t30 new connectivity and reporting client for factorytalk historian
TRANSCRIPT
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Copyright 2011 Rockwell Automation, Inc. All r ights reserved.
T30New connectivity andreporting client for
FactoryTalk HistorianJan Pingel
Product Manager, FactoryTalk Historian
Rockwell Automation
Automation Fair 2011
November 16-17, 2011
Chicago, IL McCormick Place
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FactoryTalk Historian
Announcement with OSIsoft
FactoryTalk HistorianSite Edition
Released
2006
2007
2008
2009
2010
2011
2012
FactoryTalk Historian
Site Edition 2.1
Update
FactoryTalk Historian
Machine Edition
Released
FactoryTalk Historian
Site Edition 2.2
Update
FactoryTalk Historian
Machine Edition 2.2
Update
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Soon Launching
updated version of
Historian SE with latest
version of
PI Server 2010
New
version 3.0
2006
2007
2008
2009
2010
2011
2012
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And launching
FactoryTalk Historian
Enterprise Edition
New
version 3.0
2006
2007
2008
2009
2010
2011
2012
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Agenda
2. Typical Challenges for Historian systems
5. Wrap-up
1. Introduction
4. New solutions for Information Software
3. Information solutions with Historian today
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INTRODUCTION
FactoryTalk Historian
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Turning Process Data intoManufacturing Intelligence
A single, information management application server is the central data
point for process information. The information management serverapplication offers these features:
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Control Systems
HMIs
Production
SchedulingAlarms/Events
Other Database
Systems
Computerized
Maintenance
Management
Systems
Performance
Quality
Systems
Data Historians
Laboratory
Information
Management
Systems
Supports both data
management anddecision support
Manages several
different data sets flows
into the server Supports data analysis
from the server.
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Decision Support Data Management
Data Management
A distributed, data management strategy enables different focuses of
data by various users. Operator viewing data from the machine directly in the HMI
Supervisor viewing data to make plant-wide decisions
Manager viewing key KPIs from each plant and evaluating plant performance
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ExcelDashboards
Trend ReportsPortal
KPIs
Data Collection
Data StorageProcess Book
Batch Analysis
DataLink
SQC
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Decision Support
Decision Support
A decision support strategy addresses the need to rapidly capture and
evaluate information to make business decisions. This starts by efficiently and reliably collecting data and integrates
the support
tools necessary to analyze, view, and summarize that data. Portals and dashboards
are key to presenting users the information they need, when they need it.
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Decision Support Data Management
ExcelDashboards
Trend ReportsPortal
KPIs
Data Collection
Data StorageProcess Book
Batch Analysis
DataLink
SQC
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What is a Historian?
Time Series Data collection
Data Historian
Plant Historian
Process Historian
All different names for the same function
http://raeng-sharepoint/sites/RockwellSoftware/FactoryTalk%20Presentation%20Graphics/RSTechED%202007/Factory.pnghttp://raeng-sharepoint/sites/RockwellSoftware/FactoryTalk%20Presentation%20Graphics/RSTechED%202007/Factory.png -
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Process Historian
Traditional Historians for Continuous Process
Collection continuous process data from the equipment
Temperatures
Pressures
Speed
Etc.
Trending process data over time
used by in industrial and manufacturing environments to record and report on historical data over time, which
can include process and product information, as well as network performance and IT monitoring. Automated
Results provides historian application and database consulting, support, integration, user and administrator
training, custom application development, and reporting services.
Process Trend View
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What is NOT a Historian(s task)
Not trending the data
Probably not going to use a Historian !!
Collecting records of data
Data should be stored outside a time series data store
i.e. Batch Records, Production lots, Orders, Shipments, etc.
Records with multiple columns (elements)
Should be stored in a relational database
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The Hybrid Model
The Data Model in a comprehensive plant data base Incorporates:
Real Time Data
Relational Production Data
Time Series Data
A Data Historian cant replace a
complete plant database, and
A Relational Database is not a
replacement for a good Historian
There will always be room for both technologies in a good plant data
model.
Production Data
Process Data
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The Hybrid Model
Merging both Technologies
Adding Context / Model
Moving away from a flat data structure
to an organizational structure
Link time series data to assets Adding: asset properties, events, analytics etc.
Event Framing
Store events like: Batches (full S88 model),
shifts, material flow, alarm and events etc,
Visualize the process data within those
events (fence posting)
Use analytics: Totalize data over the event
/ time boxCopyright 2011 Rockwell Automation, Inc. All rights reserved. 16
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The Hybrid Model
The connected Historian
Connecting:
The traditional Time Series Data with
Event data (Event Framing / Fence Posting)
Asset Data (Context / Properties / Analysis )
Production Data Manufacturing Data
ERP Data
Etc.
Time Series
Data
Event Data
Asset Data
Analysis
Production Data
Manufacturing Data
ERP Data
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TYPICAL CHALLENGES FORHISTORIAN SYSTEMS
FactoryTalk Historian
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Historian Challenge
Collecting the data
Identifying what to collect
Configure the data collection
Visualizing the data
Navigating the data structure Correlated Historical data with other data types
Finding the right way to present the information
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Data Historian Users
Complex configuration Many different interfaces
Many potential architectures
Time consuming
Hard to make repeatable
With multiple layers ofHistorians makes it more
complex.
Flat data structure Complex tag names
Often times 1000s of tags
Not easy for all levels of user
in an enterprise
Require lots of pre-configured content
Not easy to run quick Ad hoc
analysis from the data
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INFORMATION SOLUTIONS WITHHISTORIAN TODAY
FactoryTalk Historian Data Collection
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Deployment and Configuration made easier
Premier Integration to FactoryTalk
Pre configured: Users, Data sources, databases, systems
Auto Discovery / Auto Configuration
Standardization of code and data structures can get systems up and running quicker
Configuration Rules
Can make deployment repeatable
When a similar skid, system, line is deployed the data collection can be configured
by repeating the previous configuration.
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MOTOR1.SPEEDTANK1.TEMP
TANK1.PRESSURE
TANK1.TEMP
TANK1.SIZE
TANK1.PRESSURETANK1.VOL
TANK2.SIZE
TANK2.VOL
MOTOR1.ACC
MOTOR1.SPEED
MOTOR1. PREMOTOR1.PID.SP
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Auto Discovery and Configuration based on
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Auto Discovery and Configuration based onrules defined in included rule tool
Auto Configuration based on:
Easy to configure rules
Based on consistent naming
convention at customers
Allows to discover individual tags
and structures
Multiple rule files can be defined
for different purposes
Types of machines
Areas in customer plant
From different vendors
Etc.
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Tags discovery are also
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Tags discovery are alsoautomatically configured
For each discovery rule:
A configuration can be defined
That defines the way the tags
discovered by the rule will be
configured.
Which means that no fine tuning
of the tags will be needed after
the configuration wizard is done.
Configuration includes:
Description, units
Range, typical value
Exception and Compression
Etc.
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C l l i E i d A l i
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Calculation Engine and Analytics
Internal calculation engine
Performance equations Totalizers
ACE Advanced Computing Engine
Real-time SPC alarming on server
Including SQC client to display SQC charts Development tools
Open data access methods
OPC
OLEDB
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R d d d Hi h A il bilit
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System
Management
Tools
Thin Clients: VantagePoint, Portals,
Rich Clients: View, ProcessBook, DataLink, FactoryTalk
Applications, Custom Application
PI SDK
SecondaryHistorian
Configuration
Changes
Redundancy and High Availability
Data Buffering
Services
Historian Interfaces
Data Buffering
Services
Historian Interfaces
Secondary
Historian(s)PrimaryHistorian
If your customer wants high availability,
then you need to specify redundant
historian servers
If your customer wants redundancy,
then you need to specify redundant
interface nodes
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H b t di t ib ti f d t ll ti ?
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How about distribution of data collection?
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Multi tiered
Architecture
High Speed at
machine level with
local trending
Plant Historian with
Analysis, Calculation
and Consolidation
Enterprise Historian with multi
site aggregation capability and
enterprise visibility
With integration into Universal
Production ModelYou dontneed to know where the data
physically resides system
finds data on request
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New Embedded Historian Module for ControlLogix
Capability for High Speed data collection in the backplane
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Where traditional data
collection is done
through interfaces anddata servers
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Where traditional data
collection is done
through interfaces anddata servers
Data Transfer
transfer's archive
data directly from the
ME module to Plant
Historian
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Enterprise Historian for large scale data aggregation
Capability for collection millions of tags
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FactoryTalk Historian Enterprise Edition 3 0
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FactoryTalk Historian Enterprise Edition 3.0
Final piece to the Distributed Historian strategy now being released
Completing the architecture with the Enterprise level data aggregation
Based on latest PI Server 2010
Will be commercialized in partnership with OSIsoft
EE Customer will have access to both vendors support teams
Target Release Date: January 2012
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FactoryTalk Historian EE Positioning
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FactoryTalk Historian EE Positioning
FactoryTalk Historian ME
Machine / Line Historian Temporary Storage
Limited to circular buffer in Flash memory
Requires Plant Historian for long term storage
Reliable data collection If the machine and chassis is powered and the
controller is running the machine, the data gets
collected
Backplane data collection Scan rates down to 10 msec
Embedded Historian Module No OS or patches to maintain
Full Historian Capability Built-in Basic Calculation Engine for
Performance Equations and
Statistical Totalizers
Low Deployment cost Easy to buy, Easy to own
Up and running in less than an hour
FactoryTalk Historian SE
Plant / Site Historian Persistent Storage
As much as Drive space allows
Archive / backup strategy can be put in place for
long term storage
Redundancy required for reliability If minimal data loss is required, redundant
architectures has to be applied from the
controller and up.
Data collection based on Network Scan rates down to 100-250 msec max
Significant 3rd party connectivity
DA Component (OPC, OLE DB)
Windows Server Based Historian Maintaining a Windows Server OS
World Class Historian Added Advanced Calculations
VB.Net Adv. Calculation Engine
Analysis Framework
Easy to deploy Up and running in less than a day
FactoryTalk Historian EE
Enterprise Historian Persistent Storage
As much as Drive space allows
Archive / backup strategy can be put in place for
long term storage
Redundancy required for reliability If minimal data loss is required, redundant
architectures has to be applied from the controller
and up.
Data collection based on Network Scan rates down to 100-250 msec max
Significant 3rd party connectivity
DA Component (OPC, OLE DB)
Supports data aggregation over WAN
Windows Server Based Historian Maintaining a Windows Server OS
World Class Historian Added Advanced Calculations
VB.Net Adv. Calculation Engine
Analysis Framework
Typically requires services Complex Architectures
Multiple server connection setups etc.
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NEW SOLUTIONS FORINFORMATION SOFTWARE
FactoryTalk Historian Data Visualization
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Talk about getting data to users
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Talk about getting data to users
How to visualize data
So it make sense to the users Brings valuable insight about the process and production
In formats appropriate for the solution
FactoryTalk VantagePoint !!! Advanced trend tool
XY Plotter
Excel Add-in
Advanced Dashboards
Portal for thin client access
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Trending Made Easy
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Trending Made Easy
Compare data over different
time periods including
historical, pre-set and real time
Analyze and display multiple
tags/items from the model
concurrently
Powerful trend functionality -
drag and drop, pan, zoom,
stack and synchronize
Publish and share trends withothers through the portal
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FactoryTalk VantagePoint XY Plotter
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FactoryTalk VantagePoint XY Plotter
Analyze one value with respect
to another over time periods
including- historical, pre-
defined or real-time
Display and compare multipletag pairs concurrently
Powerful functionality including-
drag & drop, pan, zoom and
scale
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Excel Reports Available to Everyone
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Excel Reports Available to Everyone
Easily retrieve data from
Historian to use in Excel
Calculate, analyze and
format reports using Excel
functionality
Only one version of the
truth because Excel reports
are built within VantagePoint
and are saved in the model
Published reports can be
viewed by anyone with
access to a browser
Retrieve
Data From Any
Source
Calculate,
Analyzeand Format
Publish to the
VantagePoint
Portal
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Powerful Easy-to-read Dashboards
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Powerful Easy to read Dashboards
Create powerful dashboards
that monitor key
manufacturing KPIs
Dashboards can update
dynamically and on demand
Published dashboards can
be viewed by anyone with
access to a browser
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All You Need is a Browser
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All You Need is a Browser
No client install is needed to
view trends, reports and
dashboards
Simply publish reports in the
portal to allow access
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Composite Reports for Greater Visibility
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Composite Reports for Greater Visibility
Reusable
Components
Dashboard
Builder Trend
Excel
Plot
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Access From All Systems andC t t B d U R l
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Context Based on User Roles
Access to ALL plant floor, production and business systems
Integrate and organize time series and transactional data
Users at all levels of enterprise can view role-based KPIs, reportsand dashboards
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Manufacturing Intelligence via VantagePoint
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Manufacturing Intelligence via VantagePoint
The Unified Production Model is:
Logical layer oforganized information created by instances of types & theirproperties
Examples of Types include:
It can also be collections / hierarchies of types Standard set of types provided
Ability to create custom types to represent your business / manufacturing process
Reports / visualization are built on the UPM, not the source data
AssetsPump
Extruder
Tank
Filler
Welding Cell
Utility Meter
Structures
Production LineProduction Area
Plant
Enterprise
Production Schedule
Operator
Process
Quality AuditRepairs
Test / Inspection
Batch
Product Parameters
Shift
Type Example: A Pump
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Type Example: A Pump
Process Control Engineer Pressure
Flow
Speed
Production Manager Volume pumped
Product throughput
Operation history
Power consumed
Maintenance Manager Running hours
Performance spec
Manufacturer data
Spares on hand
Maintenance date
Process Engineer
Related equipment
Rating
Vibration data
Asset Manager
Purchase date
Cost
Warranty Manufacturer
Engineering specsQuality Assurance
Batch record
Leak test data
Lab sample
Live Data: Control System/HMI
Historian
Asset
Database
ERP, LMS, SQL
Database
MaintenanceManagement
System
Scalability via the Unified Production Model
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Scalability via the Unified Production Model
LogicalModel
(UPM)
Physical
Data
Sources
Site 1
Plant/Area 1 Data Sources Plant/Area2 Data Sources
VantagePoint Unified Production Model
Site 2
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Plant Model enhancement for Historian
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Plant Model enhancement for Historian
VantagePoint Historian Connector functionality:
Context Enhancement to replace the flat name structure in Historian
Logical model of the data points
Instances of types allows for quick deployment of new Historian tags to report on
Inter correlation of real time tags and historical tags
Real time tags that are historized are automatically detected
User can drag a real time tag onto a trend and automatically the system will show
historical data
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Functionality of VantagePoint since version 3.0
Plant Model enhancement for Historian (cont.)
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Plant Model enhancement for Historian (cont.)
Inter correlation of historical tags
When tags are historized in multiple historians the system can find the best sourceof information needed for a report / trend.
Makes reporting completely transparent to the end user
they only need to know one reference point (logical) for a data value
Aggregations of data are automatically handled in Historian
When users request aggregated results in VantagePoint
Requests that can be handled faster and more efficient by Historian, are
automatically forwarded to Historian for processing.
Significantly reduces the calculation loads on the VantagePoint Server
Allows for processing of aggregations at the best performing server.
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Historian to Historian tag correlation
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Historian to Historian tag correlation
System selects the correct Historian tag when:
A real time tag is pulled into a trend Best historian tags is selected
A high speed historian tags is pulled into a trend
But data is no longer stored locally
Data is aggregated to Plant Historian
A plant historian tags is pulled into a trend
But newer data is available elsewhere
Etc.
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Historian to Historian tag correlation
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g
What does it really mean?
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Correlating live data tag to best match Historian tag
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Inter correlating Historian tags based on time window
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Adding the Logical model (UPM)
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SoCAL
Area 1
Tank 1
TemperatureTemperature
Data aggregation handled by Historian
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gg g y
System diverts aggregations and calculations to Historian where
appropriate:
Interpolated values instead of raw values
Summarizations
Statistical Analysis
Etc.
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Data aggregation handled by Historian
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gg g y
What is the significance?
Performance improvements !!!
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Data aggregation handled by Historian
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Allows us to add more clients to VantagePoint without adding significant
to the overall performance requirements !!
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WRAP UPFactoryTalk Historian
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Summary: Scalable, performance Historian
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Scalable data collection
From in-chassis high speed to Advanced Plant Historian to
Enterprise level aggregation
Easiest Historian to deploy especially on a Logix platform
High Availability
Extensive calculations and aggregations included
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Summary: Informed Decision making
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Comprehensive Historian client
Excel reports, Advanced trends, dashboards, composite reports All available from a think client portal all you need is a browser
Brings context to Historian data
From complex flat data model to logical, easy to navigate Universal Production Model
Connect disparate data sources to live and historical data Makes the information valuable and relevant
And now
Seamless correlation of data points collected in various data sources
Executing presentation layer aggregations in the Historian
Summary: What results can you expect?
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Decreased overhead costs
Reduction in data collection and informationtransformation (data prep)
Increased utilization of fixed assets
Information rather than data
Advanced portal, reporting, and analytical
capability
Increased productivity, revenue, and profit
Decrease in manufacturing costs
Better understand your process, then optimize it
Reduced materials, labor, and energy
Decrease in cost of quality
Higher accuracy and agility via process control
Less scrap and material losses
Increased productivity by 10 percentin less than one year, allowing the
company to get more product to the
market at a lower price point and be
more competitive - CPG
With premier integration to our controls,
and auto configuration and tagbrowsing, we can get a system up and
running in about an hour
Pipeline company
720 man-hours saved annually ingeneration of regulatory and ad hoc
reports, estimated savings of one
man-yearin automation of billing
process - Water Wastewater
For more information on VantagePoint
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Copyright 2011 Rockwell Automation, Inc. All r ights reserved.
Thank You
For more information:
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Jan Pingel
Product Manager, FactoryTalk Historian
[email protected]+1 704 665-6026
http://discover.rockwellautomation.com/
Brian Porter
Product Manager, Information Software
[email protected]+1 440 646-6508