Software Toolbox Technical Blog

Your organization has a custom developed application that performs important tasks, and you need to provide access to that software from an HMI, SCADA, Historian, MES, or other system acting as an OPC UA Client. Adding an OPC UA server interface to a custom application that either you've developed or that you've taken over from someone else can be a daunting task. This is especially true if you're unfamiliar with the low-level details of the OPC UA specification.

Accelerate OPC UA Server Development with the OPC Wizard Toolkit

The OPC Wizard UA Server Development Toolkit addresses this reality head-on by providing a rapid development framework that handles the underlying OPC UA nuts and bolts for you. In a recent webinar we covered how to add an OPC UA Server interface to a custom .NET software application using OPC Wizard, without having to become an “OPC wizard” yourself.

Rather than spending hours on end diving into the specifications and debugging protocol details, you can utilize simple read, write, and subscribe methods, resulting in less engineering time and faster ROI.

While Halloween and this time of year offers a few good scares, our customers in manufacturing face year-round nightmares that are far less fun: connectivity issues that stop production and unreliable data collection that restricts their ability to make informed decisions.

When your SCADA system can't communicate with your PLCs, your MES is missing critical data, and your operators are working without visibility into what's actually happening on the production floor, you're dealing with the kind of problems that lead to unplanned downtime, missed targets, and lost productivity.

In this post, we'll run through how our TOP Server handles common connectivity challenges, cover some practical tips for getting the most out of your setup, and show you how using remote configuration tools can simplify management across multiple servers, which all enable you to focus on production instead of troubleshooting communication nightmares.

Industrial data is most valuable when it can be seen, understood, and acted upon. OPC UA has long been a widely adopted standard for securely exchanging data in industrial automation, but many users still face challenges: quickly visualizing live values without heavy software, sharing those values with non-technical stakeholders, and reducing setup complexity. 

That’s why we’re excited to announce a new feature in DataCaster: direct OPC UA connectivity. So excited that we made a video about it that you can watch further down this blog in which I will show you how easy this new feature is to implement.With this enhancement, DataCaster can now connect to your OPC UA servers, browse and select tags, and stream live data values into simple displays where they matter most: bridging the gap between raw data and real-time decision-making with just a few clicks.

OmniServer is a universal data acquisition application designed to bi-directionally exchange data with a wide range of Ethernet, serial, or USB devices that use “non-standard protocols” such as weigh scales, barcode readers, lab instruments, inspection machines, printers, and more.

The wide range of connectivity options enable OmniServer to send that data to HMI, SCADA, MES, or Historian systems using standard interfaces like OPC DA, OPC UA, and AVEVA SuiteLink. It also has an optional MQTT Client Plug-In that allows users to publish data to MQTT Brokers.

Since 2016, LGH File Inspector has been the trusted tool for AVEVA™ InTouch HMI users who need quick, reliable access to their historical data. Whether it’s pulling files from network drives, automating queries with batch files, or setting up scheduled reports, the Software Toolbox team has helped users integrate LGH File Inspector into a wide range of solutions.

In this post, I have collected and summarized tools and learning material to ease your experience in applying LGH File Inspector and help you get started quickly. Towards the end you will find the highlights of the webinar I hosted covering the new features of LGH File Inspector Version 4, that addressed several issues users previously faced.

Downtime is expensive — sometimes costing thousands of dollars every minute, a line sits idle. Traditional maintenance approaches often fall into one of two traps: reacting after something breaks or replacing parts on a set schedule whether they need it or not. Predictive maintenance takes a smarter route. By combining real-time data from your equipment with machine learning, it can spot problems before they cause an outage. With OPC Router, you can efficiently route PLC and sensor data into predictive models with minimal complexity.

As technical consultants at Software Toolbox, we are often approached by users who need to expose data from a software application they have written, or are writing, to communicate from systems they own to a client, HMI/SCADA, or historian. And, in many cases, there are dozens of applications at different sites that the data needs to reach. The question we are then presented with is, “how can I accomplish this quickly and efficiently while staying within budget?” 

Our hope is to answer this question and share from our experience with OPC since 1996, what our users have told us are the common reasons why they chose to use a commercial OPC server toolkit, and to help readers determine what factors to consider for their specific situation and circumstances.

In a previous blog post, we covered the basics of commercial OPC client development toolkits, with a dive into the benefits of using one, while here in part 2, our focus is on OPC server development toolkits. If you read our blog on OPC client toolkits, you will likely notice a clear overlap in the benefits you gain from using both types of commercial OPC toolkits.

When your industrial operations depend on continuous OPC UA client-server communication, even short disruptions can ripple into major consequences. OPC UA session timeouts act as a built-in heartbeat, ensuring clients and servers know if communication has stalled so resources aren’t wasted on dead connections.

But here’s the catch: poorly tuned OPC UA timeouts can trigger needless disconnects, looping reconnections, or hide real failures that delay recovery. In critical industrial automation environments, a few minutes of uncertainty can mean lost production, safety risks, or compliance issues.

In this blog, we’ll show you why OPC UA timeouts are worth your attention, and how the right practices and tools can save you from downtime, data gaps, and unnecessary headaches.