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At Eclatron Technologies, we thrive on transforming complex requirements into streamlined solutions. Recently, we had the privilege of working with a customer in the process industry to integrate OPC UA into their existing process control application. Here's a detailed look at how we approached the project, overcame challenges, and delivered impactful results.
The Challenge
Our customer operated a standalone Windows-based process control application that monitored live data from factory floor machinery, including parameters like heater temperature, pressure, flow rates, and valve statuses. While their system worked efficiently, they were new to OPC UA—an industry-standard protocol—and sought our expertise to enhance their application’s interoperability and scalability.
Our Approach
We adopted a systematic and collaborative approach to ensure a smooth transition to OPC UA:
Understanding the Process:We began by immersing ourselves in their operations. Observing the real-time data monitoring and graph plots, we visualized their process flow to identify key data points.
Mapping Processes to Nodes:We translated their process steps into OPC UA nodes. The OPC UA information model’s flexible data types, such as EURange and EngineeringUnits, enabled us to model the nodes efficiently and accurately. The built-in native types further simplified the process.
Integration:Next, we integrated their process method calls and mapped the respective data sources to the OPC UA server. This step required meticulous attention to detail to ensure seamless communication between the server and client.
Rigorous Testing:Before going live, we tested the OPC UA server using simulated data. We developed a custom test client to validate actual vs. expected responses, ensuring edge cases were handled effectively. To enable continuous testing, we integrated the OPC UA server and test client into Jenkins for automated DevOps workflows.
Key Milestones Achieved
One of the most challenging aspects was mapping all process control steps into a comprehensive OPC UA information model. Freezing the information model was a critical milestone that laid the foundation for timely development and delivery.
The Outcome
By leveraging OPC UA, our customer now benefits from:
Enhanced interoperability with other systems.
Faster and more efficient live monitoring capabilities accessible across multiple clients.
A competitive edge in their industry.
Looking Ahead
This project not only highlighted the importance of a robust information model but also demonstrated the value of collaborative problem-solving. We’re excited to share more insights in future posts, including the development of our custom test client and its role in ensuring quality.