Industrial Connectivity By Use Case

This article organizes common data integration challenges at manufacturing sites and the role of OPC servers by use case.

Why Data Integration Often Becomes a Challenge in Factory Digital Transformation

Factories operate a wide range of equipment, including robots, PLCs, sensors, and control devices. Because manufacturers and applications differ, communication protocols and data formats are not standardized. The more equipment installation timing varies, the more complex the situation becomes.

When site data is siloed within each piece of equipment, it becomes difficult to integrate it with upper-level systems such as SCADA, MES, and ERP, as well as cloud-based analytics and visualization tools. This can hold back visualization, analysis, and remote monitoring.

What Is an OPC Server, and Why Is It Used to Address Data Silos?

An OPC server is software that relays and standardizes data, making it easier to exchange data between different equipment and software. It connects to manufacturer-specific communication protocols used by PLCs and other equipment, converts collected data into OPC format, and delivers it to upper-level systems. When an upper-level system sends commands to a PLC, the OPC server also handles communication conversion.

In factories with mixed vendors and communication methods, an OPC server can serve as an effective connectivity foundation for absorbing differences in communication protocols.

OPC Server Use Cases by Factory Scenario

This section organizes the factory challenges where OPC servers can be useful into six common site scenarios.

You Want to Consolidate and Visualize Equipment Data Across a Mixed Line

At manufacturing sites, integrating equipment and aggregating data across the entire line can be difficult. By using an OPC server as a relay point, you can centrally collect data across different communication methods and create a data environment that is easier for upper-level visualization tools to access and use.

You Want to Connect Equipment to Upper-Level Systems More Easily

Even when data exists on the equipment side, separate communication handling may be required if the connection specifications for upper-level systems differ from one device to another. By setting up a standard data-publishing gateway through an OPC server, you can absorb differences between devices and streamline connections to upper-level systems.

You Want to Use Factory Data in the Cloud

OPC UA, which supports secure communication as a standard feature, is well suited for data transfer over the internet. By using an OPC server as a relay point for collecting and converting site data, it becomes easier to build an integration route with a cloud analytics platform.

You Want to Collect Data While Continuing to Use Legacy Equipment

If an OPC server can absorb legacy equipment protocols and convert data into a form that is easier to use at the upper level, it may be possible to advance data utilization in stages without fully replacing the equipment. This approach is often considered when a site wants to expand its initiatives while making use of existing assets.

You Want to Monitor and Maintain Equipment Remotely

When every equipment issue requires on-site checks or site-by-site responses, the burden on the maintenance system increases. By creating an environment where factory data can be accessed over the internet, line status can be easily monitored from headquarters or remote locations.

You Want to Integrate with Upper-Level Systems Such as SCADA, MES, and ERP

When an OPC server relays and standardizes diverse site data, applications such as ERP, MES, and SCADA with OPC UA client functionality can more easily use field device data. The benefit is that it becomes easier to integrate with systems for centralized management of production systems, data analysis, and forecasting.

Frequently Asked Questions

Q. What Is the Difference Between an OPC Server and Conventional Data Integration Middleware?

A. Conventional data integration approaches required a dedicated tool for each connection destination. An OPC server is software that serves as a standardized connectivity foundation, absorbing differences in communication protocols at manufacturing sites with equipment from different manufacturers and making data integration easier. It can also help reduce the need to develop individual communication drivers.

Q. Can Legacy PLCs Be Connected to the Cloud?

A. In some cases, yes. If an OPC server can absorb protocols on the legacy equipment side and convert them into a format that is easier to use at the upper level or in the cloud, data utilization can proceed without fully replacing the equipment.

Q. Where Should You Start When PLCs from Multiple Manufacturers Are Mixed?

A. Start by taking inventory of the manufacturers, models, communication methods, and number of connections for the PLCs used at the site, and identify where disconnections are occurring. By choosing an OPC server that supports mixed environments, it becomes easier to centrally manage data from equipment made by multiple manufacturers. You may find it easier to narrow down options by first considering products that support different PLCs and SCADA systems.

Choosing the Right OPC Server Product

OPC server products differ in many ways, including supported protocols, compatible connection destinations, cloud integration capability, scalability, and ease of operation. Because the points you should prioritize vary by project, it is important to compare based on the required specifications.

The article below features selected OPC server products by project type, each with the specifications needed to solve these challenges. Please use it for comparison and evaluation.