What is OPC UA?

History of the OPC

Developed in the mid-1990s, the original OPC (OLE for Process Control) was a Microsoft-only COM/DCOM process exchange, now called “OPC Classic.” It was primarily designed for Windows-based systems and relied on Microsoft's COM/DCOM technology for inter-process communication. OPC Classic facilitated data exchange between industrial hardware devices and software applications.

However, applications across multiple industries called for platform-independent data exchange operation and the ability to write code to run on non-Windows operating systems. Additionally, the DCOM security built into OPC Classic had known vulnerabilities and limitations. OPC UA was designed and developed to address these issues. 

Where we are today

Released in 2006, OPC UA represents a significant advancement over OPC Classic. It is used in many applications, including factory automation, smart grids, building management, data acquisition, etc. Let’s take a closer look at the benefits of OPC UA and find out which applications and industry sectors are using it.

Key benefits of OPC UA

• Interoperable: With its unified and extensible framework, OPC UA allows different devices and systems to communicate with each other, regardless of the manufacturer or platform. Compatible protocols include TCP/IP (Transmission Control Protocol/Internet Protocol used for network and internet communication), UDP/IP (User Datagram Protocol for time-sensitive services like video), WebSockets (real-time server and client communications), AMQP (Advanced Message Queuing Protocol for client/broker communications), and MQTT (Message Queuing Telemetry Transport, for limited bandwidth messaging).

• Secure: OPC UA is highly secure due to its encryption, authentication, checksums, data access, and authorization capabilities. It also provides security key management, including passwords, X.509 certificates, and tokens.

• Scalable: OPC UA is highly scalable and runs on anything from small embedded devices to enterprise-level servers.

• Flexible: The OPC UA architecture is highly flexible, supporting complex data models and allowing for the integration of new information models.

• Reliable and fault-tolerant: OPC UA is designed to ensure maximum “up time” in performance-critical applications.

• Real-time: OPC UA supports real-time data exchange, which is critical in industrial automation processes and other time-dependent applications.

• IIoT and Industry 4.0 Compatible: Because it facilitates connecting machines and systems to cloud platforms and other enterprise-level applications, OPC UA is compatible with IIoT (Industrial Internet of Things) and Industry 4.0 initiatives. 

The main components of OPC UA

OPC UA is comprised of three main components:

1. An Information Model that defines the data structure, relationships, and metadata for the data being exchanged.

2. Services like read, write, and publisher/subscriber allow OPC UA clients to interact with the OPC UA server.

3. Protocols, including binary TCP and HTTP.

Popular OPC UA applications

Here are some of the best-known OPC UA applications:

OPC UA for SCADA systems

In factory automation, OPC UA is used for real-time data acquisition, monitoring, and control in SCADA (Supervisory Control and Data Acquisition) systems. SCADA is a multi-level system where level 0 encompasses field devices like sensors and valves, level 1 contains the I/O devices, level 2 embodies the supervisory computers, level 3 contains production and control computers, and level 4 is where production scheduling is done. It enables communication between sensors, controllers, and central monitoring systems.

OPC UA interconnects PLCs (Programmable Logic Controllers) from multiple manufacturers, ensuring interoperability and integration within the system.

OPC UA connects shop-floor equipment with MES (Manufacturing Execution Systems), allowing real-time data exchange for production monitoring, quality control, and performance analysis.

OPC UA in structural monitoring applications

Popular subsets of monitoring applications include SHM (structural health monitoring) and CM (condition monitoring). The OPC UA protocol is frequently used to transfer data from the sensors installed on the bridge into the database and SCADA systems.

​​Dewesoft DAQ devices and software can output data in various formats, including “live” OPC UA output, captured data files, cloud data services, and more.

OPC UA in machine condition monitoring applications

CM (condition monitoring), aka MCM (machine condition monitoring), is a common OPC UA data transfer application. It includes vibration monitoring for various machines' gearboxes, fans, motors, and pumps. OPC UA data is frequently used and integrated with SCADA systems and diagnostics systems to monitor machinery performance and condition.

OPC UA in automated buildings

OPC UA is used in HVAC systems, integrating heating, ventilation, and air conditioning systems. It’s ideal for promoting energy efficiency and managing climate control systems within automated buildings. It can also be used to manage buildings’ lighting, access control, and security systems.

OPC UA in the energy sector

OPC UA is used in smart grid applications to monitor and control electrical grids, enabling efficient energy distribution and consumption. It is also found in power generation and distribution applications and monitoring and controlling power plants, including renewable energy sources like wind and solar farms.

OPC UA in pharmaceuticals and chemical industries 

OPC UA supports the automation of pharmaceutical and chemical batch processing, ensuring consistency, quality, and compliance with regulatory standards. It is also used in LIMS (Laboratory Information Management Systems, facilitating data exchange between laboratory instruments and information management systems for improved data integrity and analysis.

OPC UA in the oil and gas industry

OPC UA Integrates various systems within oil and gas production facilities for process control, safety monitoring, and optimization. It’s also employed for real-time monitoring and control of pipelines, ensuring the safe and efficient transportation of oil and gas. 

OPC UA in the food and beverage industry

OPC UA facilitates communication between different machines and control systems on automated food production lines for increased efficiency and product quality. Real-time monitoring and control of quality parameters during production helps manufacturers to maintain quality standards and regulatory compliance.

OPC UA in the automotive industry

OPC UA facilitates communication between robots, conveyors, and control systems on automated automotive assembly lines. In addition to improving synchronized operations and productivity, integrating testing equipment and data management systems improves vehicle test and validation processes.

OPC UA for industrial internet of things (IIoT) applications

Using OPC UA to gather and analyze data from various sensors and equipment to perform predictive maintenance helps prevent equipment failures, reducing downtime and maintenance costs. OPC UA’s remote monitoring and control capabilities enable remote access to industrial systems for monitoring and control purposes, improving operational efficiency and response times.

OPC UA for smart agriculture

Precision Farming: OPC UA integrates sensors, irrigation systems, and farm management software in agricultural “smart farming” applications, optimizing resource use and improving crop yields.

OPC UA for robotics

OPC UA’s facilitation of communication among different robotic systems and control units promotes robot control and coordination. This improves coordinated operations in manufacturing and other robotized applications. 

OPC UA support on Dewesoft data acquisition devices

Dewesoft offers broad support for UPC UA standards on both hardware and software levels. It utilizes client and server implementations via two dedicated plugins:

1. OPC UA client: With this module, all DewesoftX data acquisition systems can connect to any OPC UA server to acquire, store, process, and visualize any OPC UA data coming into Dewesoft systems. Learn more.

2. OPC UA server: This module allows all Dewesoft data acquisition systems to stream measured data in real time via the OPC UA format. This way, third-party OPC UA clients can access Dewesoft measurement data.

The newer generation of DewesotX DAQ hardware, such as OBSIDIAN, SIRIUS XHS, and SIRIUS X, utilizes OPC UA as a native data format for all data transfers. These devices can stream out OPC UA data directly, making integrating data into third-party systems easy.

Furthermore, Dewsoft is one of the founding members of the openDAQ™, an open-source SDK for test and measurement. openDAQ™ is all about simplifying the test and measurement ecosystem. It enables users to discover, stream, and configure data effortlessly with an open-source toolbox for embracing standards. 

The openDAQ SDK configuration is based on OPC-UA technology, which utilizes Ethernet TCP/IP. openDAQ extends the OPC-UA object model specification by adding an additional definition for DAQ devices. This definition is currently not available as a companion specification but rather as a vendor model from openDAQ. OPC UA is also used as the default data streaming protocol in openDAQ.

OPC UA trends and future possibilities

5G technology is already enhancing the capabilities of OPC UA. With its high-speed, low-latency communication, 5G enables faster and more reliable data exchange, which is critical for time-sensitive industrial applications. As industries continue to embrace digital transformation, OPC UA will play a crucial role in enabling seamless and secure data exchange across diverse systems and devices. 

One transformative possibility would be the integration of AI (Artificial Intelligence) and ML (Machine Learning) with OPC UA. AI-driven analytics and related self-instructive technologies can process vast amounts of data generated by OPC UA systems, providing valuable insights and improving overall productivity. 

Another possible trend shaping the future of OPC UA is edge computing, which reduces latency and enhances real-time data exchange. Combining OPC UA with edge devices will enhance data handling and control at the edge of the network, supporting faster and more reliable operations.

As industries seek to connect a growing array of devices and systems, OPC UA’s open and standardized framework will facilitate interoperability, ensuring seamless communication across different platforms and manufacturers. In summary, the future of OPC UA is bright, with 5G, AI, ML, Edge computing, and increased interoperability driving it forward. OPC UA will continue to be a vital component in the advancement of industrial automation and digital transformation.

OPC UA represents a significant advancement over OPC Classic, offering cross-platform support, modern industrial communication protocols, enhanced security, better interoperability, scalability, and flexibility. These improvements make OPC UA a more robust and future-proof solution for industrial automation and other applications requiring reliable data exchange.