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Every end-to-end connection required a custom driver to facilitate communications between specific endpoints. Figure 1 shows the use of custom drivers between every endpoint meant that even a small number of devices and applications quickly involved the use of many drivers. Each driver establishes its own connection to the device or controller that it is designed to communicate with.
These things bring the problems of custom drivers in conventional communication. OPC communication system In software network as a central controller, each device are connected to the central controller with the help of standard protocols [10].
OPC abstracts the data source e. Figure 2 shows that OPC acts as an abstraction layer that sits between the data source and the data sink, allowing them to exchange data without knowing anything about each other. What is important to note is that just because the Data Source and Data Sink can communicate with each other via OPC does not mean their respective native protocols are no longer necessary or have been replaced by OPC. Figure 1. The application device used in this project is two prototypes which consist of the bottle unscramble station controlled by PLC Mitsubishi, and the bottle filling station controlled by PLC Omron.
The two applications were made with operational functions the processes as they represented. Actually, the two applications only needed to show the working of communication system using OPC Server control two different PLC platforms. OPC abstracts the data source i. The composition of real-time communication developed in the system is shown in Figure 3. Systematic basic hardware items are displayed as follows: PC personal computer equipped with ordinary parts.
Figure 3. The interfaces use the RS to realize. Both application devices, the bottle unscramble and the bottle filling, can communicate with each other through OPC Server software configuration settings.
This information is obtained because the controller of the bottle filling process reads the data released from the sensor as a result of the detection of the presence of the bottles sent from the bottle unscramble process. Meanwhile, the bottle unscramble process will stop, if the queue of bottles in the bottle filling process is still long, and it will reactivate if the queue is empty or depends on the desired PLC program.
This information is received by the bottle unscramble process because it reading of data information from the bottle filling process. Conviguration of variable and connection The purpose of configuration connection is to set up a connection between the OPC Server and the client, and includes two following respects specifically [11, 12]. The first is hardware configuration.
The second is OPC server configuration. Before we design the real-time communication program between PLC and process devices, the two things should be finished [11].
First, the OPC Foundation offers a set of core components to browse other computers and communicate with them which do not be installed. We can get communication data between bottles unscramble and bottle filling from the process record of the KEPServerEX6 feature. PLC Omron receives data twice, the first at time 39, with details of data length 32 and the second at time 39, with details of data length 11, with each containing a series of data according to the length of the data.
The counter value will decrease according to the process that has occurred, and the process will stop when the counter value has been fulfilled the setting value is 5, and will stop if the value is 0. As shown in Figure 4, the bottle filling has a value of 2, which means that 3 filling processes have been fulfilled and 2 remaining filling processes. Figure 6 shows the Counter value is 0 zero it shows that the filling process has been fulfilled, and the value of the Stop communication is 1 one or active which will cause the process to stop.
Figure 7 shows the Reset value is 1 which means that the Reset button has been activated. The counter returns to value 5 and will start for new process for refilling bottles five times. If the Stop button on the bottle unscramble is activated, it will cause the whole process of bottle unscramble and bottle filling to be stopped.
This shows that the communication between the two is fulfilled successfully sending and receiving data. Vice versa, if the emergency button on the bottle filling is pressed activated , both processes will stop communication is fulfilled; sending and receiving data is successful. Table 1. The counter counts the value 2 of 5 Figure 5. Stop communication is active, valued 1 Figure 7. Reset is active, valued 1 3.
Furthermore when there is a demand to integrate two or more different PLC manufacturers, it still needs to be considered. In the example this application provides instructions on how OPC Server can be used in applications, consequently the usefulness of OPC Server becomes less optimal if only for this purpose. The use of web-based OPC Server in [2] and [8] has provided alternative solutions, but this is quite difficult if applied because it demands a reliable cloud system.
Another paper proposed the OPC connectivity-based approach to remote monitoring and control [20] and [21]. Zhu, et. Mahmoud, et. Data communication is one of the significant part where the nodes send data towards the destination, some are based on real-time and some are on normal data communication [25]. The use of KEPServerEX6 provides a relatively easy solution for integrator technician who will combine the controls of several other PLCs so that can communicate each other without difficulty with factory driver problems.
In this paper OPC Server has been designed and developed for integration of controls between two PLCs from different manufacturers to communicate. With the help of KEPServerEX6, integration issues two or more different control platforms can be overcome from different manufacturers can be communicated together.
Furthermore the PLC that we use is limited since does not have a serial port. By the way, this will be easily overcome if the choice of PLC used considers the existence of the ports needed for RS and serial connections. The implementation of OPC Server technology has concluded that communication between PLC Mitsubishi and PLC Omron can be done even though both have its own driver software for controlling the field application devices.
This work has come up with the finding by using KEPServerEX6 OPC server it is possible to realize the integration among the different devices and controllers which is commonly find in the industrial processes. Further work needs to be done to establish the human machine interface in this system, so that the integration and communication among the controller can be monitor and operate easily. Accesed: 13 Feb Accessed: 13 Feb Available: www.
April, pp. Van, Yoo D. Software engineering approach in the design and development of the industrial automation systems. Water Binder Master Controller System for Industrial Automation. Consumer energy management system with integration of smart meters.
Prepaid water metering. This assignment isn't simple. Each device driver requires software from its vendor. Changes in convention determinations bring about communication failure, and modifications must be made. This problem must be solved when confronting the plan and systems integration of infrastructures under cutting edge draws near. The choice of communication interface to accomplish a successful interoperability and heterogeneity the executives is an extraordinary choice that truly influences perspectives, for example, financial costs, viability, expand-ability, security, and versatility [1].
In this sense, OLE-object linking embedded-for process control OPC proved as an effective communication middle-ware mainly in industrial application. OPC provides technology to support interoperability and heterogeneity in control and automation applications, mainly devoted to industrial manufacturing [2].
OPC, as a standard interface, can communicate between numerous data sources, including devices in a factory, laboratory equipment, and database. There are a large number of papers reporting OPC applications. Each one of them focuses on specific features, just to name some are hardware in the loop [4], remote laboratory [], share workspace [9, 10], SCADA and PLC [11, 12], process control data acquisition and monitoring [].
The OPC provides open connectivity meanwhile, PLC from the different manufacturers can communicate, and LabVIEW provides the user interface so the operator can easily control and monitor the applications system. Despite the numerous works carried out on the same subject, none investigated the interoperability and connectivity between two PLC different protocols or manufacturers.
The organization of the paper is as follows. The result and discussion of this study provide in section 3 and section 4, respectively. In section 5 gives a sum of the conclusion. Table 1 gives the exposed experiment pointing out the field application system, the OPC role, the software involved for both client and server, and the hardware appliances. Table 1. Thanks to the proficiency of the OPC, their integration was easy and effective.
Such systems reveal the OPC standard as an effective tool of integration of networks of controllers, sensors, and instruments regardless of the automated process. As a rule, the capacity of an OPC is to get to the information of a field device and make them available to OPC clients, i. To do this, among other parameters to be enumerated, the used addressed in the PLC memory the format of the data and the type of access. National instruments LabVIEW package is a powerful graphical language with an impressive built- in function.
The variables transferred by such an OPC Server added to the library of a VI, so controls and indicators connected to them. Accordingly, the collected values available for operations commanded from the LabVIEW Front panel, then imported the controls and indicators. By this path, the instructions renewed those controls and indicators. In general, the LabVIEW vision works by comparing the images taken by the camera with the images used as template patterns. LabVIEW vision will output the similarity level of the two images.
By setting the similarity level limit, an application will be generated that can detect the presence or absence of certain parts of the field application. All image processing features are provided. Users don't need to do complicated programming, just take the desired feature in the form of an icon , and add it to the image. The results obtained by adding these features are also shown on the screen so that users can adjust the results according to what they want [24].
PLC and field application In signal management relate to the PLC's digital input and output ports, sensors and actuators were exploited to acquire signals in the automation process.
Such PLC controlled the field application. The Omron controlled the bottle filling process, and Mitsubishi controlled the bottle unscrambling process. This leads to adding client access to the server. Proposed architecture Figure 1 brings the block diagram of the system exploited the interconnection between two different PLC protocols. This work used two field applications, namely bottle unscrambling and bottle filling. This data got since the bottle filling controller read data from sensors as a result of the presence detection of the bottles sent from the bottle unscrambling process.
Meanwhile, the bottle unscrambling process suspend if the bottles queuing on the bottle filling process is full, and it will reactivate if the queue reduced or depend on the PLC program [25]. Figure 1. Block diagram of the proposed architecture Figure 2.
The client application is not associated with device management. The server application is answerable for dealing with the device utilizing a standard interface. Equipment suppliers and programming designers can emerge from different vendors.
This work embraces the principal answer for making a thing of OPC Client. By utilizing the front panel information joining capacity, objects buttons, indicators, and so forth can be connected to things in the OPC server through the DataSocket server.
Subsequently, the trial procedure control in the LabVIEW application is made through the element item, which is designed on the server. OPC client can understand information and compose new information to the device by utilizing OPC server [26].
Figure 3. Name both channels according to the PLC name. Figure 4. Figure 6. The variable with the same name as the tags will appear under the OPC1 folder in the New Project window.
Figure 8. In addition, the improvement from the previous study is data from OPC server can be displayed and visualized more realistically using the LabVIEW program; and data utilization becomes more flexible which can be used for more complex purposes as shown in Figure By using LabVIEW vision, we can monitor workpieces and even labels; so that monitoring can cover all aspects, not only counting the quantity but also the condition of the product.
Figure 14 shows that LabVIEW Vision will be able to detect the bottle cap if there is a manual bottle cap feeding process. All references in this work using the OPC server for data acquisition and interconnection between different controllers. These references use the PLC as a controller, but none are from different manufacturers. There is a reference [27] using two PLCs, but it comes from one manufacturer.
Therefore, the use of OPC server has become less exposed. Solely reference [25] indeed used two different PLC types, but having a limitation in the client program not upheld by the user interface to control and monitor quickly. In any case, this was better than simply applying a PLC to perform the heterogeneity and interconnectivity in control and automation applications. Table 2 provides some related works heretofore, with its focus on the type of OPC software used, the type of protocol communication used, and the hardware used.
Selected papers of the related works Related works [ref. A et al. D et al. The developed control and monitoring system has two selection modes, namely the manual and the automatic. In automatic mode, when the Start button is squeezed, the system will run consistently starting from the bottle adjusting process until the bottle filling process and stop only when the Stop button is squeezed.
This can happen due to the capacity of the NI-OPC server as a scaffold for the two PLC with various protocols, so they can impart without paying attention to the drivers of the two software.
LabVIEW software was chosen because this software provides strong support and easy connection with various hardware devices. In addition, the LabVIEW graphical programming language makes it easier to implement the program even for inexperienced. This is the idea proposed in this paper. This work has been boosted an advantage in controlling and monitoring through the functions contributed by the LabVIEW user interface.
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