OPC UA Pub/Sub Reconfiguration for Live Industrial Automation
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Solution Overview
Problem
Industrial automation systems face challenges in dynamically adapting their communication configurations, particularly in peer-to-peer setups between heterogeneous equipment from different vendors, requiring system shutdowns and expert intervention, which hinders flexibility and agility in responding to changing market demands.
Innovation Solution
The implementation of an automation system with separate OPC UA server, subscriber service, and publisher service instances on each control device allows for on-the-fly configuration of publisher-subscriber services without altering the control device application programs or engineering software, enabling peer-to-peer communication between different vendors' equipment without system downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a Pub/Sub setup is used to accommodate real-time timing constraints, then messaging timing requirements are met, but system reconfiguration requires shutdown and expert intervention
Solution Approach 1:
The system separates configuration management from the control application by implementing a dedicated configuration service that operates independently. This service can be updated, restarted, and reconfigured without affecting the running control logic, allowing configuration changes while the system remains operational.
Solution Approach 2:
A configuration service acts as an intermediary between the control application and the Pub/Sub messaging infrastructure. This mediator handles all configuration changes, subscription management, and publisher setup, allowing operators to reconfigure the system without directly modifying the control application or requiring system shutdown.
2Adaptability or versatility
If engineering tools are used to re-configure communication between equipment, then communication setup can be modified, but the process is cumbersome and requires external automation experts
Solution Approach 1:
The configuration service provides self-service capabilities through automated discovery and configuration mechanisms. The system can automatically detect available publishers and subscribers, suggest appropriate configurations, and apply changes without requiring external automation experts or complex engineering tools.
Solution Approach 2:
The configuration service provides a universal interface for managing all Pub/Sub communications across heterogeneous equipment from different vendors. It handles multiple communication protocols, device types, and configuration scenarios through a single unified service, simplifying the reconfiguration process.
3Adaptability or versatility
If configuration changes are made to Pub/Sub setup, then communication can be adapted, but all components must adopt the change simultaneously requiring system shutdown
Solution Approach 1:
The configuration service implements dynamic configuration updates that can be applied incrementally to individual components. Publishers and subscribers can be updated one at a time or in groups, allowing configuration changes to take effect progressively without requiring all components to change simultaneously or the system to shut down.
Solution Approach 2:
The configuration service allows configuration changes to be prepared and validated before being applied to the running system. Configuration files can be edited, syntax can be checked, and changes can be simulated before activation, ensuring smooth transitions without system downtime.
Data Source
AI summary
A method for configuring peer-to-peer communication in an industrial automation system including at least two control devices, each control device being arranged for hosting as separate instances an OPC UA server, an OPC UA subscriber service, and an OPC UA publisher service, the method including retrieving an OPC UA object list for each control device, the object list indicating all OPC UA objects managed by each respective control device, and presenting the OPC UA objects and control devices for user input. The method further including obtaining user input, configuring for each control device publisher and subscriber service parameters in a configuration file for each respective control device, and transferring the configuration file to the publisher and subscriber services of each respective control device. Also disclosed are an industrial automation system and industrial control devices configured to implement the disclosed method.