Advanced Automation Appliances 6.21.09

Advanced Automation Appliances
Mark Knebusch: Business Development
Laurie Wilson: Product Management
© 2008 Online Development Inc. All Rights Reserved.

Online Development Inc. (OLDI)

• Headquartered in Knoxville, TN USA with North
American and European locations.
• Develop and produce factory automation hardware
and software for companies such as Rockwell
Automation and ProSoft Technology.
• Core Competence: Computing and communications
platforms

IBM
Business
Partner

Topics

• What is an Automation Appliance?
• Latest Developments
• cATM
• eATM
• eATM tManager
• Connectivity
• Configuration/Operation
• Takeaways


Appliance: What is it?

• An Automation Appliance does just one
thing and does it well…transfer data to
and from one Application/System to
another Application/ System


Appliance: Operation

• Configure and go –
• No….
…..code to write
…...command prompt
…...installable or updateable code – updates as
full firmware images only
……installation services

Reduces installation and maintenance costs


An Automation Appliance is….

NOT a general purpose Industrial Computer


Appliances:
Representative Applications

• Recipe Material and Controller
Setup Downloads
• Weighing Data Collection
• Build to Order Requirements
• Statistical Process/Quality Control
• Dynamic Palletizing and
Warehousing
• Sensor Data Reporting
• Product Tracking and Tracing
• Alarms and Event Notifications


Customer base


Appliance Transaction Modules

• OLDI’s Appliance Transaction Modules…ATMs
• Controller to Controller…cATM
• Controller to Enterprise…eATM®
• Typically mount in ControlLogix® chassis
• Communicate
• Via CLX backplane to controller
• Via Ethernet externally
• Designed and tested to PAC/PLC environmental
specifications and certifications

Tightly integrated and physically robust

Controller-to-Controller &
Enterprise-to-Controller Connections

General Purpose Computing

Enterprise/Division IT Plant Floor Systems

eATM

Controllers cATM Controllers

Controllers


Relationships to
Enterprise/Plant Systems

Business Planning & Plant schedule: production, material use, delivery
Logistics shipping; Determining inventory levels
Level 4 Time frame: Months, weeks, days
Plant Production Scheduling,
Operational Management, etc.

Manufacturing Operations
Workflow/recipe control; Maintaining records;

eATM
Management Optimizing production process
Level 3 Dispatching Production, Detailed Time frame: Days, shifts, hours, minutes, seconds
Production Scheduling,

eATM
Reliability Assurance

Monitoring, supervisory control and automated control
Level 2
cATM of production process
Continuous Time frame: Hours, minutes, seconds, subseconds
Discrete Batch
Control Control Control

Level 1 Sensing; manipulating production process


Controller-to-Controller: cATM Bailey
cATM

• Migrate ABB Bailey Infi 90 or Network 90
Legacy DCS to ControlLogix PACs
• Flexible Data Handling
– Supports DCS Block functions:
– System status monitoring
– No hard tag limits
• ABB Bailey Database Conversion Tool
– Available from Rockwell Automation.
– Converts Bailey tag database into CSV for import
into the cATM-BLY90 appliance and RSLogix 5000
programming software.

Once configured, use with applications such as
FactoryTalk View® SE for visualization, alarming, etc.

Controller-to-Controller: cATM Kepware
cATM

• Connect ControlLogix to other systems/devices via any
Kepware driver suite…including…
– Fisher ROC
– GE Fanuc
– Honeywell UDC
– Mitsubishi FX
– Omron Host Link
– Siemens S5
– Triconex Ethernet
– Yaskawa MP Ethernet
– Yokogawa CX
• Base price includes one suite; can run multiple suites

Use any of Kepware’s driver suites in an in-chassis
ControlLogix module to migrate legacy systems

Enterprise-to-Controller: eATM tManager ®

• Enables SOA, ERP and MES
eATM

applications
• Bidirectional transactions
configured – not programmed
• Supports…
– Middleware
– Databases
– Controller Protocols
– TCP/IP, UDP, e-mail, FTP

Simplifies Transaction Handling between
Business/Plant Applications and ControlLogix® PACs

Advanced Appliance Architectures:
Appliance Transaction Modules (ATMs)


Transaction vs Data Server-based designs

•Java Message Service (JMS)
• Is a form of enterprise messaging, or Messaging Oriented
Middleware (MOM)
• A tool for building enterprise applications.
• Provides a reliable, flexible service for the asynchronous
exchange of critical business data and events throughout an
enterprise


eATM tManager Connectivity
Local Rack
ControlNet
Ethernet
Allen-Bradley® ControlLogix®
ControlLogix® PAC
ControlNet
Ethernet

CompactLogix™
DH485
DH+
Ethernet
Ethernet RA Bridges SLC™

DH485
Ethernet

MicroLogix™
Enterprise
ControlNet
Applications
Ethernet
FlexLogix™

eATM™ tManager DH+
Module
Ethernet

© 2008 Online Development Inc. All Rights Reserved. PLC-5®

eATM tManager Connectivity:
ControlLogix Backplane

• ControlLogix
• CompactLogix
• FlexLogix
• MicroLogix
• SLC 500
• PLC-5

Automatically connects via RA bridges for
legacy protocols (DH+, DH485)

eATM tManager Connectivity:
Ethernet

• RA controllers: EtherNet/IP
– ControlLogix
– CompactLogix
– FlexLogix
– MicroLogix
– SLC 500
– PLC-5
• Siemens SIMATIC S7: TCP/IP
• Schneider: Modbus/TCP

eATM tManager Appliance Block Diagram

Operating System

CPU


Database Adapters

• IBM DB2 (System i only)
• MS MSSQL
• Oracle
– Oracle database
– MySQL


Computer Adapters

• JEE Application Server JMS
– IBM WAS (default provider)
– JBOSS
• Community Edition (JBossMQ provider)
• Red Hat 4.3 (JBoss Messaging provider)
• IBM WMQ
• eMail (requires external POP3
and SMTP servers)
• FTP (requires external FTP server)
• TCP sockets
• UDP sockets
• MS Excel & Access


Schemas

• Types
– PAC & PLC tag lists
– Database (metadata)
– Subset of XSD (XML)
– Flat files
• Source
– Automatic
• Database
– Imported
• Manual (via GUI)
– XSD
– ASCII Fixed-format flat file
– ASCII Delimited-format flat file
– Binary Fixed-format flat file


eATM tManager Appliance Basic Operation

Trigger Store & Endpoint
Input Forward
Adapter Server Mapper Adapter
Handler

eATM Store &
Runtime Forward
Queues


eATM Project Editor


Input Adapter (aka Automation Adapter)

Input
Adapter


eATM Project Editor:
Endpoint (Computer Adapter)

Endpoint
Adapter


eATM Project Editor:
Map; Trigger; Message Path

Mapper

Trigger
Server


eATM tManager: Organization
Transaction Configuration Options

• Store & Forward - if the incoming message cannot be
processed immediately, it can optionally be stored in an
onboard store and forward queue
• Transaction Log - optionally all transactions to/from IT logged
to later prove receipt or absence of successful receipt
• Failover - two or more redundant adapters can be specified. If
the currently active one does not respond, the next one in the
chain is tried. Reset of the failover sequence is manual.


Feedback/Handshaking to Controller

• ControlLogix profile support
• Control
• Status
• Automation Flow Control
• Handshaking
• When data acquired from Input
• When placed in queue for Endpoint
• When message accepted by Endpoint


Status Reporting & Logging

• Status Reporting
– CLX profile bits
– Status tags
– Module front panel display
– Email
– FTP log export
• Logging
– Error logging
– Transaction logging


Takeaways

• OLDI Appliance Transaction Module line-up is
expanding
• cATMs added Bailey DCS and Kepware driver modules
• eATMs move beyond just database connections to message
oriented adapters e.g. JMS
• Connectivity includes all major Rockwell
Automation controllers plus Siemens S7 and
Modicon Modbus TCP
• Configuration is drag and drop
• Operation is secure


Advanced Automation Appliances 6.21.09

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