Automation Server Address Space for Task-Specific OPC UA Access
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Solution Overview
Problem
Modern automation systems face challenges with high resource demands due to extensive information models that require complete address spaces for all functions and parameters, especially in embedded computers, which complicates real-time operations and increases hardware requirements.
Innovation Solution
A method that dynamically generates data objects on a server based on specific technical tasks, using OPC UA services and methods, allowing clients to access only necessary functions and parameters, reducing the need for complete information models and hardware resources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If automated components are connected to a central control via a local area network, then data transmission speed and system coordination are improved, but network failures can lead to complete system shutdown and loss of production
Solution Approach 1:
The patent divides the automated system into independent islands of automation, each with its own control unit. These segments communicate through a master-control unit interface rather than being tightly coupled through a single network, allowing individual segments to continue operating independently even when network failures occur.
Solution Approach 2:
The master-control unit serves as an intermediary between the central control and individual island control units. It provides a buffer layer that allows segments to queue and process data locally when network connectivity is lost, preventing complete system shutdown while maintaining coordinated operation when the network is functional.
2Reliability
If a failure in one segment causes shutdown of the entire automated system, then system-wide safety is maintained, but productivity is severely reduced due to complete stoppage
Solution Approach 1:
The system is segmented into independent islands of automation that can operate autonomously. When a failure occurs in one segment, the segmentation architecture allows other segments to continue production without being forced to shut down, thereby maintaining productivity while preserving safety through isolated fault containment.
Solution Approach 2:
The system implements partial operation capability where only the affected segment is shut down for safety, while other segments continue operating at reduced but non-zero capacity. This partial action approach maintains sufficient productivity while achieving the necessary safety shutdown in the problematic area.
3Device complexity
If data is stored in a database on the central control, then data management is simplified, but network failures prevent access to and processing of stored data
Solution Approach 1:
The patent implements local data storage and processing capabilities at each island of automation and at the master-control unit. Each segment maintains its own data queue and can process data locally without requiring constant access to the central database, ensuring data access reliability during network failures while keeping overall data management structured.
Solution Approach 2:
Data is pre-queued in buffers at the master-control unit and individual control units before network failures occur. This preliminary action of storing data locally in readiness allows segments to continue processing operations using pre-loaded data when network connectivity is lost, maintaining data access reliability without requiring complex real-time database synchronization.
Data Source
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AI summary
The invention relates to a method for operating an automation system of a machine or an installation, wherein the automation system has an automation device (16). The automation device (16) is accessed by a client (10) via a server (18), wherein address information for the access operations is provided by the server (18) in an address space in the form of data objects that are organized in the form of nodes of a meshed network in an information model of the server (18). Based on a technical task to be performed, the client (10), by calling a functionality offered by the server (18), generates data objects on the server (18) that allow the client (10) to perform those access operations to the automation device (16) and/or at least one field device (22) networked with the server (18) via a field bus (20) that are necessary to achieve the technical task.