OPC UA Line Control Architecture for Reduced Factory Wiring
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Solution Overview
Problem
Control systems for production and distribution lines face constraints due to limited space on factory floors, requiring more space and wiring for control equipment and communication, and there is a need for cost-effective solutions that minimize these requirements.
Innovation Solution
A system comprising a master room subsystem with an OPC UA server and line control subsystems with OPC UA clients, field devices, and point-to-point digital communication interfaces, eliminating the need for dedicated control cabinets and reducing space and wiring needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional control systems with dedicated control cabinets and PLCs are used for each production line, then reliable control and monitoring are achieved, but the space requirement and wiring complexity increase significantly
Solution Approach 1:
The patent merges multiple control functions (PLC control, HMI interface, SCADA monitoring) into a single integrated industrial computer system. The all-in-one controller combines the processor, memory, display, and communication interfaces in one device, eliminating the need for separate control cabinets and multiple discrete components while maintaining full control reliability.
Solution Approach 2:
The industrial computer is designed as a universal control platform that can perform multiple functions: it acts as both a PLC for real-time control and a SCADA system for monitoring, while also providing HMI capabilities. This multi-functionality allows a single device to replace traditionally separate specialized equipment.
2Ease of operation
If traditional control systems with dedicated control cabinets are deployed for each production line, then proper control functionality is ensured, but the wiring requirements and installation complexity increase
Solution Approach 1:
The patent extracts the control functionality from the physical control cabinet structure and relocates it to a compact industrial computer. By taking out the essential control functions (processing, monitoring, user interface) from the traditional cabinet architecture and consolidating them into an integrated system, the wiring complexity is significantly reduced while maintaining all necessary control capabilities.
3Productivity
If separate control cabinets and PLCs are used for each production line, then dedicated control capacity is provided, but the cost and space consumption increase
Solution Approach 1:
The patent combines multiple control functions (PLC control, HMI interface, SCADA monitoring) into a single integrated industrial computer system. The all-in-one controller combines the processor, memory, display, and communication interfaces in one device, eliminating the need for separate control cabinets and multiple discrete components while maintaining full control reliability.
Data Source
AI summary
A system (100) for controlling a plurality of lines (10), with each line (10) being at least one of a production line and a distribution line, comprises: a first subsystem (30), hereinafter referred to as “master room subsystem”, comprising a first control device (40) hosting an OPC UA server (45); and, for each line (10), a second subsystem (50), hereinafter referred to as “line control subsystem”, comprising: (a) a second control device (60) on which an operating system is running, the second control device (60) hosting an OPC UA client (65); (b) at least one field device (70); and (c) a connection device (80) arranged for allowing communication between the field device(s) (70) and the second control device (60). The field device(s) (70) is connected to the second control device (60) through a point-to-point digital communication interface, the second control device (60) having one port per field device (70).