-01-30 Software Architecture in Process Automation UML & the “Smart Factory” Dr.-Ing. Heiko Koziolek, Senior Principal Scientist, ABB Corporate Research Ladenburg
Process Automation & Industrie 4.0 Software Architecture at ABB Modeling with the Unified Modeling Language Structure of an Automation System Reference Software Architecture for Self-commissioning Industrial IoT-Devices Experimental Evaluation & Performance Tests Conclusions Agenda
January 31, 2018 Slide 3 ABB System 800xA
World‘s Largest Paper Mill, Stora Enso, Kvarnsveden, Sweden Process Automation January 31, 2018 Slide 4 http://www.abb.com/cawp/seitp202/2e66f68dc8294228c1257654002c86bc.aspx Automated with ABB‘s System 800xA
World‘s Largest Container Ship in 2006, Emma Maersk, Denmark Process Automation January 31, 2018 Slide 5 Automated with ABB‘s System 800xA http://www.abb.de/cawp/seitp202/c12d1bb991ef3400c1257650004ceabe.aspx Automated with ABB‘s System 800xA
World‘s Largest Chemical Complex, BASF, Ludwigshafen, Germany Process Automation January 31, 2018 Slide 6 https://library.e.abb.com/public/262ee24c3ad6de1bc125768f00411eba/ABB_SuccesStory_BASF_Oppanol_final.pdf
Introduction Software Architecture January 31, 2018 Slide 7 is the set of principal design decisions for a software system determining its non-functional qualities, as well as the resulting entities and their relations. ABB Corporate Research’s Software Architecture Mission  To architect sustainable automation products, systems, and services using a risk-driven approach targeting optimal trade- offs and exploiting opportunities for software reuse.  To assist Business Units in cost-efficiently analyzing, documenting, and evolving software architectures for large- scale, embedded, and real-time systems.  To develop, refine, and validate software architecting methods and best practices in BU projects Software Architecture
Why for ABB? Software Architecture at ABB January 31, 2018 Slide 8 – New IT technologies need to be mirrored against automation requirements and tailored for ABB customer needs – Deep software development expertise necessary to manage the complexity of todays automation systems – Methods and tools for architecting are still immature: ABB can achieve a competitive advantage with a state-of-the-art methodology – Highly maintainable software systems, faster resolution of customers issues – Non-functional properties (security, resilience, performance, etc.) achieved with architecture are key market differentiator – Lower software development costs through software reuse and no redundant software development Why are we doing research in this area? What is the concrete value for ABB?
Guidelines for architecting: towards an engineering discipline Software Architecture at ABB January 31, 2018 Slide 9 To structure architecture documents: Arc42 (Word Template​) To model architecture designs: UML (Unified Modeling Language) To structure architecture models: Viewpoints & Perspectives, Modeling Guidelines​ To evaluate an architecture : Architecture Trade-off Analysis Method (from SEI) To check for architecture violations: Dependency Structure Matrices To model software architectures: Sparx System Enterprise Architect​ To sketch architecture designs: Microsoft Visio To clean-up source code component dependencies: Structure101, CppDepend, Ndepend, dv8 (beta) To generate source code statistics for various languages: scitools Understand To document architecture decisions in Enterprise Architect: DA4EA (beta), ADMentor ​(beta) Architecting methods and tools at ABB are constantly being improved supported by universities and commercial partners. Methods Tools
Reminder: Modeling with UML Software Architecture at ABB January 31, 2018 Slide 10 class Class Model Account AddressBook - name: String + getContact(): Contact + getContacts(): Contact[] + getName(): String + insertContact(Contact): void + setName(String): void Contact ContactGroup Operations Attributes Aggregation RelationshipComposition Relationship Classes sd Sequence Diagram cust:Customer teller:ATM theBank:Bank seq Balance Lookup opt Lifeline Object Message Fragment withdrawCash() :cash :balance debit(accountNumber, account) getBalance()
Reminder: Modeling with UML Software Architecture at ABB January 31, 2018 Slide 11 Component Diagrams Deployment Diagrams cmp Class Model Web Server SQL Database Web Client Components Provided Interface Required Interface deployment Class Model Client Workstation Internet Linux Server :Web Client :Web Server Deployment Nodes Deployed Component
Modeling Software Architecture Decisions with ADMentor (Free Enterprise Architect Add-in) Software Architecture at ABB January 31, 2018 Slide 12 Problem (Decision Point) Connections Options https://github.com/IFS-HSR/ADMentor
How to model an automation system in UML? January 31, 2018 Slide 13
ANSI/ISA 95 Structure of an Automation System January 31, 2018 Slide 14 cmp ISA95 EngineeringSupervision Enterprise Resource Planning Manufacturing Execution System Supervision Engineering Controller Controller Level 4 Gateway «device» Sensor «device» Actuator «device» Sensor «device» Actuator «device» Sensor «device» Actuator «device» Actuator «device» Sensor Remote I/O Level 3 Level 2 Level 1 Fieldbus Fieldbus Ethernet Ethernet Fieldbus Point-to-Point
Level 2 Structure of an Automation System January 31, 2018 Slide 15 ABB 800xA Extended Operator Workplace  For high-level supervision, starting batch processes, handling alarms  Distributed system: 2-20 servers  Windows Server OS or Linux OS  C++, ~10 MLOC  Cloud Connectivity  Clients: 1-40 Operator Stations  Windows 10 OS, .NET/#C  MS Windows Presentation Foundation  Large displays for control room  Video streams from production process L2: Supervision
Level 2 Structure of an Automation System January 31, 2018 Slide 16 Real-time controllers  To handle deterministic, cyclic control  Power PC, RISC Processors  450 MHz  256 MB RAM  Real-time OS: Wind River VxWorks I/O (Input/Output) Cabinets  To process sensor signals  Analog/Digital I/O Signals  Wireless I/O  Remote I/O  Supported temperatures: -40 to +70°C  Optional redundancy L2: Control & IO
Structure of an Automation System January 31, 2018 Slide 17 Sensors  Flow  Pressure  Temperature  Level  … Actuators  Valves  Motors  Drives  Robots  …. L1: Field Devices Sensor: Laser Level Transmitter Sensors: Flowmeters Level 1
1. An engineer… a) places a sensor into the asset, connects it to power & network b) sets a fieldbus address manually c) uses a configuration tool on laptop to retrieve sensor type/ID d) selects a driver (e.g., a GSD file for Profibus) on laptop, downloads it to the sensor, to enable basic communication e) engineer enters a dozen configuration parameters for the sensor (e.g., maximum level value), uploads it to the sensor 2. A control logic programmer… a) imports the network configuration into programming tool, maps program variables (e.g., levelValue) to bus addresses (e.g., 0xFC) b) compiles and downloads the configured control logic programs to the real-time controller 3. Repeat 1) and 2) for all devices (e.g., 100s-10.000s) in a plant 4. Production is ready to start Steps to get a sensor running How to commission a field device today January 31, 2018 Slide 18 This may take months for a mid-sized plant!
R1: Standardized communication protocol R2: Automated network discovery R3: Standardized device description R4: Field devices provide standardized signal interface R5: Standardized control logic language R6: Automated signal matching R7: Human approval step for discovered configurations R8: Real-time communication ( >1 ms cycle time) R9: Security via authentication and optional encryption „Plug & Produce“ Requirements for self-commissioning field devices January 31, 2018 Slide 19 ABB Corporate Research has designed a Reference Architecture to address these requirements.
A software reference architecture is a software architecture where the structures and respective elements and relations provide templates for concrete architectures in a particular domain or in a family of software systems. Definition What is a Reference Architecture? January 31, 2018 Slide 20 Java Platform Enterprise Edition, Layered ArchitectureAUTOSAR: AUTomotive Open System ARchitecture https://goo.gl/4vCQNb
Purpose: Address the requirements for self-commissioning IIoT devices, so that field devices and controllers of different vendors can commission themselves with minimal human intervention. Architecture Viewpoints: • Static View: UML Component Diagrams • Dynamic View: UML Interaction Diagrams • Deployment View: UML Deployment Diagrams • Information View: UML Class Diagrams • Architecture Decisions: ADMentor Experimental Evaluation: • Prototype at ABB Corporate Research • No commercial implementations yet Overview Reference Architecture for Self-commissioning IIoT devices January 31, 2018 Slide 21
cmp ISA95 EngineeringSupervision Enterprise Resource Planning Manufacturing Execution System Supervision Engineering Controller Controller Level 4 Gateway «device» Sensor «device» Actuator «device» Sensor «device» Actuator «device» Sensor «device» Actuator «device» Actuator «device» Sensor Remote I/O Level 3 Level 2 Level 1 Fieldbus Fieldbus Ethernet Ethernet Fieldbus Point-to-Point ANSI/ISA 95 Structure of an Automation System January 31, 2018 Slide 22 Focus of the reference architecture (Level 1+2)
Static View January 31, 2018 Slide 23 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
Static View January 31, 2018 Slide 24 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
Novel Industry Standard for IoT Machine-to-Machine Communication What is OPC UA? January 31, 2018 Slide 25 OPC UA Server with device parameter and signal values Level Transmitter (Sensor) Communication & Platforms: • Supported protocols: HTTP, SOAP, UA Binary, MQTT, AMQP, … • Supported programming languages: C, C++, Java, Python, … • Supported OS: Windows, Linux, MacOS, VxWorks, … Object-oriented Information Model: • For example to build up tree-like structures • Static data (e.g., parameter), dynamic data (e.g., sensor value) • Standardized models for field devices, robots, drives, … Services: • Connect, Read, Write, Subscribe, AddNode, CallMethod, … • Alarms and Conditions: to detect regular and irregular events • Historical Access: long-term storage for visualizing trends Features
Excerpts from the OPC UA Metamodel in UML What is OPC UA? January 31, 2018 Slide 26
Novel Industry Standard for IoT Machine-to-Machine Communication What is OPC UA? January 31, 2018 Slide 27 Co-authored by ABB Corporate Research Brochure from the OPC Foundation
Becoming Industrial Internet-of-Things (IIoT) Devices Controller OPC UA Server / Device OPC UA Server January 31, 2018 Slide 28 Controller UA Server with PLCopen (IEC 61131) control programs OPC UA Server with device parameter and signal values Level Transmitter (Sensor)
Becoming Industrial Internet-of-Things (IIoT) Devices Controller OPC UA Server / Device OPC UA Server January 31, 2018 Slide 29 cmp ISA95 EngineeringSupervision Enterprise Resource Planning Manufacturing Execution System Supervision Engineering Controller Controller Level 4 Gateway «device» Sensor «device» Actuator «device» Sensor «device» Actuator «device» Sensor «device» Actuator «device» Actuator «device» Sensor Remote I/O Level 3 Level 2 Level 1 Fieldbus Fieldbus Ethernet Ethernet Fieldbus Point-to-Point OPC UA over AMQP
Static View January 31, 2018 Slide 30 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime Static View January 31, 2018 Slide 31
Static View January 31, 2018 Slide 32 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
1. An engineer… a) places a sensor into the asset, connects it to power & network b) sets a fieldbus address manually c) uses a configuration tool on laptop to retrieve sensor type/ID d) selects a driver (e.g., a GSD file for Profibus) on laptop, downloads it to the sensor, to enable basic communication e) engineer enters a dozen configuration parameters for the sensor (e.g., maximum level value), uploads it to the sensor 2. A control logic programmer… a) imports the network configuration into programming tool, maps program variables (e.g., levelValue) to bus addresses (e.g., 0xFC) b) compiles and downloads the configured control logic programs to the real-time controller 3. Repeat 1) and 2) for all devices (e.g., 100s-10.000s) in a plant 4. Production is ready to start Steps to get a sensor running Reminder: How to commission a field device today January 31, 2018 Slide 33 These steps may take weeks for a mid-sized plant!
Static View January 31, 2018 Slide 34 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
Static View January 31, 2018 Slide 35 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
Dynamic View 1/2 January 31, 2018 Slide 36 sd DeviceConfig :Device Management :Communication Channel :Device OPC UA Server :Public Device Driver Repository :Engineering Repository opt loop Only necessary if fieldbus communication is required. Via Local Discovery Server announce() :deviceDriver :configData :deviceId getDeviceIds() retrieveDeviceDriver() getDeviceId() :deviceIds :signalConfigReady :addresses scan() configureDevice() populateUaServer() retrieveConfigData() downloadDriversAndConfig()
1. An engineer… a) places a sensor into the asset, connects it to power & network b) sets a fieldbus address manually c) uses a configuration tool on laptop to retrieve sensor type/ID d) selects a driver (e.g., a GSD file for Profibus) on laptop, downloads it to the sensor, to enable basic communication e) engineer enters a dozen configuration parameters for the sensor (e.g., maximum level value), uploads it to the sensor 2. A control logic programmer… a) imports the network configuration into programming tool, maps program variables (e.g., levelValue) to bus addresses (e.g., 0xFC) b) compiles and downloads the configured control logic programs to the real-time controller 3. Repeat 1) and 2) for all devices (e.g., 100s-10.000s) in a plant 4. Production is ready to start Steps to get a sensor running Reminder: How to commission a field device today January 31, 2018 Slide 37 These steps may take weeks for a mid-sized plant!
cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime Static View January 31, 2018 Slide 38
Static View January 31, 2018 Slide 39 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
Static View January 31, 2018 Slide 40 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
Dynamic View 2/2 January 31, 2018 Slide 41 sd SignalMatching :Plug and Produce Service :Device OPC UA Server :Controller OPC UA Server :Communication Channel :61131 Runtime opt loop loop Via Local Discovery Server if signals match: activate publishing / subscribing via multicast addresses cyclic communication signalIn() browseForSignals() :approved :endpointURL disconnect() :signalNames readSignalNames() enableSubscription() subscribe() signalOut() :signalNames enablePublishingCaculatedSignalValues() connect() connect() queryForHumanApproval() findOPCUAServer() SignalRetrieval via MulticastUdp() enableSubscription() matchSignalNames()
Information View January 31, 2018 Slide 42 class IoT Device Model Root Objects DeviceSet IoT Device CtrlConfiguration Resources FieldDevice Programs Main FB_IoTDevice Input Variable OutputVariable Local Variable CtrlProgramOrganizationUnit CtrlResource SerialNumber Manufacturer ProtocolSupport [...] Device TopologyElement OPC UA for Devices PLCOpen for OPC UA e.g., GSD- file e.g., level transmitter
Classical Deployment with IO Gateway Deployment View (1/2) January 31, 2018 Slide 43 deployment DeploymentClassical Controller IO Gateway «device» Field Device 1 :Controller OPC UA Server :61131 Runtime :Controller Local Discovery :Device Local Discovery :Device OPC UA Server :Communication Channel Device Management Server :Plug and Produce Service :Device Management Ethernet Network Link Fieldbus or Analog Connection e.g., Windows server, Linux server, ... Embedded Real-time Controller e.g., sensor, actuator e.g., Profibus, HART, Modbus, ... «device» Field Device 2 «device» Field Device n [...] optional: TSN
Deployment with intelligent IIoT Devices Deployment View (2/2) January 31, 2018 Slide 44 deployment DeploymentIntelligentDevice Controller :Plug and Produce Service :Controller Local Discovery :Controller OPC UA Server :61131 Runtime Device Management Server :Device Management Ethernet Network Link Intelligent Field Device 1 :Device Local Discovery :Device OPC UA Server Intelligent Field Device 2 Intelligent Field Device n :Device OPC UA Server :Device Local Discovery :Device Local Discovery :Device OPC UA Server [...] Laptop Industry PC Field device with integrated OPC UA Server
Decisions provide different way of viewing the architecture Important to document the rationale for an architectural decision List considered options and chosen alternative Helps to understand the design better, especially during later life-cycle phases ~10 decision made for the reference architecture Documented with AD-Mentor in Enterprise Architect Overview Architecture Decisions January 31, 2018 Slide 45 cmp Static View with Decisions Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device (Chosen) OPC UA Discovery (Chosen) Automated, decoupled from controller (Chosen) OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals «trace» retrieve device driver exchange configuration data and signals «trace» announce startup approve configuration and supervise cyclic signal exchange browse for signals, enable subscriptions upload device driver «trace» multicast probe & announce retrieve signal configuration, arbitrate 61131 runtime monitor announce startup retrieve engineering data upload control logic «trace» exchange control logic and signals https://github.com/IFS-HSR/ADMentor
Communication Architecture Decisions (Example 1/2) January 31, 2018 Slide 46 SolutionOverview Communication (Solved) Controller to IO Communication (Neglected) Ethernet-based Fieldbus (Neglected) DDS (Neglected) MQTT (Chosen) OPC UA (Neglected) SOAP + DPWS (Solved) Network Discovery (Neglected) SOAP + DPWS (Chosen) OPC UA Discovery (Neglected) SSDP «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» https://github.com/IFS-HSR/ADMentor
Signal Matching Architecture Decisions (Example 2/2) January 31, 2018 Slide 47 SolutionOverview Signal Matching (Solved) Signal Mapping (Solved) Signal Matching (Neglected) IEC 61804 (Neglected) IEC 61158 (Foundation Fieldbus) (Chosen) PLCopen (Neglected) Automated, integrated to controller (Chosen) Automated, decoupled from controller (Neglected) Manual matching «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy»
Boiler Demo Setup Reference Architecture Experimental Evaluation January 31, 2018 Slide 48 OPC UA Server 3 OPC UA Server 1 OPC UA Server 4 Boiler FT 1001 FT 1002 Pipe1002 Valve 1001 LI 1001 LC 1001 OPC UA Server 2 OPC UA Client Legend LC: Level Controller LI: Level Indicator FT: Flow Transmitter flow disturbance flow disturbance Simulation Component Simulates input and output of process medium
Reference Architecture Experimental Evaluation January 31, 2018 Slide 49 Deployment deployment DeploymentDemo Raspberry Pi :Plug and Produce Service :Controller Local Discovery :Controller OPC UA Server :61131 Runtime Ethernet Network Link Raspberry Pi :Device Local Discovery :Device OPC UA Server Raspberry Pi Raspberry Pi :Device OPC UA Server :Device Local Discovery :Device Local Discovery :Device OPC UA Server Raspberry Pi :Device OPC UA Server :Device Local Discovery OPC UA C++ Server SDK V1.5.5 (Linux)
Live Demo Reference Architecture Experimental Evaluation January 31, 2018 Slide 50
OPC UA Client showing controller behavior Reference Architecture Experimental Evaluation January 31, 2018 Slide 51 Level value (cm) Valve position (%) Setpoint reached (133 cm) 80 seconds
Performance Measurements Reference Architecture Experimental Evaluation January 31, 2018 Slide 52 Max measured jitter: 104 microseconds  Scenarios with 1 ms update rate can be analyzed reasonably Signal publishing with 1 ms update rate Publisher CPU idle time decrease with a higher number of encoded signals At most it can handle 800 signals per ms Signal subscribing with 1 ms update rate Subscriber latency increases with higher number of encoded signals At most it can handle 600 signals per ms A commercial controller usually manages ~350 analog and digital signals, our prototype managed > 500 signals. Raspberry Pi Jitter Publisher OPC UA Encoding Subscriber OPC UA Decoding
Distributed control systems are used for various industry applications. Process control systems are evolving to the Industrial Internet-of-Things. A Smart Factory will be faster to set up and much more flexible than today. Software Architecture helps to manage the complexity of such systems. Architects use UML to describe systems and information models. UML can also be used to capture architecture decisions and their rationale. The Reference Architecture enables self-commissioning IIoT systems. Controllers and devices from different vendors can find each other. Performance tests validated its feasibility based on a prototype. Software Architecture in Process Automation Conclusions January 31, 2018 Slide 53 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime Industrie 4.0 / IIoT needs talented Software Architects!
Internships, Master Theses, Open Positions ABB Corporate Research in Ladenburg January 31, 2018 Slide 54 http://new.abb.com/de/karriere Internship: “Software development for the Internet-of-Things” Master / Bachelor Thesis: “Big Data Analytics System for Industrial Plants” Industry Researcher: “Software Architecture”
Software Architecture in Process Automation: UML & the "Smart Factory"

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Software Architecture in Process Automation: UML & the "Smart Factory"

  • 1. GUEST LECTURE, UNIVERSITY OF HEIDELBERG, 2018-01-30 Software Architecture in Process Automation UML & the “Smart Factory” Dr.-Ing. Heiko Koziolek, Senior Principal Scientist, ABB Corporate Research Ladenburg
  • 2. Process Automation & Industrie 4.0 Software Architecture at ABB Modeling with the Unified Modeling Language Structure of an Automation System Reference Software Architecture for Self-commissioning Industrial IoT-Devices Experimental Evaluation & Performance Tests Conclusions Agenda
  • 3. January 31, 2018 Slide 3 ABB System 800xA
  • 4. World‘s Largest Paper Mill, Stora Enso, Kvarnsveden, Sweden Process Automation January 31, 2018 Slide 4 http://www.abb.com/cawp/seitp202/2e66f68dc8294228c1257654002c86bc.aspx Automated with ABB‘s System 800xA
  • 5. World‘s Largest Container Ship in 2006, Emma Maersk, Denmark Process Automation January 31, 2018 Slide 5 Automated with ABB‘s System 800xA http://www.abb.de/cawp/seitp202/c12d1bb991ef3400c1257650004ceabe.aspx Automated with ABB‘s System 800xA
  • 6. World‘s Largest Chemical Complex, BASF, Ludwigshafen, Germany Process Automation January 31, 2018 Slide 6 https://library.e.abb.com/public/262ee24c3ad6de1bc125768f00411eba/ABB_SuccesStory_BASF_Oppanol_final.pdf
  • 7. Introduction Software Architecture January 31, 2018 Slide 7 is the set of principal design decisions for a software system determining its non-functional qualities, as well as the resulting entities and their relations. ABB Corporate Research’s Software Architecture Mission  To architect sustainable automation products, systems, and services using a risk-driven approach targeting optimal trade- offs and exploiting opportunities for software reuse.  To assist Business Units in cost-efficiently analyzing, documenting, and evolving software architectures for large- scale, embedded, and real-time systems.  To develop, refine, and validate software architecting methods and best practices in BU projects Software Architecture
  • 8. Why for ABB? Software Architecture at ABB January 31, 2018 Slide 8 – New IT technologies need to be mirrored against automation requirements and tailored for ABB customer needs – Deep software development expertise necessary to manage the complexity of todays automation systems – Methods and tools for architecting are still immature: ABB can achieve a competitive advantage with a state-of-the-art methodology – Highly maintainable software systems, faster resolution of customers issues – Non-functional properties (security, resilience, performance, etc.) achieved with architecture are key market differentiator – Lower software development costs through software reuse and no redundant software development Why are we doing research in this area? What is the concrete value for ABB?
  • 9. Guidelines for architecting: towards an engineering discipline Software Architecture at ABB January 31, 2018 Slide 9 To structure architecture documents: Arc42 (Word Template​) To model architecture designs: UML (Unified Modeling Language) To structure architecture models: Viewpoints & Perspectives, Modeling Guidelines​ To evaluate an architecture : Architecture Trade-off Analysis Method (from SEI) To check for architecture violations: Dependency Structure Matrices To model software architectures: Sparx System Enterprise Architect​ To sketch architecture designs: Microsoft Visio To clean-up source code component dependencies: Structure101, CppDepend, Ndepend, dv8 (beta) To generate source code statistics for various languages: scitools Understand To document architecture decisions in Enterprise Architect: DA4EA (beta), ADMentor ​(beta) Architecting methods and tools at ABB are constantly being improved supported by universities and commercial partners. Methods Tools
  • 10. Reminder: Modeling with UML Software Architecture at ABB January 31, 2018 Slide 10 class Class Model Account AddressBook - name: String + getContact(): Contact + getContacts(): Contact[] + getName(): String + insertContact(Contact): void + setName(String): void Contact ContactGroup Operations Attributes Aggregation RelationshipComposition Relationship Classes sd Sequence Diagram cust:Customer teller:ATM theBank:Bank seq Balance Lookup opt Lifeline Object Message Fragment withdrawCash() :cash :balance debit(accountNumber, account) getBalance()
  • 11. Reminder: Modeling with UML Software Architecture at ABB January 31, 2018 Slide 11 Component Diagrams Deployment Diagrams cmp Class Model Web Server SQL Database Web Client Components Provided Interface Required Interface deployment Class Model Client Workstation Internet Linux Server :Web Client :Web Server Deployment Nodes Deployed Component
  • 12. Modeling Software Architecture Decisions with ADMentor (Free Enterprise Architect Add-in) Software Architecture at ABB January 31, 2018 Slide 12 Problem (Decision Point) Connections Options https://github.com/IFS-HSR/ADMentor
  • 13. How to model an automation system in UML? January 31, 2018 Slide 13
  • 14. ANSI/ISA 95 Structure of an Automation System January 31, 2018 Slide 14 cmp ISA95 EngineeringSupervision Enterprise Resource Planning Manufacturing Execution System Supervision Engineering Controller Controller Level 4 Gateway «device» Sensor «device» Actuator «device» Sensor «device» Actuator «device» Sensor «device» Actuator «device» Actuator «device» Sensor Remote I/O Level 3 Level 2 Level 1 Fieldbus Fieldbus Ethernet Ethernet Fieldbus Point-to-Point
  • 15. Level 2 Structure of an Automation System January 31, 2018 Slide 15 ABB 800xA Extended Operator Workplace  For high-level supervision, starting batch processes, handling alarms  Distributed system: 2-20 servers  Windows Server OS or Linux OS  C++, ~10 MLOC  Cloud Connectivity  Clients: 1-40 Operator Stations  Windows 10 OS, .NET/#C  MS Windows Presentation Foundation  Large displays for control room  Video streams from production process L2: Supervision
  • 16. Level 2 Structure of an Automation System January 31, 2018 Slide 16 Real-time controllers  To handle deterministic, cyclic control  Power PC, RISC Processors  450 MHz  256 MB RAM  Real-time OS: Wind River VxWorks I/O (Input/Output) Cabinets  To process sensor signals  Analog/Digital I/O Signals  Wireless I/O  Remote I/O  Supported temperatures: -40 to +70°C  Optional redundancy L2: Control & IO
  • 17. Structure of an Automation System January 31, 2018 Slide 17 Sensors  Flow  Pressure  Temperature  Level  … Actuators  Valves  Motors  Drives  Robots  …. L1: Field Devices Sensor: Laser Level Transmitter Sensors: Flowmeters Level 1
  • 18. 1. An engineer… a) places a sensor into the asset, connects it to power & network b) sets a fieldbus address manually c) uses a configuration tool on laptop to retrieve sensor type/ID d) selects a driver (e.g., a GSD file for Profibus) on laptop, downloads it to the sensor, to enable basic communication e) engineer enters a dozen configuration parameters for the sensor (e.g., maximum level value), uploads it to the sensor 2. A control logic programmer… a) imports the network configuration into programming tool, maps program variables (e.g., levelValue) to bus addresses (e.g., 0xFC) b) compiles and downloads the configured control logic programs to the real-time controller 3. Repeat 1) and 2) for all devices (e.g., 100s-10.000s) in a plant 4. Production is ready to start Steps to get a sensor running How to commission a field device today January 31, 2018 Slide 18 This may take months for a mid-sized plant!
  • 19. R1: Standardized communication protocol R2: Automated network discovery R3: Standardized device description R4: Field devices provide standardized signal interface R5: Standardized control logic language R6: Automated signal matching R7: Human approval step for discovered configurations R8: Real-time communication ( >1 ms cycle time) R9: Security via authentication and optional encryption „Plug & Produce“ Requirements for self-commissioning field devices January 31, 2018 Slide 19 ABB Corporate Research has designed a Reference Architecture to address these requirements.
  • 20. A software reference architecture is a software architecture where the structures and respective elements and relations provide templates for concrete architectures in a particular domain or in a family of software systems. Definition What is a Reference Architecture? January 31, 2018 Slide 20 Java Platform Enterprise Edition, Layered ArchitectureAUTOSAR: AUTomotive Open System ARchitecture https://goo.gl/4vCQNb
  • 21. Purpose: Address the requirements for self-commissioning IIoT devices, so that field devices and controllers of different vendors can commission themselves with minimal human intervention. Architecture Viewpoints: • Static View: UML Component Diagrams • Dynamic View: UML Interaction Diagrams • Deployment View: UML Deployment Diagrams • Information View: UML Class Diagrams • Architecture Decisions: ADMentor Experimental Evaluation: • Prototype at ABB Corporate Research • No commercial implementations yet Overview Reference Architecture for Self-commissioning IIoT devices January 31, 2018 Slide 21
  • 22. cmp ISA95 EngineeringSupervision Enterprise Resource Planning Manufacturing Execution System Supervision Engineering Controller Controller Level 4 Gateway «device» Sensor «device» Actuator «device» Sensor «device» Actuator «device» Sensor «device» Actuator «device» Actuator «device» Sensor Remote I/O Level 3 Level 2 Level 1 Fieldbus Fieldbus Ethernet Ethernet Fieldbus Point-to-Point ANSI/ISA 95 Structure of an Automation System January 31, 2018 Slide 22 Focus of the reference architecture (Level 1+2)
  • 23. Static View January 31, 2018 Slide 23 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
  • 24. Static View January 31, 2018 Slide 24 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
  • 25. Novel Industry Standard for IoT Machine-to-Machine Communication What is OPC UA? January 31, 2018 Slide 25 OPC UA Server with device parameter and signal values Level Transmitter (Sensor) Communication & Platforms: • Supported protocols: HTTP, SOAP, UA Binary, MQTT, AMQP, … • Supported programming languages: C, C++, Java, Python, … • Supported OS: Windows, Linux, MacOS, VxWorks, … Object-oriented Information Model: • For example to build up tree-like structures • Static data (e.g., parameter), dynamic data (e.g., sensor value) • Standardized models for field devices, robots, drives, … Services: • Connect, Read, Write, Subscribe, AddNode, CallMethod, … • Alarms and Conditions: to detect regular and irregular events • Historical Access: long-term storage for visualizing trends Features
  • 26. Excerpts from the OPC UA Metamodel in UML What is OPC UA? January 31, 2018 Slide 26
  • 27. Novel Industry Standard for IoT Machine-to-Machine Communication What is OPC UA? January 31, 2018 Slide 27 Co-authored by ABB Corporate Research Brochure from the OPC Foundation
  • 28. Becoming Industrial Internet-of-Things (IIoT) Devices Controller OPC UA Server / Device OPC UA Server January 31, 2018 Slide 28 Controller UA Server with PLCopen (IEC 61131) control programs OPC UA Server with device parameter and signal values Level Transmitter (Sensor)
  • 29. Becoming Industrial Internet-of-Things (IIoT) Devices Controller OPC UA Server / Device OPC UA Server January 31, 2018 Slide 29 cmp ISA95 EngineeringSupervision Enterprise Resource Planning Manufacturing Execution System Supervision Engineering Controller Controller Level 4 Gateway «device» Sensor «device» Actuator «device» Sensor «device» Actuator «device» Sensor «device» Actuator «device» Actuator «device» Sensor Remote I/O Level 3 Level 2 Level 1 Fieldbus Fieldbus Ethernet Ethernet Fieldbus Point-to-Point OPC UA over AMQP
  • 30. Static View January 31, 2018 Slide 30 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
  • 31. cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime Static View January 31, 2018 Slide 31
  • 32. Static View January 31, 2018 Slide 32 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
  • 33. 1. An engineer… a) places a sensor into the asset, connects it to power & network b) sets a fieldbus address manually c) uses a configuration tool on laptop to retrieve sensor type/ID d) selects a driver (e.g., a GSD file for Profibus) on laptop, downloads it to the sensor, to enable basic communication e) engineer enters a dozen configuration parameters for the sensor (e.g., maximum level value), uploads it to the sensor 2. A control logic programmer… a) imports the network configuration into programming tool, maps program variables (e.g., levelValue) to bus addresses (e.g., 0xFC) b) compiles and downloads the configured control logic programs to the real-time controller 3. Repeat 1) and 2) for all devices (e.g., 100s-10.000s) in a plant 4. Production is ready to start Steps to get a sensor running Reminder: How to commission a field device today January 31, 2018 Slide 33 These steps may take weeks for a mid-sized plant!
  • 34. Static View January 31, 2018 Slide 34 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
  • 35. Static View January 31, 2018 Slide 35 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
  • 36. Dynamic View 1/2 January 31, 2018 Slide 36 sd DeviceConfig :Device Management :Communication Channel :Device OPC UA Server :Public Device Driver Repository :Engineering Repository opt loop Only necessary if fieldbus communication is required. Via Local Discovery Server announce() :deviceDriver :configData :deviceId getDeviceIds() retrieveDeviceDriver() getDeviceId() :deviceIds :signalConfigReady :addresses scan() configureDevice() populateUaServer() retrieveConfigData() downloadDriversAndConfig()
  • 37. 1. An engineer… a) places a sensor into the asset, connects it to power & network b) sets a fieldbus address manually c) uses a configuration tool on laptop to retrieve sensor type/ID d) selects a driver (e.g., a GSD file for Profibus) on laptop, downloads it to the sensor, to enable basic communication e) engineer enters a dozen configuration parameters for the sensor (e.g., maximum level value), uploads it to the sensor 2. A control logic programmer… a) imports the network configuration into programming tool, maps program variables (e.g., levelValue) to bus addresses (e.g., 0xFC) b) compiles and downloads the configured control logic programs to the real-time controller 3. Repeat 1) and 2) for all devices (e.g., 100s-10.000s) in a plant 4. Production is ready to start Steps to get a sensor running Reminder: How to commission a field device today January 31, 2018 Slide 37 These steps may take weeks for a mid-sized plant!
  • 38. cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime Static View January 31, 2018 Slide 38
  • 39. Static View January 31, 2018 Slide 39 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
  • 40. Static View January 31, 2018 Slide 40 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime
  • 41. Dynamic View 2/2 January 31, 2018 Slide 41 sd SignalMatching :Plug and Produce Service :Device OPC UA Server :Controller OPC UA Server :Communication Channel :61131 Runtime opt loop loop Via Local Discovery Server if signals match: activate publishing / subscribing via multicast addresses cyclic communication signalIn() browseForSignals() :approved :endpointURL disconnect() :signalNames readSignalNames() enableSubscription() subscribe() signalOut() :signalNames enablePublishingCaculatedSignalValues() connect() connect() queryForHumanApproval() findOPCUAServer() SignalRetrieval via MulticastUdp() enableSubscription() matchSignalNames()
  • 42. Information View January 31, 2018 Slide 42 class IoT Device Model Root Objects DeviceSet IoT Device CtrlConfiguration Resources FieldDevice Programs Main FB_IoTDevice Input Variable OutputVariable Local Variable CtrlProgramOrganizationUnit CtrlResource SerialNumber Manufacturer ProtocolSupport [...] Device TopologyElement OPC UA for Devices PLCOpen for OPC UA e.g., GSD- file e.g., level transmitter
  • 43. Classical Deployment with IO Gateway Deployment View (1/2) January 31, 2018 Slide 43 deployment DeploymentClassical Controller IO Gateway «device» Field Device 1 :Controller OPC UA Server :61131 Runtime :Controller Local Discovery :Device Local Discovery :Device OPC UA Server :Communication Channel Device Management Server :Plug and Produce Service :Device Management Ethernet Network Link Fieldbus or Analog Connection e.g., Windows server, Linux server, ... Embedded Real-time Controller e.g., sensor, actuator e.g., Profibus, HART, Modbus, ... «device» Field Device 2 «device» Field Device n [...] optional: TSN
  • 44. Deployment with intelligent IIoT Devices Deployment View (2/2) January 31, 2018 Slide 44 deployment DeploymentIntelligentDevice Controller :Plug and Produce Service :Controller Local Discovery :Controller OPC UA Server :61131 Runtime Device Management Server :Device Management Ethernet Network Link Intelligent Field Device 1 :Device Local Discovery :Device OPC UA Server Intelligent Field Device 2 Intelligent Field Device n :Device OPC UA Server :Device Local Discovery :Device Local Discovery :Device OPC UA Server [...] Laptop Industry PC Field device with integrated OPC UA Server
  • 45. Decisions provide different way of viewing the architecture Important to document the rationale for an architectural decision List considered options and chosen alternative Helps to understand the design better, especially during later life-cycle phases ~10 decision made for the reference architecture Documented with AD-Mentor in Enterprise Architect Overview Architecture Decisions January 31, 2018 Slide 45 cmp Static View with Decisions Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device (Chosen) OPC UA Discovery (Chosen) Automated, decoupled from controller (Chosen) OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals «trace» retrieve device driver exchange configuration data and signals «trace» announce startup approve configuration and supervise cyclic signal exchange browse for signals, enable subscriptions upload device driver «trace» multicast probe & announce retrieve signal configuration, arbitrate 61131 runtime monitor announce startup retrieve engineering data upload control logic «trace» exchange control logic and signals https://github.com/IFS-HSR/ADMentor
  • 46. Communication Architecture Decisions (Example 1/2) January 31, 2018 Slide 46 SolutionOverview Communication (Solved) Controller to IO Communication (Neglected) Ethernet-based Fieldbus (Neglected) DDS (Neglected) MQTT (Chosen) OPC UA (Neglected) SOAP + DPWS (Solved) Network Discovery (Neglected) SOAP + DPWS (Chosen) OPC UA Discovery (Neglected) SSDP «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» https://github.com/IFS-HSR/ADMentor
  • 47. Signal Matching Architecture Decisions (Example 2/2) January 31, 2018 Slide 47 SolutionOverview Signal Matching (Solved) Signal Mapping (Solved) Signal Matching (Neglected) IEC 61804 (Neglected) IEC 61158 (Foundation Fieldbus) (Chosen) PLCopen (Neglected) Automated, integrated to controller (Chosen) Automated, decoupled from controller (Neglected) Manual matching «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy» «adAddressedBy»
  • 48. Boiler Demo Setup Reference Architecture Experimental Evaluation January 31, 2018 Slide 48 OPC UA Server 3 OPC UA Server 1 OPC UA Server 4 Boiler FT 1001 FT 1002 Pipe1002 Valve 1001 LI 1001 LC 1001 OPC UA Server 2 OPC UA Client Legend LC: Level Controller LI: Level Indicator FT: Flow Transmitter flow disturbance flow disturbance Simulation Component Simulates input and output of process medium
  • 49. Reference Architecture Experimental Evaluation January 31, 2018 Slide 49 Deployment deployment DeploymentDemo Raspberry Pi :Plug and Produce Service :Controller Local Discovery :Controller OPC UA Server :61131 Runtime Ethernet Network Link Raspberry Pi :Device Local Discovery :Device OPC UA Server Raspberry Pi Raspberry Pi :Device OPC UA Server :Device Local Discovery :Device Local Discovery :Device OPC UA Server Raspberry Pi :Device OPC UA Server :Device Local Discovery OPC UA C++ Server SDK V1.5.5 (Linux)
  • 50. Live Demo Reference Architecture Experimental Evaluation January 31, 2018 Slide 50
  • 51. OPC UA Client showing controller behavior Reference Architecture Experimental Evaluation January 31, 2018 Slide 51 Level value (cm) Valve position (%) Setpoint reached (133 cm) 80 seconds
  • 52. Performance Measurements Reference Architecture Experimental Evaluation January 31, 2018 Slide 52 Max measured jitter: 104 microseconds  Scenarios with 1 ms update rate can be analyzed reasonably Signal publishing with 1 ms update rate Publisher CPU idle time decrease with a higher number of encoded signals At most it can handle 800 signals per ms Signal subscribing with 1 ms update rate Subscriber latency increases with higher number of encoded signals At most it can handle 600 signals per ms A commercial controller usually manages ~350 analog and digital signals, our prototype managed > 500 signals. Raspberry Pi Jitter Publisher OPC UA Encoding Subscriber OPC UA Decoding
  • 53. Distributed control systems are used for various industry applications. Process control systems are evolving to the Industrial Internet-of-Things. A Smart Factory will be faster to set up and much more flexible than today. Software Architecture helps to manage the complexity of such systems. Architects use UML to describe systems and information models. UML can also be used to capture architecture decisions and their rationale. The Reference Architecture enables self-commissioning IIoT systems. Controllers and devices from different vendors can find each other. Performance tests validated its feasibility based on a prototype. Software Architecture in Process Automation Conclusions January 31, 2018 Slide 53 cmp Static View Engineering Repository Process Control System Device Management Public Device Driver Repository 61131 Runtime Plug and Produce Service Controller Local Discovery Device Local Discovery Controller OPC UA Server Device OPC UA Server Communication Channel «device» Field Device OPC UA OPC UA OPC UA OPC UA OPC UA OPC UA HTTPS HTTPS UDP Publish UDP Subscribe UDP Subscribe UDP Publish OPC UA OPC UA exchange configuration data and signals upload device driver announce startup retrieve engineering data retrieve device driver announce startup cyclic signal exchange multicast probe & announce approve configuration and supervise monitor exchange control logic and signals exchange configuration data and signals browse for signals, enable subscriptions upload control logic retrieve signal configuration, arbitrate 61131 runtime Industrie 4.0 / IIoT needs talented Software Architects!
  • 54. Internships, Master Theses, Open Positions ABB Corporate Research in Ladenburg January 31, 2018 Slide 54 http://new.abb.com/de/karriere Internship: “Software development for the Internet-of-Things” Master / Bachelor Thesis: “Big Data Analytics System for Industrial Plants” Industry Researcher: “Software Architecture”