Using Virtualization and XML to Maximize your HMI Investments
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Transcript of Using Virtualization and XML to Maximize your HMI Investments
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Using Virtualization and XMLto Maximize your HMI
Investments
Dallas West
Jim Craib
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Agenda
Introductions Is It Time To Upgrade or Prolong Life? Why, and How Much Will it Cost? Industry Changing Technologies What is Virtualization? Advantages of Virtualization? Case Study What Does the Future Hold? Conclusions Questions & Answers
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Introductions
Jim Craib President, Orion Automation and Controls
Engineering 25 Years of Automation and Controls
Experience 16 Years of PLC/HMI Experience 10 Years of Experience Managing Automation
Projects BBA Degree from Golden Gate University ISA Member since 1988
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Introductions
Dallas West BS. Biotechnology Hons. (1999) BS. Chemical Engineering (2001) Joined Genentech SSF Automation 2004 Current Role:
Cell Culture Automation Manager DCS & PLC Batch Operations
Currently Reading www.digg.com Globaleconomicanalysis.blogspot.com Blink by Malcolm Gladwell
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Is the Time Right?
Has the vendor released a major revision?Is the vendor planning to end support?Does the system often crash or have
performance issues?Can operations staff perform their jobs
effectively and efficiently?
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
What Will it Cost?
Engineering Design and Documentation $1,000 to $25,000
Screen and Database Conversion $0 to $5,000 per screen or database tag
Hardware (COTS PC or Industrial PC) $400 to $20,000
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
What Will it Cost?
Software (OS and Vendor HMI Package) $1,000 to $50,000
Commissioning and Qualification $0 to $5,000 per screen
Validation $5,000 to $100,000
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
How Long Will It Take?
Conceptual/Preliminary/Detailed Design 1 to 3 months
Development/Build/Testing 1 to 6 months
Deployment/Training 1 to 3 months
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Industry Changing Technology
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Napsters Impact on the Music Industry
Global music sales dropped from: $38 Billion in 1999 $32 Billion in 2003
Stan J. Liebowitz argues in a series of papers (2005, 2006) that file sharing had a significant negative impact on record sales.
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
So What?
Music Industryis to the
Automation Industry
is to the
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
What is Virtualization?
Virtualization provides a means to run multiple instances of varying operating systems simultaneously on the same computer.
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Types of Virtualization
Server VirtualizationDesktop VirtualizationPresentation VirtualizationApplication Virtualization
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
How does this relate to HMIs?
The story of Jimmy
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Slide from a 2008 Automation Vendor Conference
1987 – Product Life Cycle for an average HMI Console: 20 Years
2007 – Product Life Cycle for an average HMI Console: 5 - 7 Years
"Modern Technology has changed the Process Control Industry!"
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Case Study
WinView HMI
BATT
PROC
FORCE
COMM
A B
A B
AB PLC 5/80EControlling a
ChromatographySkid
Ethernet
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
System Highlights
Mature HMI No changes made in year prior to project
Existing HMI met all current user requirements
Problem HMI PC would crash unexpectedly HMI PC hardware was failing causing unplanned
downtime
Question How can we extend the useful life of the existing system
while minimizing our investment costs?
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Case Study Solution
Windows 95 Virtual Machine was created in a VMWare ACE Environment
HMI software was loaded and configured within the Virtual Machine. Virtual Machine package was installed on a new Corporate
Standard PC.
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Case Study Outcome
Total invested cost = $2,000 Virtualization Software: $80 Corporate IT issued desktop computer: $750 Engineering Time:
Rebuilding New Image: 2 hrs x $200 per hr HMI Application Configuration: 4 hrs x $200 per hr
Time to deploy preconfigured Virtual Machine: 15 minutes
Cost savings on a 5-7 year basis: Ranges from $38,000 to $123,000!
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Case Study Outcome
Based upon this success, other production systems were virtualized, including: Windows 95 Systems Windows NT Systems Windows 2003 Server Systems
Quote from Operations Staff “I never knew Windows 95 could run so fast!”
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Advantages for End Users
Increases the longevity of a HMI Application Decreases downtime in the event of a failed HMI
PC Breaks the dependency between HMI Software
and Hardware.
Bottom Line It’s easier to do than a full HMI Upgrade! It’s going to save you downtime and money!
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Attention all Vendors!!!
Who’s going to be the next Apple? Who’s going to be the first to sell a prepackaged
Virtual Machine? Think iTunes for Automation Software!
How many calls do your Call Centers get for Software Configuration issues? Potential Call Center call volume reduction
Competitive Advantage for whoever gets there first! My HMI will run indefinitely, Vendor Y’s is only good
for 5-7 years.
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Limitations
Not all I/O is easily virtualized Rockwell: DH+ connections Foxboro: Nodebus connections
Non x86 machines cannot currently be virtualized to run on a x86 machine. ie.) Sun SPARC Workstations cannot be virtualized to run on
Windows Machine.
Licensing Disclaimer Read your EULA to determine what impact virtualization might
have on any licensing agreements you have.
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
What’s Does the Future Hold?
Seamless Software Upgrades At some point your going to want to upgrade
Take advantage of new features Take advantage of increased support
How will you do it in the most cost effective means? XML & XSLT!
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
What the XML is XSLT?
XML - eXtensible Markup Language.• Provides an means to expose data within an application
file.• Once the data is visable we can do something to it!
XSLT - eXtensible Stylesheet Language Transformation• XML-based language used for
doing some sort of action to an XML document or file.
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
XSLT Translation Process
OutputData
OutputData
InputData
InputData
MagicBlackBox
XML Input XSLT
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
XSLT Translation Process
Microsoft WordManufacturing Formula
Microsoft WordManufacturing Formula
Microsoft ExcelInput
Microsoft ExcelInput
RSBatchRecipe Output
RSBatchRecipe Output
MagicBlackBox
XML Input XSLT
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Unlock the possibilities!!!
HMI Rev NewOutput
HMI Rev NewOutput
HMI Rev OldInput
HMI Rev OldInput
MagicBlackBox
XML Input XSLT
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Unlock the possibilities!!!
Vendor BCode
Vendor BCode
Vendor ACode
Vendor ACode
MagicBlackBox
XML Input XSLT
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Attention all Vendors!!!
Who’s going to be the first to offer XSLTs that… Transform design docs to code/HMI? Transform design docs to commissioning test
scripts? Transform a competitors code/HMI to yours? Validate your XSLT’s for the regulated
industries?
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Conclusion
When your ready to upgrade Explore how you can use XSLT translations to
make your next upgrade more cost effective!
Don’t be a victim of Microsoft! Use Virtualization to maximize your HMI
investments!
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Questions and Comments?
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
What is Virtualization?
"Virtualization is a framework or methodology of dividing the resources of a computer into multiple execution environments, by applying one or more concepts or technologies such as hardware and software partitioning, time-sharing, partial or complete machine simulation, emulation, quality of service, and many others."