A global beverage manufacturer sought to modernize its data workflows by integrating operational technology (OT) with enterprise systems. Specifically, they needed to transfer real-time data from their Rockwell Automation PLCs to their SAP system to automate workflows, enhance traceability, and streamline processes. The legacy setup relied on outdated communication methods, introducing inefficiencies and potential failure points. To overcome these challenges, the company required a robust, scalable, and future-ready solution.
This blog will give you an insight into how that solution became a reality and how they got there. Also, if you have not done so, please subscribe to our blogs to not miss out on similar topics.
Challenges in Data Integration for Manufacturing Systems
Existing System Complexities
The company’s existing infrastructure relied on communication methods that were prone to inefficiencies. The systems struggled to meet the increasing demands of real-time data transfer and lacked the flexibility needed to scale with the company’s growth. Upgrading to a more modern solution required overcoming the limitations of these systems while maintaining operational continuity.
Real-Time Data Transfer
Ensuring the seamless transfer of data in real time from Allen Bradley ControlLogix PLCs to the SAP system was a critical challenge. The existing solution architecture was slow, unreliable, and prone to data loss or delays, affecting critical business decisions. Achieving a reliable, secure, and scalable data flow between the plant floor and enterprise systems was necessary to maintain operational efficiency and improve decision-making processes.
Trigger Logic Optimization
The existing trigger logic, which was responsible for initiating the data transfer from the PLCs to SAP, needed fine-tuning to prevent redundant data processing. Without optimization, the triggers could potentially activate too frequently, leading to excessive data transfers and increased processing overhead. Ensuring that the triggers fired only when needed, without redundancy, was essential to streamline the system and avoid unnecessary strain on resources.
The Solution: Connecting Rockwell Automation PLCs with SAP
The Software Toolbox team proposed a solution leveraging TOP Server and OPC Router. This approach ensured reliable device connectivity, secure real-time data transfer, and customized workflows tailored to the customer’s operational needs.
- Device Connectivity: TOP Server’s Allen-Bradley Suite of OPC drivers was used to establish seamless and efficient communication with Rockwell Automation PLCs, eliminating legacy dependencies and ensuring a stable connection.
- Data Transfer: Data was transferred from TOP Server to OPC Router via OPC UA, a secure, platform-independent communication protocol. This ensured reliable and scalable data flow.
- Trigger-Based Integration: OPC Router employed bit triggers to monitor Boolean tags in the PLCs. These triggers ensured data was sent to SAP only when specific conditions, such as a print request, were met.
- Data Formatting: OPC Router transformed the collected data into a format compatible with SAP, eliminating the need for additional middleware and streamlining the integration process.
Figure 1 - Integrating Rockwell Automation PLCs with SAP involves using OPC Router and TOP Server to ensure secure data transfer and eliminate legacy system inefficiencies.
Overcoming Implementation Challenges
During implementation there was an issue with the trigger logic. Initially the trigger activated repeatedly during each 500-millisecond scan, rather than firing once per rising edge transition. This posed a risk of redundant data transfers and increased processing overheads. The support team investigated the issue and used OPC Router’s 'Waiting for falling edge' bit trigger setting to ensure the trigger activates only once when transitioning from low to high. This ensured that the trigger fired only once per rising edge transition, aligning with the desired one-shot logic. The adjustment eliminated redundant processing and optimized the data transfer process.
Results and Benefits of Real-Time Data Integration
Seamless Data Flow
The integration between Rockwell Automation PLCs and SAP was successfully implemented, ensuring smooth, uninterrupted data flow. With secure, real-time data transfer now fully operational, the system effectively captures and transmits print requests from the plant floor to SAP without delays or data loss. This streamlined data flow has improved overall productivity by reducing bottlenecks and manual interventions, ensuring more accurate and timely decision-making.
Customized Triggers
The team was able to visually configure highly customized trigger logic within OPC Router without writing any scripting or code, ensuring that data was sent to SAP only when specific conditions were met, such as a print request. By fine-tuning the trigger settings, the company achieved precise workflows tailored to operational needs, eliminating inefficiencies and reducing the risk of errors. This optimization resulted in a more efficient data transfer process, reducing unnecessary load on the system and improving accuracy.
Improved Efficiency
With optimized data transfer and trigger logic, the company saw a significant reduction in processing overheads. Redundant trigger activations were eliminated, leading to faster response times and less strain on both the PLCs and SAP system. The automation of workflows also freed up valuable resources, allowing the team to focus on higher-value tasks. The system now operates with greater speed and reliability, contributing to a noticeable improvement in overall operational efficiency.
Future Scalability
The implemented solution was designed with scalability in mind, ensuring that it can grow alongside the company’s future needs. The flexibility of the integration, with modern tools like OPC Router and TOP Server, means that the system can easily accommodate future enhancements, such as expanding the number of connected devices or adding new workflows. This future-proof architecture provides the company with confidence that their system will continue to evolve and support their operational goals for years to come.
Solve Complex Data Integration with OPC Router
This project demonstrated the power of combining TOP Server and OPC Router to address complex data integration challenges. By eliminating legacy communication dependencies and implementing customized trigger logic, the solution met the customer’s immediate operational needs while laying the groundwork for future scalability.
The global beverage manufacturer now benefits from streamlined workflows, enhanced traceability, and a future-proof integration between their OT and IT systems. This successful implementation underscores how innovative, flexible tools can modernize systems and deliver lasting value.
Contact Software Toolbox for a Consultation
Ready to optimize your data integration and streamline your operations? At Software Toolbox, we specialize in bridging the gap between operational technology and enterprise systems, creating tailored solutions that drive efficiency, scalability, and success. Contact us today to schedule a consultation and discover how we can help you modernize your processes and unlock the full potential of your systems.
For more insights, check out our OPC UA/DA to SAP Integration Video Tutorial or download our SAP-PLC-OT Production Integration Whitepaper to learn more about the powerful solutions we offer. Let’s take your business to the next level!
