Hue Industrial 4.0 Kit - User Manual - V - 3.0

HUE University
“Industrial 4.0 User Manual”
Author : Martine Rose Devaraj

INDEX
 WELCOME STATEMENT i4TECH PTE LTD
 MES OVERVIEW
 MES ARCHITECTURE
 PLC
 SCADA & HMI
 KEPWARE
 IGNITION
Welcome Statement i4TECH pte Ltd
 i4TECH Pte Ltd is a Systems Integration company providing professional expertise in

the domains of Manufacturing Operations Management, supply chain integration and
overall enterprise digitalization
 i4TECH has the objective to facilitate the digitalization journey to manufacturing

companies in Southeast Asia, where we observe a significant demand for guidance and
support to deploy digitalization rollouts, starting from PoCs and pilot projects, all the way
to enterprise deployments across the value chain (source – make – deliver)
 Our breadth of experience covers domain knowledge in CPG, Pharma, Automotive,

Semiconductors and Energy related installations, which can be supported locally
across the region
HUE University, Vietnam -- Student User Manual Property of i4TECH Pte Ltd 3
 i4TECH teams have a wide experience with digitalization projects including MES and IIoT with
leading manufacturing companies in different sectors like automotive (Ford, Volvo, MRF,
Mahindra) and Consumer Packaged Goods (Unilever, Mars, Universal Robina Corporation)
1. MES Overview
1.1 MES Introduction
 A manufacturing execution system (MES) is an information system that connects,
monitors and controls complex manufacturing systems and data flows on the factory
floor. The main goal of an MES is to ensure effective execution of the manufacturing
operations and improve production output
 An MES helps achieve that goal by tracking and gathering accurate, real-time data
about the complete production lifecycle, beginning with order release until the
product delivery stage for finished goods
 The MES collects data about product genealogy, performance, traceability,

material management and work in progress (WIP) and other plant activities as
they occur. This data, in turn, allows decision-makers to understand the current
settings of the factory floor and better optimize the production process
 A standard MES provides customized data on the manufacturing lifecycle, starting with
the release of orders until the finished goods distribution point of the commodity. Like
any piece of software, a production solution also comes with a whole bunch of
functions, benefits, and workflow that helps business goals
 MES is the comprehensive system that controls all the activities occurring on the shop
floor. It begins with all the various orders from customers, the MRP system, the master
schedule, and other planning sources; and then builds the products in the most effective,
low cost, expedient, and high- quality way possible.
 A comparative example occurs in the construction business where the construction team
(MES) builds a tower from the architectural plans (inputs from MRP, Master schedule, etc.)
1.2 MES Basics
 MES is an intensive scheme with multifaceted manufacturing execution capabilities for the
plant floor. So, let’s see how every flow creates a functional layer
Step 1. Ordering
• The software solution will configure order forms, and collects data to
centralize orders in any language
Step 2. Quoting & Costing
• ME software will prepare product simulation, formula, or volume
• It will then generate quotations & cost sheets for customers and internal use
Step 3. Production Planning
• MES will provide daily, weekly, and monthly charts to enable you to plan production and work
instruction ahead of time
• It will create jobs and product workflows automatically
Step 4. Machine Connectivity & Scheduling
• Manufacturing execution IT systems recommends job assignments to available machines and

personnel based on availability and delivery dates
• The assignment is tracked for each individual part sequence and generates job assignments and
processing task lists instantly
• MES will also adjust rescheduling failed prints or shifting jobs in the scheduled downtime
Step 5. Optimize Manufacturing Routes
• Manufacturing execution systems will conduct quality checks taking samples as

products progress through the factory point of view
• MES helps to recommend changes in product routes based on input from

production data or on data from production machinery
Step 6. Automatic Delivery
• MES that are connected with ERP solutions, delivers the full job pack with
product information to the operator
• It also displays production feedback from machinery that is needed for decision-
makers
Step 7. Data Collection
• Track manufacturing execution parameters and quality data for each serialized part
and job
• Auto-generate product quality reports from data stored across upstream and
downstream business processes
• Capture the digital thread and enable repeatability of end-use parts
Step 8. Analytics and Reports
• It offers data analytic dashboards to track KPIs and metrics every day, weekly, and
monthly.
• It also helps you to push & pull data and get a holistic view of your operation through
3rd party business networks
1.3 MES Advantages
 An MES is often integrated with ERP, supply chain management, product lifecycle management and
other key IT systems. A key benefit of using an MES includes:
• Increased customer satisfaction
• Improved regulatory compliance
• Better agility and time to market
• Improved supply chain visibility
• Reduced manufacturing cycle time
• Elimination of paperwork and manual data-entry processes
• Reduced order lead time
• Lower labor costs
• Reduced WIP inventory
• Increased machine utilization
1.4 MES Domain Overview
 While MES is a one-stop solution for the production sector, the value is spent differently
in each department by each manufacturing execution feature. Let’s take a look.
1. Operations/Detailing Sequencing
 To provide your employees with a global view of planned production orders and their
production routing and execution system including job cards, this function ensures that
your entire staff is on the same page and reduces errors due to miscommunication
2. Resource Allocation and Status
 As part of the method routing concept, the MES systems list the resource specifications
for each manufacturing execution job. It is then moved to the method of ERP or
scheduling software solution. This lets you define and monitor the status of your assets
and how they are used in the manufacturing process.
 Manufacturing organizations can handle the allocation and status of resources

including equipment, tools, materials, and labor.
3. Dispatching Production Unit
 Dispatch function is focused on enterprise resource planning (ERP) global guidance

tailored to the availability of services, scheduling specifications, and capability
 To control the bidirectional flow of output data between the ERP and the workshop in
real-time, the manufacturing execution guarantees that output data is still precise,
accurate, and up to date
4. Performance Analysis
 This manufacturing execution software feature helps you to understand how the
manufacturing process functions and how it might be expanded
 Businesses can define and record key performance indicators (KPIs), conduct
predictive production performance analysis, deliver performance tracking, and
monitor dashboard displays and datasets
5. Maintenance Management
 To minimize downtime and production output interruptions, preventive system

maintenance as part of MES can be scheduled more quickly and effectively
 To reduce the effect on plant activities, companies can improve the preparation
of preventive maintenance practices. Just plan for inevitable repairs without
hindering performance and allow for a seamless flow of production
6. Process Management
 One of the important functions of the manufacturing execution process is to manage

the production process, including guided work phases and work orders, from order
release to work in process (WIP) to finished products
 Therefore, manufacturing systems offer support with process routing and operational
sequencing to provide complete traceability of output.
7. Quality Management
 You may incorporate this feature directly into the manufacturing execution software
or use external software to overcome regulatory compliance
 Integrated quality control in the manufacturing process assists you in the workflows
of corrective and preventive action (CAPA), verification, and non-conformance
8. Data Collection/Acquisition
 You may call this feature the heart of the MES systems as it enables the input of all
information, manually or automatically. You can monitor and accumulate important
details and, when you need it, retrieve the data quickly
 Just collect and store data from end-users, accounts, or computers, on databases or
embedded historians
9. Product Tracking and Genealogy
 With this execution system function, you can track each object in the manufacturing
process, unique recognition of parts and components, as well as the equipment and
workers involved in handling it
 Then, from the raw material to the product assembly, you may group final parts or
lots with all their corresponding manufacturing execution details
10. Labor Management
 Production execution systems let you control and use the highest productivity
and attributes of workers and services in the most desirable places as you
automate manpower. Handle the employees, objects, & activities and monitor
the skills they require
 This means that, at each stage of the manufacturing execution process,
you always have the right people in charge
11. Document Control
 Manufacturing execution systems also provide the operators with a quick

way to view substantial records as they need them, including manuals,
drawings, and notes
 This saves time for you and your team by not having to dig
for the details you need across file cabinets
1.5 Introduction to Plant Floor Systems
 Any system builds to support the plant floor operations are termed as plant
floor systems.
 Plant floor systems feed accurate, real-time information into plant and
enterprise level ERP systems.
 Any system which is capable of handling data collection and plant

monitoring functions are termed as plant floor systems.
 Plant floor functions includes maintenance, quality, compliance, HACCP,

SPC, recipe management, production planning, engineering, process
simulation, lot tracking and distribution
 MES is also one of the plant floor systems
2. MES Architecture
2.1 Business planning and logistics

 Describes the role of the ERP system for business planning and logistics which includes
the establishment of a basic plant schedule and time frame for production, material use,
delivery and shipping
2.2 Manufacturing operations management
 Describes manufacturing operations management handled by MES that includes a
detailed workflow for manufacturing the desired end products. The team also maintains
the records and optimizes the production process
2.3 Manufacturing control system
 Defines the manufacturing control system where you monitor and automate the control
process of production from work in progress to output. It includes basic control,
supervisory control, process sensing, and process manipulation
 What makes the MES framework relevant is that it acts as a practical layer between
the ERP and the shop floor process control systems (execution system), offering clarity,
consistency, and insight into the real-time workflow.
3. PLC
3.1 What is PLC?
 A programmable logic controller (PLC) is an industrial computer control system that
continuously monitors the state of input devices and makes decisions based upon a custom
program to control the state of output devices
 Almost any production line, machine function, or process can be greatly enhanced using this
type of control system. However, the biggest benefit in using a PLC is the ability to change
and replicate the operation or process while collecting and communicating vital information
 Another advantage of a PLC system is that it is modular. That is, you can mix and match the
types of Input and Output devices to best suit your application
3.2 History of PLC
 The first Programmable Logic Controllers were designed and developed by

Modicon as a relay re-placer for GM and Landis
• These controllers eliminated the need for rewiring and adding additional
hardware for each new configuration of logic
• The new system drastically increased the functionality of the controls while
reducing the cabinet space that housed the logic
• The first PLC, model 084, was invented by Dick Morley in 1969
• The first commercial successful PLC, the 184, was introduced in 1973 and was
designed by Michael Greenberg
3.3 What is inside a PLC?
 The Central Processing Unit, the CPU, contains an internal program that tells the
PLC how to perform the following functions:
• Execute the Control Instructions contained in the User's Programs. This
program is stored in "non-volatile" memory, meaning that the program will
not be lost if power is removed
• Communicate with other devices, which can include I/O Devices,
Programming Devices, Networks, and even other PLCs.
• Perform Housekeeping activities such as Communications, Internal
Diagnostics, etc.
3.4 What Programming Language is used to program a PLC?
 While Ladder Logic is the most used PLC programming language, it is not the only
one. The following table lists of some of languages that are used to program a PLC
 Ladder Diagram (LD) Traditional ladder logic is graphical programming language. Initially
programmed with simple contacts that simulated the opening and closing of relays, Ladder
Logic programming has been expanded to include such functions as counters, timers, shift
registers, and math operations
 Function Block Diagram (FBD) - A graphical language for depicting signal and data flows
through re-usable function blocks. FBD is very useful for expressing the interconnection of
control system algorithms and logic
 Structured Text (ST) – A high level text language that encourages structured programming.
It has a language structure (syntax) that strongly resembles PASCAL and supports a wide
range of standard functions and operators. For example
If Speed1 > 100.0 then

Flow_Rate: = 50.0 + Offset_A1;
Else
Flow_Rate: = 100.0; Steam: = ON
End_If;
 Instruction List (IL): A low level “assembler like” language that is based on similar
instructions list languages found in a wide range of today’s PLCs.
LD R1
MPC RESET
LD PRESS_1
ST MAX_PRESS
RESET: LD 0
ST A_X43
 Sequential Function Chart (SFC) A method of programming complex control systems at

a more highly structured level. A SFC program is an overview of the control system, in
which the basic building blocks are entire program files.
 Each program file is created using one of the other types of programming languages. The
SFC approach coordinates large, complicated programming tasks into smaller, more
manageable tasks
3.5 Rockwell PLC Designer
 The Studio 5000 Automation Engineering & Design Environment® combines engineering and
design elements into a common environment. The Studio 5000® environment is the
foundation for the future of Rockwell Automation® engineering design tools and capabilities
 The Studio 5000 environment is the one place for design engineers to develop all
elements of their control system.
 The following diagram shows how View Designer works with the Studio 5000 suite to
create a control and visualization system to monitor and control the manufacturing process
Item Name Description
1 View Designer Build the projects that are downloaded to an HMI device.
2 Tag Browser Search for and select tags within a Logix Designer project file to bind the tags to the
properties of graphic elements and screens in the View Designer project.
3 Logix Designer Develop control logic for an industrial automation system.

4 ACD file The Automation Control Database (ACD) file that is the Logix Designer project file
containing the logic or code, including tags and data types, that runs within a
controller. View Designer uses the Tag Browser to read data from the ACD file
5 HMI project The user-defined screens, controller references, information about the target HMI
device, and so forth. Projects are stored in files with a .vpd extension.
6 View Designer Download Runtime Application Transfer the HMI project to the HMI device.
Wizard
7 HMI device The Human Machine Interface (HMI) device, such as a PanelView 5000 device, that
runs the HMI project. At runtime, the HMI device communicates directly with the
controllers.
8 VPDR file Save a Runtime Application VPDR file from View Designer.
9 Load from media Load a Runtime Application VPDR file from removable media such as an SD Card or
USB storage device to the HMI device.
10 Controller A controller with the ACD file and tags used in the View Designer project.
 Studio 5000 Logix Designer® is a design and configuration software based on the
Rockwell Automation Integrated Architecture™. It provides a common environment
for users programming the Allen-Bradley® ControlLogix® and CompactLogix™
controllers, in standard and safety configurations, along with a wide range of
redundancy, communication, motion, and I/O modules available for each
 Whether you have discrete, process, batch, motion, safety and drive-based applications,
Studio 5000 Logix Designer offers an easy-to- use IEC61131-3 compliant interface,
symbolic programming with structures and arrays and a comprehensive instruction set that
serves many types of applications
 It provides ladder logic, structured text, function block diagram and sequential
function chart editors for program development as well as support for the S88
equipment phase state model for batch and machine control applications
 The Integrated Architecture system and Studio 5000 Logix Designer together help
customers drive plant-wide optimization efficiently and effectively in a vast range of
industries
 The platform provides users with access to real-time information, and helps them maximize
performance, save project development, and commissioning time, reduce maintenance and
training costs and improve overall productivity
 Simulink PLC Coder™ allows users to deploy control algorithms designed in Simulink to
the Studio 5000 Logix Designer programming environment as IEC 61131-3 structured text
 This structured text can be imported as a Routine or as an Add-On Instruction (AOI) into
Studio 5000 Logix Designer
4. SCADA & HMI
4.1 Scada
 Many companies in the early 1990s faced the challenge of managing a network of
remote equipment without the cost getting out of control. This challenge led to the
development of Scada systems
 At the basics of Scada systems involves a central computer managing remote equipment
 The central computer otherwise known as a server typically involves specific software
for monitoring, controlling, logging, trending, and alerting of remote equipment
4.2 Scada Systems are used for which of the following?
 SCADA Systems are used for water management & waste treatment, onshore and
offshore gas and oil production, gas pipelines, manufacturing, telecommunications,
mining, metals and cement, life sciences and agriculture
 In addition to those pillar Industries SCADA systems can be used in any industry
you can think of using a single command central for monitoring and controlling
remote equipment. Let's investigate more detail of SCADA Systems and how to
use it for your equipment
4.3 What are SCADA Systems?
 SCADA stands for supervisory control and data acquisition, which is a type of
computer system that is meant to gather and quickly analyze real-time data. These
systems are commonly used within production facilities and industrial plants
 When put in use, a SCADA system is designed to help with the control and
monitoring of an entire plant or equipment that deals specifically with time-
sensitive and critical events. For instance, when a leak occurs in a pipeline, the
SCADA system that’s in place will help to detect the leak and transfer the
information pertaining to the leak back to a central location
4.4 Where can I get a SCADA system from?
 They're many companies that sell SCADA Systems. One company that comes
to mind is Rockwell Automation FactoryTalk® View SE HMI SCADA
software which can communicate on Allen-Bradley ControlLogix®
programmable automation controllers (PAC)
 If your equipment has an Allen-Bradley ControlLogix® programmable

controller, then this would be a great choice.
4.5 FactoryTalk® View Studio Overview
 FactoryTalk® View Machine Edition (ME) software is a versatile HMI application that
provides a dedicated and powerful solution for machine-level operator interface devices
 As an integral element of the Rockwell Automation visualization solution, FactoryTalk

View ME provides superior graphics, runtime user management, language switching,
and faster commissioning time through a common development environment
 FactoryTalk View ME allows for a consistent operator interface across multiple
platforms, including PanelView Plus and Windows desktop solutions, and consists of:
 FactoryTalk View Studio. Configuration software for developing and

testing HMI applications.
 FactoryTalk View ME Station. A traditional stand-alone HMI solution

that provides an integrated operator interface that runs the same HMI
application on PanelView Plus 7, PanelView Plus 6, Mobile View
terminal, Rockwell Automation Industrial Computers, or other
industrial PC.
 When you start FactoryTalk View Studio, you can open an existing application or
create a new one using the items from the File menu. Once you open an application,
the application appears in the Explorer window on the left side of the main window.
Item Name Description
Menu bar It contains the menu items for the active window. Each editor has its own set of
menus.
Toolbar It contains commonly used menu items providing quick access to the items without
opening the menu. All editors use the Standard toolbar. The Graphic Displays, Graphic
Libraries, Runtime Security, and Tags editors have additional toolbars.
Explorer window It includes the Application tab and the Communications tab.
Toolbox It is a searchable toolbox containing all project elements. Right-click in the toolbox to
add frequently used objects to Common Objects or to show the objects in a list view.
Object Explorer and Property Panel It includes Object Explorer and Property Panel. Object Explorer provides a list of all the
objects on the current graphic display. Property Panel provides the functions to
configure graphic objects. You can group or ungroup Object Explorer and Property
Panel.
Title bar It shows the program name.
Diagnostics list It shows messages about system activities. You can specify the types of messages to
show in the Diagnostics List, move the list, resize it, and clear the messages in it.
Status bar It shows information about the active window, the selected tool or menu item, or the
selected graphic object, such as its size and position.
Workbook tabs If you select Workbook Mode from the View menu, the workspace shows tabs on the
top of each open editor or component.
Workspace It is the blank area of the FactoryTalk View Studio window. You can drag icons from the
Explorer window to the workspace to open editors and components.
4.6 FactoryTalk® View ME Window size & runtime screen resolution
 This section describes the difference between project window size and runtime screen resolution
and describes how these two settings can affect the behavior of your application at runtime
 The project window size is the amount of room your application occupies on the runtime
terminal or computer screen, in pixels
 The runtime screen resolution is the actual size of the runtime terminal or computer screen, in pixels.
Therefore, the project window size must be less than or equal to the runtime screen resolution
 In the following example, the screen resolution is 1024 x 728, and the project window size is 800 x 600
 Usually, an application is designed to completely fill the runtime terminal or computer screen. If
you want your application to do this, set the project window size to the resolution of the screen in
pixels. For information on setting the project window size, see Specify project settings
4.7 FactoryTalk® View SE Overview
 FactoryTalk View Site Edition (SE) is an integrated software package for developing and running human-
machine interface (HMI) applications that can involve multiple users and servers, distributed over a network
 In FactoryTalk View Studio, you can create network distributed, network station, or local station
applications that mirror your plant or process
 Use the editors in FactoryTalk View Studio to create and test the application components you
need. Then set up the FactoryTalk View SE clients to let operators interact with the
application after it is deployed
 FactoryTalk View Site Edition provides all the tools you need to create powerful, dependable
process monitoring and supervisory control applications
 FactoryTalk Services Platform provides a set of common services (such as diagnostic

messages, health monitoring services, and access to real-time data) for all the FactoryTalk
products and applications used in a control system.
 Using the FactoryTalk Services Platform, FactoryTalk products can share and gain
simultaneous access to resources such as tags and graphic displays that you only need to define
once in the system
4.8 FactoryTalk® View SE Features
 FactoryTalk View SE provides the flexibility and features you need to create powerful
automation systems for your plant or process. For example, you can:
• Create local station applications for parts of the plant or process that are self-
contained and are not related to other parts of the process.
• Create complex applications that mirror the layout of a plant or process. A
FactoryTalk View SE network distributed application can contain several servers
running on multiple computers, connected over a network. Multiple client users
can connect simultaneously to a network distributed application.
• Open and modify network applications remotely using FactoryTalk View Studio.
• Use the health monitoring and redundancy features built into FactoryTalk and
FactoryTalk View SE to support system availability at runtime.
• Use FactoryTalk Security services to centralize the authentication and

authorization of system users at the FactoryTalk Directory.
 Modify HMI tags at runtime, and have changes take effect at connected clients,
without restarting the clients. In a redundant network distributed application,
changes made at the active HMI server can be replicated to the standby server.
 Create a complete alarm monitoring system with FactoryTalk Alarms and

Events. Using FactoryTalk Alarms and Events services, FactoryTalk View SE
applications can subscribe to and display device-based alarms, programmed
directly into Studio 5000® controllers.
 Customize alarm summaries and banners to provide specific alarm data, rather
than displaying alarms for the entire system.
 Create global objects in global object displays, and use copies of these objects
throughout an application. When you modify the original object, all linked
copies are also updated.
 Dock selected displays to an edge of the FactoryTalk View SE Client window so
they can be viewed in a fixed position, at all times.
 Use the FactoryTalk View SE Client Object Model, VBA, and PowerShell scripts to
extend the capabilities of FactoryTalk View SE, and to share and interoperate with
Windows programs such as Microsoft SQL Server and Microsoft Excel.
 Create trends that show process variables plotted against time. FactoryTalk View SE
trends can display real-time or historical data, with up to 100 pens (tags) in each
trend.
 Log data simultaneously to the FactoryTalk Diagnostics log and to remote ODBC
(Open Database Connectivity) databases to provide various records of production
data.
5. KEPWARE
 This software-based server is designed for accurate communications, quick setup, and
unmatched interSTXoperability between client applications, industrial devices, and systems.
The server provides a wide range of plug-ins and device drivers and components that suit most
communication needs
 The plug-in design and single user interface provides consistent access from standards-
based applications and non-standardsSTXbased applications with native interfaces.
5.1 Components
 The server implements client / server architecture. The components include Configuration,
Runtime, Administration, and Event Log
 Configuration
The Configuration is the client-user interface that is used to modify the

runtime project. The Configuration can be launched by multiple users and supports remote
Runtime configuration.
 CSV Import and Export
This server supports the import and export of tag data in a Comma
Separated Variable (CSV) file. When using CSV import and export, tags are created quickly in
the desired application.
 Runtime
The Runtime is the server component that starts as a service by default.

Clients can connect to the runtime remotely or locally
 Administration
The Administration is used to view and/or modify settings and launch

applications that pertain to user management and the server.By default, the Administration
is started and sent to the System Tray when a user account logs onto the operating system.
 Project
The Project file contains the channel, device, and tag definitions as well
as preferences and other saved settings.
 Event Log
The Event Log service collects information, warning, error, and security
events. These events are sent to the Configuration's Event Log window for viewing.
5.2 Interfaces and Connectivity
 This communications server simultaneously supports the client / server

technologies listed below
Server - a software application designed to bridge the communication between a

device, controller, or data source with a client application. Servers can only respond to
requests made by a client.
Client - a software program that is used to contact and obtain data from a server
(either on the same computer or on another computer). A client makes a request and the
server fulfills the request. An example of a client would be an e-mail program connecting
to a mail server or an Internet browser client connecting to a web server
Human Machine Interface (HMI) - a software application (typically a
Graphical User Interface or GUI) that presents information to the operator about
the state of a process and to accept and implement the operator control
instructions. It may also interpret the plant information and guide the interaction
of the operator with the system.
Man Machine Interface (MMI) - a software application (typically a

Graphical User Interface or GUI) that presents information to the operator about
the state of a process and to accept and implement the operator control
instructions. It may also interpret the plant information and guide the interaction
of the operator with the system.
6. IGNITION
6.1 IIoT Basics
 Along with Internet Cloud computing and other advancements with the Internet,
we are now in the middle of the next industrial revolution mining and turning data
into information.
 This period of evolution is called Industry 4.0 or the Fourth Industrial Revolution
which includes Industrial Internet of Things (IIoT) and Digital Transformation
mechanisms that facilitate this evolved 4th generation period of Automation.
 The industrial Internet of Things (IIoT) connects your people, products, and
processes to power digital transformation. Using industrial IoT platforms,
companies connect, monitor, analyze, and act on data in new ways
 Difference between IIoT & IOT
The Industrial Internet of Things is a subcategory of the Internet of Things, which also
includes consumer-facing applications such as wearable devices, smart home technology and self-
driving cars. Sensor-embedded devices, machines and infrastructure that transmit data via the
Internet and are managed by software are the hallmark of both concepts.
6.2 Introduction to Ignition
 Ignition SCADA by Inductive Automation® combines an unlimited licensing model, with
instant web-based deployment, and the industry-leading toolset for supervisory control and
data acquisition (SCADA) — all on one open and scalable universal platform
 Ignition is The New SCADA because it solves all the major pain points of old SCADA.
Ignition empowers your business to easily control your processes, and track, display, and
analyze all your data, without limits. Ignition is designed from the ground up to be
approachable and easy to get started with while it is flexible and capable of scaling up to
the largest projects
 Ignition is unlimited, so for the low cost of one server license you can seamlessly
connect all your data, design any kind of industrial application with ease, and instantly
web-deploy unlimited clients to anyone, anywhere — all from one universal platform
for industrial automation
Web-
Simple launched
Licensing Designer
and Clients
Server Cross
Based Platform
Working With Ignition
Ignition is simple to set up and use, unlike anything else you've encountered in the
HMI/SCADA world before. Getting installed and running is easy, and once you have your
project set up it's extremely simple to start using. After installation, setting up and using a
project follows this simple set of steps:
Launch the Gateway Webpage
 The Gateway Webpage is where all of your information is stored, and where all of
the general configuration happens
 Here you can set up your Device connections, your Database Connections,
alter your security, make backups, and set up redundancy
Launch the Designer
 Once your connections are in place, you can start using them to create a project.
Opening a Designer is as simple as clicking a link in the Gateway
 No installation is necessary, and you can even launch the Designer from any other
computer on the network. Add Tags, query databases, show status, history trends, and
alarms in your project.
Save your project
 When you save, Ignition is sending all your data and all your changes back to the Gateway. Everything
is centrally stored in the Gateway so you never have to worry about managing several versions or trying
to combine many changes into one.
 You can even launch many Designers concurrently to allow multiple people to work on the same project
at the same time. Projects aren't limited in scope, and you can create anything you can think of. HMI,
SCADA, Reporting, Historian, and Alarming
Launch Clients
 Launch one Client or 20! Clients launch the same way as the Designer: simply click a link in the Gateway,
no install is necessary. All of your clients talk directly to the Gateway to get new information on the fly, so
there's no need to worry about them ever getting out of sync or loading changes individually to Clients.
 Ignition's modular platform can support requirements of any type by selecting the modules for your needs
and building processes suited for your business. Just create your project, it's all managed in one central
platform and can be launched anywhere you want.
6.3 Ignition Advantages
• Ignition is cross-platform, including every version of Windows.
• Runs well on server-class, desktop, laptop, and embedded hardware such as

Raspberry Pi.
• Designers and runtime versions are always in sync.
• Ignition server installs in under 3 minutes. Runtime clients deploy in seconds.
• Hot-pluggable modules allow you to add functionality without shutting down

your system.
• Unlimited designer clients allow multiple developers to work on any projects at

the same time.
• Simple, fast, 24/7/365 activation. Transferring licensing is a snap

• Ignition comes with unlimited tags and clients
6.4 Ignition Platform Installation
 The installation process for Ignition is designed to be as simple as possible. You can
find installers on our Downloads page:
https://inductiveautomation.com/downloads/ignition/
 You'll find both ZIP files, as well as dedicated graphical Installers (called just "installer") for
all major operating systems. Both options install Ignition, but the installers are generally
easier to use. Download an installer, and head to the next steps below
1. Download an installer from above Mentioned Link.
2. Run the installer and follow the steps in the installation wizard.
3. After the installation wizard finishes, a web browser will open and start the
Commissioning process. At this point you'll need to select your edition
6.5 Ignition Gateway
 Gateway is the Heart of the Ignition System.The Ignition Gateway is the primary software
service that drives everything in Ignition. It is a single application that runs as a web server and
accessed through a web browser. It connects to data and PLCs, executes modules, and
communicates with clients
 You can customize the Homepage to fit your needs using the Gateway Settings. From the
Gateway, you activate Ignition, transfer licenses, backup and restore the Ignition Gateway,
and setup redundancy. You can even set up a Gateway Network that allows two or more
Gateways to connect to one another and share data
 Launching a Gateway
The Gateway is accessed through a web browser. The web browser,

running on any machine, must have network access to the host that is running
the Gateway.
 By default, Ignition installs by using the 8088 port. For example, if the host's IP address is
10.0.28.30, you access the Gateway via the URL: http://10.0.28.30:8088. When Ignition is
installed on the computer that you are logged into, you can access it by typing
http://localhost:8088 to display the Gateway Homepage
 Any other computer on the same network can access the Gateway by using the IP Address or
Host Name of the computer where Ignition is installed: i.e., http://192.#.#.#:8088, and it will
launch the Gateway and bring up the Gateway Homepage.
 Starting and Stopping the Gateway

After installation, the Gateway starts automatically.The Gateway runs as a
service, so you can use your operating system's normal mechanisms to start or stop the
service.You can also start or stop the Gateway using the Gateway Command-line Utility.
 Gateway Webpage
 The Gateway Webpage performs a cadre of functions and is the hub for accessing all
the functions of the Gateway server. It drives everything in Ignition! The Gateway
Webpage is where you setup your licensing and activation, configure your Gateway
settings, databases, devices, projects, modules, security, and alarming
 When the Gateway server is running, you can connect to a device, connect to a database,
launch the Designer, and launch a Vision client or Perspective session. You can also
check the status of your system, network, agents, sessions, tasks, reports, and alarms
 The Gateway Webpage has three tabs on the left side of the page that lead you to the
key sections of the server: Home, Status, and Config. The top of the page shows you
the path of where you are on the Gateway Webpage.
 You can perform a host of Gateway functions from configuring your system and
modules, checking the status of all your Gateway connections, to launching clients
and sessions, and many tasks in between.You can even redirect the Gateway
Homepage to display another URL.
 When you're first introduced to Ignition, the Homepage is the landing page. It's where you'll
find the Designer Launcher, Vision Client Launcher, and Perspective Session Launcher
 The Designer Launcher locates all Gateways that are available on your local network. Once you
open the Designer, you can access existing projects or create new projects on the Gateway
 The Vision Client Launcher opens Vision Clients from any Ignition Gateway. It browses all
Gateways for Vision projects that are available on your local network and remote locations. Once
your Vision projects are added to the Vision Client Launcher, they will be displayed and all you
have to do is click the link to launch a Vision Client
 The Perspective Sessions Launcher opens a session directly in your browser or you can download
the native application
 Ignition Status
 The Status page provides in-depth information about the status of the different
parts of the Ignition system. The list of options on the left menu in the Status
page changes based on what modules are installed. You can select any of the
available options to get more detailed information.
 Ignition Config
 If you are not already logged into your Gateway, Config tab presents you with a
login screen. Enter the username and password for the Ignition administrator. This
was the first account created during installation
 From the Config page, you can setup all connections, projects, and perform
all the Gateway and platform operations. The list of options on the left menu
changes based on what modules are installed
 You can select any of the available options to get more detailed information.
This page also provides some links to common actions to help get you get
started
 Ignition Architecture
 Ignition is flexible enough to meet the demands of any enterprise infrastructure large, small, or
somewhere in-between. You can deploy Ignition at one site, multiple sites, or host it in the Cloud
 This section displays several common architecture examples. Many are simply examples, but they
are a great starting point. Additionally, these example architectures can be modified or scaled out to
accommodate a number of different requirements
Types of Architecture
 Standard Architecture
 Scale Out Architecture
 Hub and Spoke Architecture
 Edge Architecture
 IIoT Architecture
 Enterprise Architecture
 Redundancy Architecture
 Cloud Based Architecture
 Standard Architecture
 Ignition's most basic architecture is a standard single installation. This is very simple to
set up and it provides the powerful functionality of the Ignition Gateway and it can
serve as a starting point for more complicated architectures
 The Standard Architecture consists of a single Gateway that can connect to

multiple PLCs, databases, and other devices, all with a single licensed install. With
the Ignition licensing system, it's easy to add new devices, databases, and clients
 Simply connect them to the Ignition Gateway, no licensing changes required. The
Ignition Gateway can launch multiple clients on everything from touch panels to
workstations and even mobile devices, all from one Ignition installation
 Scale out Architecture
 In larger systems, it is often easier to have multiple Ignition installations to help split the
load between the front-end tasks and the back-end tasks. This is perfect for single large
systems that aren't split up into different sites. In those cases, the Hub and Spoke
Architecture is usually a better fit
 In the Scale Out Architecture, we have at least one Gateway that handles back-end
communications. The back-end Gateway deals with all PLC and device communications
 The front-end Gateway handles all of the Clients, serving up the data pulled from the
back-end Gateway. This is made possible through the Gateway Network, connecting
Gateways to each other, and allowing Tags to be shared through remote Tag providers
HUE University, Vietnam -- Student User Manual

HUE University, Vietnam -- Student User Manual Property of i4TECH Pte Ltd Property of i4TECH Pte Ltd 70
 Hub and Spoke Architecture
 The Hub and Spoke Architecture involves multiple Ignition installations (the Spokes)
communicating and forwarding data points to a centralized Ignition installation (the Hub). The
Hub and Spoke Architecture is unique in that you start with a single Ignition install at a central site
 Ignition can then be installed at as many other remote or local sites as needed. These sites
can then be customized or configured to suit that specific site's needs.
 Ignition IIoT Architecture
 Ignition can collect data from any devices at the edge of the network, publish that data to a
central broker, and push that data to subscribed industrial and line-of-business applications
 Ignition IIoT can connect to PLCs in the field through the use of the MQTT Transmission
module, field devices with Ignition Edge MQTT installed, and/or MQTT-enabled edge
gateways and field devices that use the Cirrus Link Sparkplug MQTT specification.
 This data is published to an MQTT broker, this broker can be located on-premise, in the
cloud, or a hybrid of the two. The MQTT Engine module located on an Ignition
Gateway can subscribe to any data published from the broker. This data can be used in
any Ignition application
 IIoT architecture typically involves the use of the MQTT protocol to communicate with a large number of devices.
MQTT is a lightweight and secure protocol that makes use of a unique publish/subscribe transportation method.
Additional information on the MQTT protocol and modules can be found in the Cirrus Link documentation
 The Standard Architecture can easily be expanded with the MQTT modules to collect data from
numerous Edge of Network devices. Data collected by the MQTT Engine can be historized and
presented in a client with the Vision module, or via reports with the Reporting module.
 Enterprise Architecture
 Many types of architecture involve multiple Ignition servers. Eventually, some assistance
overseeing each server can be helpful. Enterprise Architecture typically involves having a
mechanism to monitor and manage multiple Ignition Gateways. This involves utilizing the
Enterprise Administration Module (EAM)
 EAM specifies one Gateway as the Controller, and the others as Agents. Connections between
these Gateways take advantage of the Gateway Network, which is a secure method multiple
Gateways can use to share information
Why Use Enterprise Architecture
System Management
 Monitoring the health of several systems can be time consuming. EAM streamlines system
management by having each Gateway report to a single Controller Gateway. This
Controller can then generate alarms when problems occur, or assist in recovering from a
hardware failure
 Agent events can be stored in a SQL database, and easily incorporated into an Ignition
Report. The best part is that the EAM can easily be incorporated into any architecture
where multiple Gateways are present
Project Synchronization
 When multiple Gateways are used to launch clients, such as in the Hub and Spoke
Architecture, standardizing the look and feel of projects across both Gateways is
important for a consistent organization
 With EAM, the Controller can synchronize resources across multiple Agents, allowing
development to occur on one Gateway, and updates pushed out to other Agent automatically
 Redundancy Architecture
 Using Redundancy, two Ignition installations can be linked together, so if one server fails,
the other takes over and continues executing. All of the clients connected will be redirected
to the backup machine, and historical data will continue to be logged
 The transition is seamless, meaning processes will never be prevented from executing due
to one server going down.
 Any single installation in the System Architectures can be replaced with a redundant pair
of Ignition Gateways. If you have a dedicated backup computer, Inductive Automation
offers a cheaper Backup-specific license.
Redundancy and Ignition in the Cloud
 When Ignition is hosted on in the cloud, we do not recommend using Ignition's built-in
redundancy: most cloud providers offer built-in redundancy, meaning a new instance is
created in the event the original fails. As a result, you should not consider purchasing a
backup server for any primary servers that are in the cloud
 Cloud Based Architecture
Hosted Ignition Server:
 Ignition server can be hosted in the Cloud. Inductive Automation does not provide cloud
services, but there are many great providers out there, such as Amazon EC2, or Windows Azure
 The server can connect to the PLCs at the remote or customer sites via Round Robin Poll, Cell
Tower, Satellite, or Secure VPN. The clients are connected to the Ignition server via Internet
Architecture Example:
 In this example, we see the Standard Architecture, but with the Ignition Server and Database
both running on cloud servers. Note, that the Database and Ignition are on different cloud servers
 This is because cloud service providers generally have specialized services that are
designed explicitly for hosting SQL databases, as well as more general-purpose services
such as running Ignition
 This type of architecture is ideal in smaller organizations since you don't have to worry about
maintaining a server. Additionally, there is no on-site IT staff required to monitor the system
 If Ignition is hosted in the cloud, then it is very common to have your database also hosted in the
cloud. However, many of our customers find that also having a controls database on-site to store
temporary or in-progress data useful. This is great when you want to have data stored locally
Cloud Service Suggestions-Amazon Web Services, Microsoft Azure
6.6 How to connect Allen-Bradley ControlLogix Device PLC with Ignition
1. Go to the Config section of the Gateway Webpage.
2. Scroll down and select OPC UA > Device Connections.
3. On the Devices page, find the blue arrow and click on Create new Device.
4. Select Legacy Allen-Bradley ControlLogix, and click Next.
5. On the Devices page, leave all the default values and type in the following fields:
Name: CLX
Hostname: Enter the IP address for the PLC, for example 10.20.4.50.
6. Click Create New Device.
The Devices page is displayed showing the ControlLogix device is added to Ignition.
The Status will show as Disconnected and then Connected.
7. To see all the Tags, go to OPC Client > Quick Client in the Config section.
On the OPC Quick Client page, expand the ControlLogix folder and in the Global folder
you can see all the tags.
--- End ---

Hue Industrial 4.0 Kit - User Manual - V - 3.0

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hue Industrial 4.0 Kit - User Manual - V - 3.0

Uploaded by

Copyright:

Available Formats

HUE University

“Industrial 4.0 User Manual”

Author : Martine Rose Devaraj

 WELCOME STATEMENT i4TECH PTE LTD

 SCADA & HMI

 i4TECH Pte Ltd is a Systems Integration company providing professional expertise in

 i4TECH has the objective to facilitate the digitalization journey to manufacturing

 Our breadth of experience covers domain knowledge in CPG, Pharma, Automotive,

 The MES collects data about product genealogy, performance, traceability,

• ME software will prepare product simulation, formula, or volume

Step 3. Production Planning

• It will create jobs and product workflows automatically

Step 4. Machine Connectivity & Scheduling

• Manufacturing execution IT systems recommends job assignments to available machines and

• Manufacturing execution systems will conduct quality checks taking samples as

• MES helps to recommend changes in product routes based on input from

Step 6. Automatic Delivery

• Capture the digital thread and enable repeatability of end-use parts

Step 8. Analytics and Reports

2. Resource Allocation and Status

 Manufacturing organizations can handle the allocation and status of resources

 Dispatch function is focused on enterprise resource planning (ERP) global guidance

 To minimize downtime and production output interruptions, preventive system

 One of the important functions of the manufacturing execution process is to manage

11. Document Control

 Manufacturing execution systems also provide the operators with a quick

 Any system which is capable of handling data collection and plant

 Plant floor functions includes maintenance, quality, compliance, HACCP,

 MES is also one of the plant floor systems

2.1 Business planning and logistics

 The first Programmable Logic Controllers were designed and developed by

3.3 What is inside a PLC?

If Speed1 > 100.0 then

 Sequential Function Chart (SFC) A method of programming complex control systems at

3 Logix Designer Develop control logic for an industrial automation system.

4.3 What are SCADA Systems?

4.4 Where can I get a SCADA system from?

 If your equipment has an Allen-Bradley ControlLogix® programmable

 As an integral element of the Rockwell Automation visualization solution, FactoryTalk

 FactoryTalk View Studio. Configuration software for developing and

 FactoryTalk View ME Station. A traditional stand-alone HMI solution

 FactoryTalk Services Platform provides a set of common services (such as diagnostic

• Use FactoryTalk Security services to centralize the authentication and

 Create a complete alarm monitoring system with FactoryTalk Alarms and

The Configuration is the client-user interface that is used to modify the

 CSV Import and Export

The Runtime is the server component that starts as a service by default.

The Administration is used to view and/or modify settings and launch

 This communications server simultaneously supports the client / server

Server - a software application designed to bridge the communication between a

Man Machine Interface (MMI) - a software application (typically a

6.1 IIoT Basics

Working With Ignition

• Ignition is cross-platform, including every version of Windows.

• Runs well on server-class, desktop, laptop, and embedded hardware such as

• Designers and runtime versions are always in sync.

• Ignition server installs in under 3 minutes. Runtime clients deploy in seconds.

• Hot-pluggable modules allow you to add functionality without shutting down

• Unlimited designer clients allow multiple developers to work on any projects at

• Simple, fast, 24/7/365 activation. Transferring licensing is a snap

The Gateway is accessed through a web browser. The web browser,

 Starting and Stopping the Gateway