Highest data transparency with SQL4automation
Intermediary between MES and the production level
Exchanging data simply, quickly and flexibly between PLC, robot controls and SQL databases – this was almost impossible up until now without great effort or performance losses. The SQL4automation Connector can do this with only a few clicks. This means that manufacturing execution systems also have simple access to the production data.
The connection of the automation level to the IT-world makes it possible to make production and machine data available step-by-step throughout the company in order to evaluate, plan, coordinate and optimise operating procedures. Manufacturing execution systems (MES), which can be found in the intersection between ERP systems and production implementation processes. In order for them to function efficiently, they depend on data from the production level.
Up until now, it was often complicated to extract data from the production level, since often an additional high-level programming language program and an OPC server were used. Special tools are available for specific controllers, but there are hardly any general tools for the controllers. Additionally, there are performance losses with large data amounts, when data is accessed via OPC. The company Inasoft provides a manufacturer-independent protocol for communication from the machine to the database with the SQL4automation-Connector. As a result, simplicity, speed and flexibility are put into focus.
Problem-free data exchange with the MES solution
"The SQL4automation Connector is a software solution for conveniently connecting robot controls and PLC with databases", Ruedi Gloor, director of Inasoft Systems GmbH, explains. With this solution, controls have full access to SQL databases with high flexibility and using familiar programming environments. It only takes a few settings to create a database connection with the connector. The SQL command is programmed in the PLC or the robot control and sent to the connector. The connector meets very high standards when it comes to reliability and performance – irrespective of the hardware producer. This enables uncomplicated data exchange with the MES or ERP level.
The software solution SQLautomation runs with Windows as well as Linux and uses TCP/IP data transferring. At the same time, the database access is characterised by high flexibility and speed. An OPC server is not required. "This has a positive effect on the performance and transparency of the system", the automation expert is convinced. With the SQL (structured query language) data can be retrieved from tables, added to tables, changed or deleted. In this process, a cycle only takes a few milliseconds. This advantage in speed pays off especially when large data amounts are concerned, because even 1,000 points can be transferred at the same time – as opposed to OPC with serial transmission. "With ODBC, very large amounts of data can be transferred in a short amount of time", according to R. Gloor.
"All databases with ODBC interfaces are supported", the Inasoft director proceeds. This means that data can not only be written in Microsoft SQL Server, SAP, Oracle, MaxDB or MySQL, but even in Excel-sheets. If it should come to changes or further development of the standard interfaces, this is the database producer's concern. The user will not be affected by this. The Connector software only serves as a gateway. This makes adjustments easier, since these are carried out in the PLC programming software. In the controller, settings about which data is passed on are made. No project-specific changes have to be made at the connector. With the query tool, an SQL command can be easily simulated and tested, before being implemented into the controller (top image).
And the best part: The software functions hardware-independently. Every control which has a TCP/IP interface is a potential data supplier. Data transferring therefore works with controllers with the corresponding TCP/IP interface, such as Allen Bradley, Siemens S7, CODESYS 2.0 and CODESYS 3.0 (Bosch Rexroth, Wago, Elau, Schneider Electric, Festo among others), Beckhoff, B&R and Sigmatek, as well as robot controls by Kuka, Stäubli and ABB. For these controllers, finished libraries are already available, which only have to be implemented into the project. "The structure which decides which data is transferred is laid bare", R. Gloor emphasises. The respective libraries are available for download on the homepage; for CODESYS also in the CODESYS-store. Based on the existing libraries, users parameterise the data transfer quickly with a few clicks. "But we also offer this as a service", the director stresses.
Versions for different requirements
SQL4automation exists as a light version for one controller, as a standard version for ten connections and as an ultimate version for more than ten connections. Several controllers can also be connected to the Connector in very short time, the automation expert tells us and gives an example: "A variable workpiece length is entered into the database and several controls access this to retrieve the data via the connector." Connector, which runs as a service therefore enables fast access to a central "data vessel" for the complete automation solution. This saves a lot of effort. (right-hand side image) shows the config tool of the solution. Depending on the controller, a standard query can for instance take 150 ms. There are, however, also applications with more than 20 queries per second.
When the controller writes data directly into the SQL-database, it is possible, for instance, to log workpiece data. "Workpiece number, measurement readings, date, time, serial number as well as production site/line or machine is now all transparently and accessibly available in the database, as well as any form of notifications and important machine data, for example overall/production and standstill time, amount and time of the workpiece production, as well as the abrasion of machine parts", the director underlines. This concentrated production information can then be used for example for MES solutions or production data acquisition. But it also works the other way around: Production information from the MES solution concerning the current product type is shared with the SQL database, which can then be read by the controller. R. Gloor: "When dealing with larger applications, it is recommended to use an intermediary computer." The company has these top hat rail PCs in its portfolio.
The SQL4automation-Connector was developed in 2007 for industrial use and has proved successful with versions for different requirements in many different industry applications. The director names an example for the use of a connector for process data acquisition: "Testing data for the unequivocal identification of the workpiece are shared with the database. This enables the retrace-ability of testing data back to the workpiece." This matrix code for different parts can also be used when different parts are assembled at the same time to retrace a default. With the help of the database, it can be found out exactly where the faulty component was produced.
The Plüderhausen based company Wilhelm Bahmüller Maschinenbau Präzisionswerkzeuge GmbH uses the SQL4automation Connector, to share controller data in the folding box gluing machine Turbox II directly with production data acquisition. The data exchange with the BDE system runs conveniently over a firebird database. The collected information can be used throughout the company.
The connector ensures the highest possible data transparency and is an important contribution to vertical integration. Thus, the software tool plays an important role as an "enabler" for the fourth industrial revolution. A demo license can be downloaded for free at the homepage.