What is OPC UA?
OPC UA is short for "Open Platform Communications Unified Architecture." It refers to an interoperability standard for industrial data exchange. OPC UA was developed specifically for applications in the Industry 4.0 environment and the Internet of Things (IoT). Unlike the old OPC standard, which relied on Windows DCOM and was mainly for local use, OPC UA is platform-independent. It is service-oriented and designed for secure use across networks.
The standard enables scalable, secure communication between a wide variety of devices and systems. It ensures uniform data formats and protocols at the interfaces of various components, and protects communication with comprehensive security mechanisms.
These are the benefits:
Platform independence:
Standardized communication between different systems is possible, regardless of the manufacturer, operating system, or technical environment. The platform-independent architecture establishes a foundation for seamless machine-to-machine communication and enhances interoperability in industrial applications.
Security:
The underlying architecture is based on modern security mechanisms. Encryption, authentication, and authorization reliably protect data, even in open networks or cloud environments. Companies keep control over data access at all times. They also meet important data protection and IT security needs, especially in Industry 4.0.
Flexibility and scalability:
The Service Oriented Architecture (SOA) of OPC UA forms the foundation for a highly flexible and modular communication structure. This architecture defines standardized interfaces for exchanging data and services, making it independent of the underlying transport protocols.
It supports a wide range of protocols, including TCP/IP, HTTPS, MQTT, and OPC UA over TSN. This flexibility allows different devices and systems to work together seamlessly. It helps the OPC UA standard fit into many applications, from old control systems to new IoT devices.
This structured and scalable design makes it easy to add new devices or OPC clients. It does this without disrupting current communication systems or data models. This ensures long-term adaptability and protects your investment.
Standardization:
The OPC UA standard is maintained by the OPC Foundation and is internationally recognized. It ensures standardized communication and thus offers long-term investment security. It is supplemented by so-called Companion Specifications, which are specially tailored to individual industries. These extensions are based on information modeling and enable a clear, object-oriented description of industrial data - an important prerequisite for integration into modern Industry 4.0 systems.
How does OPC UA communication work?
The data transmission occurs via a classic client-server model or a publisher-subscriber (pub/sub) principle. Both approaches are based on a service-oriented architecture (SOA) and support flexible, scalable integration into modern Industry 4.0 environments.
Client-server model:
In this model, the server acts as the data provider. OPC clients can specifically request, write, or subscribe to information, for example, in the case of data changes, states, or alarms. Communication is handled via standardized Data Access services, enabling reliable and timely responses to changes within the system. This approach is particularly well-suited for targeted queries and direct control tasks.
Publisher-subscriber model:
In this model, a publisher actively sends data to one or more subscribers without the need for a direct query. This structure is ideal for applications that require the distribution of information to many recipients in real time, such as in widely branched systems or for machine-to-machine communication. Using OPC UA over TSN makes this model suitable for time-critical applications in production environments.
How can OPC UA be used for data integration with Industry 4.0 and IoT applications?
There are several typical scenarios and project situations in which OPC UA is used at the interface between OT and IT:
1. Modernization of legacy systems through OPC UA integration
Many machines and devices in existing systems lack a standardized OPC UA interface and instead rely on older communication protocols or proprietary interfaces. In modernization projects, it is often necessary to integrate these machines and devices into innovative solutions using OPC UA in order to leverage the benefits of Industry 4.0 and IoT applications and to ensure effective data integration.
2. Efficient connection and integration of OPC UA servers in modern facilities
Today, numerous devices come equipped with integrated OPC UA servers out of the box. The challenge lies in connecting applications efficiently, easily, and securely to a wide range of data sources. In addition, there is often a need for IT applications to access data from OPC UA servers using widely adopted standard protocols such as MQTT.
3. Standardization and integration through Companion Specifications and OPC UA information models
With advancing digitalization, the demand for standardized interfaces using Companion Specifications and OPC UA Information Models is growing. These models enable consistent descriptions of devices, machines, and systems — including semantic information — and simplify their integration into modern IoT solutions, for example through so-called “Unified Name Spaces” (UNS).
How can OPC UA solutions be adapted to individual operational processes and infrastructures?
All of the requirements and application scenarios mentioned can generally be addressed using standard products that support OPC UA, thereby minimizing project-specific integration efforts.
However, since users vary in terms of organization, operational processes, and existing infrastructure, the optimal OPC UA-based data integration solution may differ depending on the situation. Depending on the context, Docker-based software solutions, Windows-based software solutions, or hardware solutions may be the best choice to tailor the integration to the specific needs of the organization.
Softing OPC UA expertise and portfolio
Softing OPC UA expertise and portfolio With our extensive experience in OPC technology and close collaboration with the OPC Foundation, we are the ideal partner for your OPC data integration needs. Whether for legacy systems or new installations, and whether supporting traditional operations or IT-driven and automated processes, Softing Industrial offers tailored end-user products for OPC UA-based data integration.
In addition to these end-user products, we develop and market Software Development Kits (SDKs) for project-specific development of OPC UA client and server components. These SDKs can be used for both device and software applications. We are also utilizing these SDKs in the development of our OPC UA-based end-user products. The synergies created by this approach benefit both the users of our end-user products and the users of the SDKs.
Complementing our standard products, we offer a comprehensive training and service program to provide our customers with the best possible support.
Softing products for OPC UA data integration
Windows-based OPC servers and middleware serve as software interfaces for exchanging data between different systems and devices. The OPC servers collect data from different devices and make it available in a standardized format, while OPC middleware facilitates data forwarding and processing between different systems.
Product: dataFEED OPC Suite
Integration platforms for data aggregation collect, combine and consolidate vast data volumes from different sources. This allows users to control data at a single point and manage it easily and securely.
Products: Secure Integration Server, edge Aggregator
Docker-based OPC UA software solutions run as containers and offer a flexible and scalable way to use OPC UA functionalities.
Products: edge Aggregator, edgeConnectors, edgePlugs, smartLink SW-HT, smartLink SW-PN
OPC UA Software Development Kits (SDKs) provide the necessary tools and libraries to develop applications that can act as OPC UA clients or servers. These applications collect, process and forward data from various devices and controllers.
Products: OPC UA SDKs
Hardware gateways for network access parallel to the controller are ideal for expanding existing systems. They provide additional communication options via OPC UA without affecting the operation of the control system.
Products: smartLink gateways
Hardware gateways for direct access to controller data are suited for applications that require tight integration and direct access to controller information.
Products: edgeGate, ua Gates, eATM Manager Control Logix
