Scalable power system communications emulation with OPC UA

The dependability on real-time control is significantly increasing due to the transition from synchronous grids to converter-dominated grids. Distributed control schemes can significantly decrease the degree of single-points-of failure of Smart Grid control schemes, thereby introducing new complexity of power system communications. We propose a scalable approach for validation of distributed control schemes by emulating the communication in a decentralised manner, utilising the Open Platform Communications Unified Architecture service-oriented architecture in a controller-hardware-in-the-loop environment. As a proof-of-concept, we apply communication delay Denial-of-Service attacks to a converter-dominated communication-heavy and consensus-based microgrid control algorithm and thereby elaborate how scalable power systems communications emulation can help selecting appropriate mitigation strategies for telecommunication-based stress conditions

Integración de comunicaciones a nivel de planta empleando sistemas ciber-físicos de producción de bajo coste

[Resumen] Los sistemas de automatización industrial actuales tienen que hacer frente a los desafíos que surgen al tratar de solventar las necesidades generadas por un mercado altamente competitivo. Estos desafíos conducen a la utilización de una nueva generación de sistemas de automatización basado en los denominados Sistemas Ciber-físicos de Producción (CPPS – Cyber-Physical Production Systems). Los CPPSs permiten la integración de sistemas de adquisición de datos tradicionales y novedosos sistemas de procesamiento inteligente de datos, con el objetivo de extraer información y mejorar el rendimiento general del sistema productivo. Para lograrlo, es necesario cerrar la brecha existente entre los sistemas de control y los niveles superiores. Este trabajo propone una aproximación en el desarrollo de aplicaciones bajo la norma IEC-61499 para el intercambio de datos entre el nivel de planta y las capas más altas empleando el estándar industrial OPC UA. La comunicación OPC UA ofrece mecanismos de suscripción que permiten una integración eficiente y sencilla de recursos que residen en diferentes dispositivos. Además, dado que la arquitectura OPC UA permite su ejecución incluso en dispositivos empotrados, la propuesta aportada en este artículo permite adquirir información de la planta empleando arquitecturas de bajo coste, al mismo tiempo que se posibilita un diseño basado en componentes con independencia de la plataforma hardware utilizada.Este trabajo ha sido financiado por la Universidad del País Vasco (UPV/EHU) en el marco del proyecto UFI 11/28, por el MCYT y FEDER bajo el proyecto DPI2015-68602-R, y por el Ministerio de Educación e Investigación de Ecuador a través de subvención SENESCYT-2014Universidad del País Vasco = Euskal Herriko Unibertsitatea; UFI 11/28https://doi.org/10.17979/spudc.978849749808

A cyber-physical machine tools platform using OPC UA and MTConnect

Cyber-Physical Machine Tools (CPMT) represent a new generation of machine tools that are smarter, well connected, widely accessible, more adaptive and more autonomous. Development of CPMT requires standardized information modelling method and communication protocols for machine tools. This paper proposes a CPMT Platform based on OPC UA and MTConnect that enables standardized, interoperable and efficient data communication among machine tools and various types of software applications. First, a development method for OPC UA-based CPMT is proposed based on a generic OPC UA information model for CNC machine tools. Second, to address the issue of interoperability between OPC UA and MTConnect, an MTConnect to OPC UA interface is developed to transform MTConnect information model and its data to their OPC UA counterparts. An OPC UA-based CPMT prototype is developed and further integrated with a previously developed MTConnect-based CPMT to establish a common CPMT Platform. Third, different applications are developed to demonstrate the advantages of the proposed CPMT Platform, including an OPC UA Client, an advanced AR-assisted wearable Human-Machine Interface and a conceptual framework for CPMT powered cloud manufacturing environment. Experimental results have proven that the proposed CPMT Platform can significantly improve the overall production efficiency and effectiveness in the shop floor

Vertical Integration in factories using OPC-UA and IEC-61499

Nowadays, factory automation systems need to cope with very different challenges, such as big data, IIoT, etc. These challenges lead to a new generation of automation systems based on the so-called Cyber-Physical Production Systems (CPPS) globally connected to form a flexible System of Cyber-Physical Production Systems (SoCPPS). CPPSs require acquisition of production system data and smart data processing to extract information to improve the overall system performance. To achieve that it is needed to bridge the gap between the control systems and higher layers. This paper discusses an approach to use the IEC 61499 function block concept to exchange data between plant floor and higher layers using an industrial standard like OPC UA. The OPC UA server offers subscription mechanisms, making possible the integration of several resources residing at plant floor. As it runs on embedded devices, the proposal makes possible to acquire plant information at low cost, enabling at the same time, a component-based design for enterprise plant floor control with independence of the hardware platform use

Automation Architecture based on Cyber Physical Systems for Flexible Manufacturing within Oil&Gas Industry

[ES] Es evidente que en los próximos años gran parte de las tecnologías recogidas bajo el marco de la denominada Industria 4.0 tendrá un profundo impacto en todas las empresas y entre ellas, en las relacionadas con la explotación y producción de petróleo y gas. La automatización de bajo coste promueve arquitecturas de referencia rentables y nuevos enfoques de desarrollo para aumentar la flexibilidad y la eficiencia de las operaciones de producción en una planta industrial. En este sentido, OPC UA, proporciona acceso local y remoto a la información de planta, facilitando un mecanismo reconocido de integración tanto horizontal como vertical de manera correcta, segura y eficiente. El objetivo principal de este artículo es presentar una arquitectura abierta para la integración vertical basada en sistemas ciber-físicos de producción, configurados bajo la norma IEC 61499 y usando OPC UA, apta para su utilización en la fabricación flexible en la industria de petróleo ygas.[EN] It is clear that in the next few years most of the technologies involved in the so-called Industry 4.0 will have a deep impact on manufacturing companies, including those related to Oil & Gas exploration and production. Low cost automation promotes reference architectures and development approaches aiming at increasing the flexibility and efficiency of production operations in industrial plants. In this sense, OPC UA, in addition to allowing companies to join the Industry 4.0 initiative, provides local and remote access to plant information, enabling a recognized mechanism for both, horizontal and vertical integration in a reliable, safe and efficient way. The contribution of this article is an open architecture for vertical integration based on cyber-physical production systems, configured under IEC 61499 and using OPC UA, suitable to achieve flexible manufacturing within Oil & Gas industry.Este trabajo ha sido financiado por el MINECO/FEDER, UE del Gobierno de España bajo el proyecto DPI2015-68602-R y por el Gobierno Vasco/EJ bajo el reconocimiento de grupo de investigación IT914-16. Así mismo como al Gobierno Ecuatoriano a través de la Beca SENESCYT “Convocatoria abierta 2013”.García, MV.; Irisarri, E.; Pérez, F.; Estévez, E.; Marcos, M. (2018). Arquitectura de Automatización basada en Sistemas Ciberfísicos para la Fabricación Flexible en la Industria de Petróleo y Gas. Revista Iberoamericana de Automática e Informática industrial. 15(2):156-166. https://doi.org/10.4995/riai.2017.8823OJS156166152DIAC, 2017. IEC 61499 Implementation for Distributed. Available at: https://eclipse.org/4diac/Claassen, A., Rohjans, S. & Lehnhoff Member, S., 2011. Application of the OPC UA for the Smart Grid. In 2011 2nd IEEE PES International Conference and Exhibition on Innovative Smart Grid Technologies. IEEE, pp. 1-8. Available at: http://ieeexplore.ieee.org/lpdocs/epic03/wrapper.htm?arnumber=6162627.Garcia, M. V. et al., 2014. Building industrial CPS with the IEC 61499 standard on low-cost hardware platforms. Proceedings of the 2014 IEEE Emerging Technology and Factory Automation (ETFA), pp.1-4. https://doi.org/10.1109/ETFA.2014.7005272Garcia, M. V. et al., 2015. Developing CPPS within IEC-61499 based on low cost devices. IEEE International Workshop on Factory Communication Systems - Proceedings, WFCS, 2015-July, pp.1-4.GmbH, 4DIAC Consortium. PROFACTOR, 2010. Framework for Distributed Industrial Automation and Control (4DIAC). Available at: http://www.fordiac.org.Hazarika, P. et al., 2015. Mobile cloud integration for industrial data interchange. 2015 International Conference on Advances in Computing, Communications and Informatics, ICACCI 2015, pp.1118-1122. https://doi.org/10.1109/ICACCI.2015.7275760Hussain, T. & Frey, G., 2004. Developing IEC 61499 compliant distributed systems with network enabled controllers. In IEEE Conference on Robotics, Automation and Mechatronics, 2004. IEEE, pp. 507-512. Available at: http://ieeexplore.ieee.org/document/1438972/.International Electrotechnical Commission, 2014. International Electrotechnical Commission Std. (2005) IEC 61499: Function blocks, Part 1-4. Available at: http://www.iec.ch.Jain, S., Yuan, C. & Ferreira, P., 2002. EMBench: A Rapid Prototyping Environment for Numerical Control Systems. In Dynamic Systems and Control. ASME, pp. 7-13. Available at: http://proceedings.asmedigita lcollection.asme.org/proceeding.aspx?articleid=1580998.Kim, J. et al., 2014. M2M service platforms: Survey, issues, and enabling technologies. 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In 2016 Second International Conference on Event-based Control, Communication, and Signal Processing (EBCCSP). IEEE, pp. 1-8. Available at: http://ieeexplore.ieee.org/document/7605263/.Rentschler, M., Trsek, H. & Durkop, L., 2016. OPC UA extension for IP auto-configuration in cyber-physical systems. In 2016 IEEE 14th International Conference on Industrial Informatics (INDIN). IEEE, pp. 26-31. Available at: http://ieeexplore.ieee.org/document/7819128/.Sande, O., Fojcik, M. & Cupek, R., 2010. OPC UA Based Solutions for Integrated Operations. Communications in Computer and Information Science, 79, pp.76-83. https://doi.org/10.1007/978-3-642-13861-4_8Schwab, C., Tangermann, M. & Ferrarini, L., 2005. Web based methodology for engineering and maintenance of distributed control systems: the TORERO approach. In INDIN '05. 2005 3rd IEEE International Conference on Industrial Informatics, 2005. IEEE, pp. 32-37. Available at: http://ieeexplore.ieee.org/document/1560348/. https://doi.org/10.1109/INDIN.2005.1560348Stambolov, G. & Batchkova, I., 2011. Reconfiguration processes in manufacturing systems on the base of IEC 61499 standard. In Proceedings of the 6th IEEE International Conference on Intelligent Data Acquisition and Advanced Computing Systems. IEEE, pp. 161-166. Available at: http://ieeexplore.ieee.org/document/6072731/. https://doi.org/10.1109/IDAACS.2011.6072731Stojmenovic, I., 2014. Machine-to-Machine Communications with In-network Data Aggregation, Processing and Actuation for Large Scale Cyber-Physical Systems. IEEE Internet of Things Journal, PP(99), pp.1-1. Available at: http://ieeexplore.ieee.org/lpdocs/epic03/wrapper.htm? arnumber=6766661.Strasser, T. et al., 2011. Design and Execution Issues in IEC 61499 Distributed Automation and Control Systems. IEEE Transactions on Systems, Man, and Cybernetics, Part C (Applications and Reviews), 41(1), pp.41-51. 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Bundle : A Group-Based Programming Abstraction for Cyber-Physical Systems. , 8(2), pp.379-392.Vyatkin, V., Cheng Pang & Tripakis, S., 2015. Towards cyber-physical agnosticism by enhancing IEC 61499 with PTIDES model of computations. In IECON 2015 - 41st Annual Conference of the IEEE Industrial Electronics Society. IEEE, pp. 001970-001975. Available at: http://ieeexplore.ieee.org/document/7392389/.Wang, L. et al., 2001. Realizing Holonic Control with Function Blocks. Integr. Comput.-Aided Eng., 8(1), pp.81-93. Available at: http://dl.acm.org/citation.cfm?id=1275723.1275730.Wang, L., Keshavarzmanesh, S. & Feng, H.Y., 2008. Design of adaptive function blocks for dynamic assembly planning and control. Journal of Manufacturing Systems, 27(1), pp.45-51. Available at:https://doi.org/10.1016/j.jmsy.2008.06.003Wang, L., Song, Y. & Gao, Q., 2009. Designing function blocks for distributed process planning and adaptive control. 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Machine Tool Communication (MTComm) Method and Its Applications in a Cyber-Physical Manufacturing Cloud

The integration of cyber-physical systems and cloud manufacturing has the potential to revolutionize existing manufacturing systems by enabling better accessibility, agility, and efficiency. To achieve this, it is necessary to establish a communication method of manufacturing services over the Internet to access and manage physical machines from cloud applications. Most of the existing industrial automation protocols utilize Ethernet based Local Area Network (LAN) and are not designed specifically for Internet enabled data transmission. Recently MTConnect has been gaining popularity as a standard for monitoring status of machine tools through RESTful web services and an XML based messaging structure, but it is only designed for data collection and interpretation and lacks remote operation capability. This dissertation presents the design, development, optimization, and applications of a service-oriented Internet-scale communication method named Machine Tool Communication (MTComm) for exchanging manufacturing services in a Cyber-Physical Manufacturing Cloud (CPMC) to enable manufacturing with heterogeneous physically connected machine tools from geographically distributed locations over the Internet. MTComm uses an agent-adapter based architecture and a semantic ontology to provide both remote monitoring and operation capabilities through RESTful services and XML messages. MTComm was successfully used to develop and implement multi-purpose applications in in a CPMC including remote and collaborative manufacturing, active testing-based and edge-based fault diagnosis and maintenance of machine tools, cross-domain interoperability between Internet-of-things (IoT) devices and supply chain robots etc. To improve MTComm’s overall performance, efficiency, and acceptability in cyber manufacturing, the concept of MTComm’s edge-based middleware was introduced and three optimization strategies for data catching, transmission, and operation execution were developed and adopted at the edge. Finally, a hardware prototype of the middleware was implemented on a System-On-Chip based FPGA device to reduce computational and transmission latency. At every stage of its development, MTComm’s performance and feasibility were evaluated with experiments in a CPMC testbed with three different types of manufacturing machine tools. Experimental results demonstrated MTComm’s excellent feasibility for scalable cyber-physical manufacturing and superior performance over other existing approaches

Machine Tool Communication (MTComm) Method and Its Applications in a Cyber-Physical Manufacturing Cloud

The integration of cyber-physical systems and cloud manufacturing has the potential to revolutionize existing manufacturing systems by enabling better accessibility, agility, and efficiency. To achieve this, it is necessary to establish a communication method of manufacturing services over the Internet to access and manage physical machines from cloud applications. Most of the existing industrial automation protocols utilize Ethernet based Local Area Network (LAN) and are not designed specifically for Internet enabled data transmission. Recently MTConnect has been gaining popularity as a standard for monitoring status of machine tools through RESTful web services and an XML based messaging structure, but it is only designed for data collection and interpretation and lacks remote operation capability. This dissertation presents the design, development, optimization, and applications of a service-oriented Internet-scale communication method named Machine Tool Communication (MTComm) for exchanging manufacturing services in a Cyber-Physical Manufacturing Cloud (CPMC) to enable manufacturing with heterogeneous physically connected machine tools from geographically distributed locations over the Internet. MTComm uses an agent-adapter based architecture and a semantic ontology to provide both remote monitoring and operation capabilities through RESTful services and XML messages. MTComm was successfully used to develop and implement multi-purpose applications in in a CPMC including remote and collaborative manufacturing, active testing-based and edge-based fault diagnosis and maintenance of machine tools, cross-domain interoperability between Internet-of-things (IoT) devices and supply chain robots etc. To improve MTComm’s overall performance, efficiency, and acceptability in cyber manufacturing, the concept of MTComm’s edge-based middleware was introduced and three optimization strategies for data catching, transmission, and operation execution were developed and adopted at the edge. Finally, a hardware prototype of the middleware was implemented on a System-On-Chip based FPGA device to reduce computational and transmission latency. At every stage of its development, MTComm’s performance and feasibility were evaluated with experiments in a CPMC testbed with three different types of manufacturing machine tools. Experimental results demonstrated MTComm’s excellent feasibility for scalable cyber-physical manufacturing and superior performance over other existing approaches

Metodologías para el diseño de sistemas de control distribuido bajo el estándar IEC 61499 aplicados al control de procesos

167 p.Es evidente que en los próximos años gran parte de las tecnologías recogidas bajo el marco de la denominada Industria 4.0 tendrá un profundo impacto en todas las empresas y, entre ellas, las relacionadas con la explotación y producción de petróleo y gas. Sin embargo, la apresurada adopción de tecnologías de la información sin un conocimiento adecuado de las mismas y su aplicación a los diferentes aspectos de los sistemas de control de planta, sistema de planificación de recursos empresariales (Enterprise Resource Planning ¿ ERP) y sistemas orientados a la ejecución de la fabricación (Manufacturing Execution Systems ¿ MES) puede derivar en que las compañías de petróleo y gas automaticen sus sistemas industriales con un injustificado alto coste, de manera potencialmente peligrosa y propensa a errores. La automatización de bajo coste promueve arquitecturas de referencia rentables y nuevos enfoques de desarrollo para aumentar la flexibilidad y la eficiencia de las opera-ciones de producción en una planta industrial. Esto ha llevado a la adopción por parte este tipo de empresas de estándares de redes industriales para las comunicaciones a todos los niveles. En este sentido, OPC UA, además de permitir adherirse a las empresas a la iniciativa de la Industria 4.0, proporciona acceso local y remoto a la información de planta, facilitando un mecanismo reconocido de integración tanto horizontal como vertical de manera correcta, segura y eficiente. El objetivo principal de esta tesis doctoral es presentar una arquitectura abierta para la integración vertical basada en sistemas ciber-físicos de producción, configurados bajo la norma IEC 61499 y usando OPC UA, apta para su utilización en la fabricación flexible en la industria de petróleo y ga