1 Scope

The OPC UA for Metal Forming specification contains various building blocks for metal forming that enable use cases to be addressed across different types of metal forming machines defined in different companion specifications. The aim of the specification is to be able to map metal forming machines and define all relevant process values for metal forming. The Metal Forming specification is an instance of the existing Machine Tools specification. The Machine Tools specification is extended by the Metal Forming specification, which allows the description of metal forming processes and machines.

2 Normative references

The following documents are referred to in the text in such a way that some or all of their content constitutes requirements of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments and errata) applies.

OPC 10000-1, OPC Unified Architecture - Part 1: Overview and Concepts

http://www.opcfoundation.org/documents/10000-1/

OPC 10000-2, OPC Unified Architecture - Part 2: Security Model

http://www.opcfoundation.org/documents/10000-2/

OPC 10000-3, OPC Unified Architecture - Part 3: Address Space Model

http://www.opcfoundation.org/documents/10000-3/

OPC 10000-4, OPC Unified Architecture - Part 4: Services

http://www.opcfoundation.org/documents/10000-4/

OPC 10000-5, OPC Unified Architecture - Part 5: Information Model

http://www.opcfoundation.org/documents/10000-5/

OPC 10000-6, OPC Unified Architecture - Part 6: Mappings

http://www.opcfoundation.org/documents/10000-6/

OPC 10000-7, OPC Unified Architecture - Part 7: Profiles

http://www.opcfoundation.org/documents/10000-7/

OPC 10000-8, OPC Unified Architecture - Part 8: Data Access

http://www.opcfoundation.org/documents/10000-8/

OPC 10000-9, OPC Unified Architecture - Part 9: Alarms and Conditions

http://www.opcfoundation.org/documents/10000-9/

OPC 10000-16, OPC Unified Architecture - Part 16: State Machines

http://www.opcfoundation.org/documents/10000-16/

OPC 10000-19, OPC Unified Architecture - Part 19: Dictionary References

http://www.opcfoundation.org/documents/10000-19/

OPC 10000-100, OPC Unified Architecture - Part 100: Devices

http://www.opcfoundation.org/documents/10000-100/

OPC 10000-200, OPC Unified Architecture - Part 200: Industrial Automation

http://www.opcfoundation.org/documents/10000-200/

OPC 30081, Process Automation Devices – PADIM

http://www.opcfoundation.org/documents/30081/

OPC 40001-1, OPC UA for Machinery - Part 1: Basic Building Blocks

http://www.opcfoundation.org/documents/40001-1/

OPC 40001-2, OPC UA for Machinery - Part 2: Machinery Process Values

http://www.opcfoundation.org/documents/40001-2/

OPC 40501-1, Machine Tools: Monitoring and Job Overview

http://www.opcfoundation.org/documents/40501-1/

3 Terms, definitions and conventions

3.1 Overview

It is assumed that basic concepts of OPC UA information modelling are understood in this specification. This specification will use these concepts to describe the Metal Forming Information Model. For the purposes of this document, the terms and definitions given in OPC 10000-1, OPC 10000-2, OPC 10000-3, OPC 10000-4, OPC 10000-5, OPC 10000-6, OPC 10000-7,OPC 10000-8, OPC 10000-16,OPC 10000-19,OPC 10000-100, OPC 10000-200, OPC 40001-1, OPC 40001-2, OPC 30081 and OPC 40501-1 as well as the following apply.

Note that OPC UA terms and terms defined in this specification are italicized in the specification.

3.2 OPC UA for Metal Forming terms

For the sake of clarity, the number of one workpiece will be referred to in the following. Nevertheless, it is also possible to produce a set of parts which consists of more than one workpiece.

3.2.1

dead centre

the point where the upper tool is during its movement:

either nearest/closest to the lower tool (generally, it corresponds to the end of the closing stroke), known as bottom dead centre (BDC);

or furthest from the lower tool (generally, it corresponds to the end of the opening stroke), known as top dead centre (TDC)

Note 1 to entry: Tool/punch is replaced by upper tool.

Note 2 to entry: Die is replaced by lower tool.

[SOURCE: ISO 16092-1:2017, 3.2.4]

3.2.2

job order

unit of scheduled work that is dispatched for execution (IEC 62264-3:2016(en))

Note: A job order is the concrete implementation of a set of information that a machine needs to execute a task. This information can be composed of one or more programs or recipes, or it can consist only of metadata and parameters (production-specific) or of all of these. Several job orders can be running at the same time.

[SOURCE: OPC 40001-3 v.1.0.0, 3.2.1]

3.2.3

run

completed execution or completed subset of the execution carried out according to the data provided with the job order. [SOURCE: OPC 40001-3 v.1.0.0, 3.2.2]

3.2.1 Untitled

EXAMPLE 2 The machine needs several cycles, e.g. five strokes on a spindle press, to complete the forming process on the machine for one workpiece – the run­ consists of five repetitive cycles (monitored process values of each cycle can be different).

3.2.4

tooling stage

3.2.2 Untitled

representation of a coherent local tooling unit within one machine

Note 1 to entry: A machine consists of at least one stage; a run through in succession with multiple stages in a machine is possible.

3.2.5

tool

combination of upper tool and lower tool

Note 1 to entry: Tool/punch is replaced by upper tool.

Note 2 to entry: Die is replaced by lower tool.

[SOURCE: ISO 16092-1:2017, 3.2.15]

3.2.6

function

operation of a machine or a part of a machine which is specific or required for the intended machine task

[SOURCE: ISO 16092-1:2017, 3.4.3]

3.2.7

cycle

complete movement of the slide and other devices of the machine used for production (e.g. cushions, workpiece ejectors) including feeding and removal of the material or workpiece

Note 1 to entry: Press is replaced by machine.

Note 2 to entry: A cycle is represented by characteristic positions.

EXAMPLE 1 For hydraulic or pneumatic machines or mechanical servo machines, along a programmed motion path from the initial start position back to the same position.

EXAMPLE 2 For mechanical machines with clutch, from the cycle start position [normally top dead center] through to bottom dead center back to the cycle stop position.

[SOURCE: ISO 16092-1:2017, 3.4.4]

3.3 Abbreviated terms

3.4 Conventions used in this document

3.4.1 Conventions for Node descriptions

3.4.1.1 Node definitions

Node definitions are specified using tables (see Table 2).

Attributes are defined by providing the Attribute name and a value, or a description of the value.

References are defined by providing the ReferenceType name, the BrowseName of the TargetNode and its NodeClass.

If the TargetNode is a component of the Node being defined in the table the Attributes of the composed Node are defined in the same row of the table.

The DataType is only specified for Variables; “[<number>]” indicates a single-dimensional array, for multi-dimensional arrays the expression is repeated for each dimension (e.g. [2][3] for a two-dimensional array). For all arrays the ArrayDimensions is set as identified by <number> values. If no <number> is set, the corresponding dimension is set to 0, indicating an unknown size. If no number is provided at all the ArrayDimensions can be omitted. If no brackets are provided, it identifies a scalar DataType and the ValueRank is set to the corresponding value (see OPC 10000-3). In addition, ArrayDimensions is set to null or is omitted. If it can be Any or ScalarOrOneDimension, the value is put into “{<value>}”, so either “{Any}” or “{ScalarOrOneDimension}” and the ValueRank is set to the corresponding value (see OPC 10000-3) and the ArrayDimensions is set to null or is omitted. Examples are given in Table 1.

The TypeDefinition is specified for Objects and Variables.

The TypeDefinition column specifies a symbolic name for a NodeId, i.e. the specified Node points with a HasTypeDefinition Reference to the corresponding Node.

The ModellingRule of the referenced component is provided by specifying the symbolic name of the rule in the ModellingRule column. In the AddressSpace, the Node shall use a HasModellingRule Reference to point to the corresponding ModellingRule Object.

If the NodeId of a DataType is provided, the symbolic name of the Node representing the DataType shall be used.

Note that if a symbolic name of a different namespace is used, it is prefixed by the NamespaceIndex (see 3.4.2.2).

Nodes of all other NodeClasses cannot be defined in the same table; therefore only the used ReferenceType, their NodeClass and their BrowseName are specified. A reference to another part of this document points to their definition. Table 2 illustrates the table. If no components are provided, the DataType, TypeDefinition and ModellingRule columns may be omitted and only a Comment column is introduced to point to the Node definition.

Each Type Node or well-known Instance Node defined shall have one or more ConformanceUnits defined in 11.1 that require the Node to be in the AddressSpace.

The relations between Nodes and ConformanceUnits are defined at the end of the tables defining Nodes, one row per ConformanceUnit. The ConformanceUnits are reflected in the Category element for the Node definition in the UANodeSet (see OPC 10000-6).

The list of ConformanceUnits in the UANodeSet allows Servers to optimize resource consumption by using a list of supported ConformanceUnits to select a subset of the Nodes in an Information Model.

When a Node is selected in this way, all dependencies implied by the References are also selected.

Dependencies exist if the Node is the source of HasTypeDefinition, HasInterface, HasAddIn or any HierarchicalReference. Dependencies also exist if the Node is the target of a HasSubtype Reference. For Variables and VariableTypes, the value of the DataType Attribute is a dependency. For DataType Nodes, any DataTypes referenced in the DataTypeDefinition Attribute are also dependencies.

For additional details see OPC 10000-5.

Components of Nodes can be complex that is containing components by themselves. The TypeDefinition, NodeClass and DataType can be derived from the type definitions, and the symbolic name can be created as defined in 3.4.3.1. Therefore, those containing components are not explicitly specified; they are implicitly specified by the type definitions.

The Other column defines additional characteristics of the Node. Examples of characteristics that can appear in this column are show in Table 3.

If multiple characteristics are defined they are separated by commas. The name or the short name may be used.

3.4.1.2 Additional References

To provide information about additional References, the format as shown in Table 4 is used.

References can be to any other Node.

3.4.1.3 Additional sub-components

To provide information about sub-components, the format as shown in Table 5 is used.

3.4.1.4 Additional Attribute values

The type definition table provides columns to specify the values for required Node Attributes for InstanceDeclarations. To provide information about additional Attributes, the format as shown in Table 6 is used.

There can be multiple columns to define more than one Attribute.

3.4.2 NodeIds and BrowseNames

3.4.2.1 NodeIds

The NodeIds of all Nodes described in this standard are only symbolic names. Annex A defines the actual NodeIds.

The symbolic name of each Node defined in this document is its BrowseName, or, when it is part of another Node, the BrowseName of the other Node, a “.”, and the BrowseName of itself. In this case “part of” means that the whole has a HasProperty or HasComponent Reference to its part. Since all Nodes not being part of another Node have a unique name in this document, the symbolic name is unique.

The NamespaceUri for all NodeIds defined in this document is defined in Annex A. The NamespaceIndex for this NamespaceUri is vendor-specific and depends on the position of the NamespaceUri in the server namespace table.

Note that this document not only defines concrete Nodes, but also requires that some Nodes shall be generated, for example one for each Session running on the Server. The NodeIds of those Nodes are Server-specific, including the namespace. But the NamespaceIndex of those Nodes cannot be the NamespaceIndex used for the Nodes defined in this document, because they are not defined by this document but generated by the Server.

3.4.2.2 BrowseNames

The text part of the BrowseNames for all Nodes defined in this document is specified in the tables defining the Nodes. The NamespaceUri for all BrowseNames defined in this document is defined in 12.2.

For InstanceDeclarations of NodeClass Object and Variable that are placeholders (OptionalPlaceholder and MandatoryPlaceholder ModellingRule), the BrowseName and the DisplayName are enclosed in angle brackets (<>) as recommended in OPC 10000-3.

If the BrowseName is not defined by this document, a namespace index prefix is added to the BrowseName (e.g., prefix '0' leading to ‘0:EngineeringUnits’ or prefix '2' leading to ‘2:DeviceRevision’). This is typically necessary if a Property of another specification is overwritten or used in the OPC UA types defined in this document. Table 45 provides a list of namespaces and their indexes as used in this document.

3.4.3 Common Attributes

3.4.3.1 General

The Attributes of Nodes, their DataTypes and descriptions are defined in OPC 10000-3. Attributes not marked as optional are mandatory and shall be provided by a Server. The following tables define if the Attribute value is defined by this specification or if it is server-specific.

For all Nodes specified in this specification, the Attributes named in Table 7 shall be set as specified in the table.

3.4.3.2 Objects

For all Objects specified in this specification, the Attributes named in Table 8 shall be set as specified in the table. The definitions for the Attributes can be found in OPC 10000-3.

3.4.3.3 Variables

For all Variables specified in this specification, the Attributes named in Table 9 shall be set as specified in the table. The definitions for the Attributes can be found in OPC 10000-3.

3.4.3.4 VariableTypes

For all VariableTypes specified in this specification, the Attributes named in Table 10 shall be set as specified in the table. The definitions for the Attributes can be found in OPC 10000-3.

3.4.3.5 Methods

For all Methods specified in this specification, the Attributes named in Table 11 shall be set as specified in the table. The definitions for the Attributes can be found in OPC 10000-3.

3.4.4 Structures

OPC 10000-3 differentiates between different kinds of Structures. The following conventions explain, how these Structures shall be defined.

The first kind are Structures without optional fields where none of the fields allows subtype (except fields with abstract DataTypes). Its definition is in Table 12.

The second kind are Structures with optional fields where none of the fields allows subtypes (except fields with abstract DataTypes). Its definition is in Table 13.

Structures with fields that are optional have an “Optional” column. Fields that are optional have True set, otherwise False.

The third kind are Structures without optional fields where one or more of the fields allow subtypes. Its definition is in Table 14.

Structures with fields that allow subtypes have an “Allow Subtypes” column. Fields that allow subtypes have True set, otherwise False. Fields with abstract DataTypes can always be subtyped.

4 General information to Metal Forming and OPC UA

4.1 Introduction to Metal Forming

The metal forming principles are one of the most widely used manufacturing processes in the world. During the forming process of the incoming metal sheets, bars, plates, tubes or powder, the material is plastically deformed by a force to obtain the required size and shape, as well as the physical properties of the desired product. Figure 1 shows the main principles of metal forming covered in this specification. These principles are classified into three main categories: bulk forming, sheet forming, and powder forming. The selection of the metal forming process depends on the application, material properties, and desired shape and properties of the final product.

There are different types of metal forming machines, which can be divided into several categories based on their specific applications and processes. The basic definitions for the DeviceClass Variable are used in the MachineIdentificationType as defined by OPC 10000-100. Next to the already defined technologies which are also commonly used in metal forming, like bending machine, forming machine, forging machine, punching machine and press, last mentioned can be extended and subdivided into hydraulic press, mechanic press and servo-electric press as they describe the widely distributed kinds of press machines.

There are several types of tools used in metal forming processes to shape and manipulate metal. Figure 2 shows a sheet metal forming press of a multi-stage press line in action. Between the upper and lower tool, which forms relevant shapes, the transfer moves the blank sheets from one stage to the next. Especially in the environment of press machines, the designation of a metal forming tool differs from tools in e.g. CNC machining context. Moreover, a tool is a combination of two or more individual parts, like upper tool, lower tool, blank holders or a kind of matrix in between.

4.2 Introduction to OPC Unified Architecture

4.2.1 What is OPC UA?

OPC UA is an open and royalty free set of standards designed as a universal communication protocol. While there are numerous communication solutions available, OPC UA has key advantages:

A state of art security model (see OPC 10000-2).

A fault tolerant communication protocol.

An information modelling framework that allows application developers to represent their data in a way that makes sense to them.

OPC UA has a broad scope which delivers for economies of scale for application developers. This means that a larger number of high-quality applications at a reasonable cost are available. When combined with semantic models such as Metal Forming, OPC UA makes it easier for end users to access data via generic commercial applications.

The OPC UA model is scalable from small devices to ERP systems. OPC UA Servers process information locally and then provide that data in a consistent format to any application requesting data - ERP, MES, PMS, Maintenance Systems, HMI, Smartphone or a standard Browser, for examples. For a more complete overview see OPC 10000-1.

4.2.2 Basics of OPC UA

As an open standard, OPC UA is based on standard internet technologies, like TCP/IP, HTTP, Web Sockets.

As an extensible standard, OPC UA provides a set of Services (see OPC 10000-4) and a basic information model framework. This framework provides an easy manner for creating and exposing vendor defined information in a standard way. More importantly all OPC UA Clients are expected to be able to discover and use vendor-defined information. This means OPC UA users can benefit from the economies of scale that come with generic visualization and historian applications. This specification is an example of an OPC UA Information Model designed to meet the needs of developers and users.

OPC UA Clients can be any consumer of data from another device on the network to browser based thin clients and ERP systems. The full scope of OPC UA applications is shown in Figure 3.

OPC UA provides a robust and reliable communication infrastructure having mechanisms for handling lost messages, failover, heartbeat, etc. With its binary encoded data, it offers a high-performing data exchange solution. Security is built into OPC UA as security requirements become more and more important especially since environments are connected to the office network or the internet and attackers are starting to focus on automation systems.

4.2.3 Information modelling in OPC UA

4.2.3.1 Concepts

OPC UA provides a framework that can be used to represent complex information as Objects in an AddressSpace which can be accessed with standard services. These Objects consist of Nodes connected by References. Different classes of Nodes convey different semantics. For example, a Variable Node represents a value that can be read or written. The Variable Node has an associated DataType that can define the actual value, such as a string, float, structure etc. It can also describe the Variable value as a variant. A Method Node represents a function that can be called. Every Node has a number of Attributes including a unique identifier called a NodeId and non-localized name called as BrowseName. An Object representing a ‘Reservation’ is shown in Figure 4.

Object and Variable Nodes represent instances and they always reference a TypeDefinition (ObjectType or VariableType) Node which describes their semantics and structure. Figure 5 illustrates the relationship between an instance and its TypeDefinition.

The type Nodes are templates that define all of the children that can be present in an instance of the type. In the example in Figure 5 the PersonType ObjectType defines two children: First Name and Last Name. All instances of PersonType are expected to have the same children with the same BrowseNames. Within a type the BrowseNames uniquely identify the children. This means Client applications can be designed to search for children based on the BrowseNames from the type instead of NodeIds. This eliminates the need for manual reconfiguration of systems if a Client uses types that multiple Servers implement.

OPC UA also supports the concept of sub-typing. This allows a modeller to take an existing type and extend it. There are rules regarding sub-typing defined in OPC 10000-3, but in general they allow the extension of a given type or the restriction of a DataType. For example, the modeller may decide that the existing ObjectType in some cases needs an additional Variable. The modeller can create a subtype of the ObjectType and add the Variable. A Client that is expecting the parent type can treat the new type as if it was of the parent type. Regarding DataTypes, subtypes can only restrict. If a Variable is defined to have a numeric value, a sub type could restrict it to a float.

References allow Nodes to be connected in ways that describe their relationships. All References have a ReferenceType that specifies the semantics of the relationship. References can be hierarchical or non-hierarchical. Hierarchical references are used to create the structure of Objects and Variables. Non-hierarchical are used to create arbitrary associations. Applications can define their own ReferenceType by creating subtypes of an existing ReferenceType. Subtypes inherit the semantics of the parent but may add additional restrictions. Figure 6 depicts several References, connecting different Objects.

The figures above use a notation that was developed for the OPC UA specification. The notation is summarized in Figure 7. UML representations can also be used; however, the OPC UA notation is less ambiguous because there is a direct mapping from the elements in the figures to Nodes in the AddressSpace of an OPC UA Server.

A complete description of the different types of Nodes and References can be found in OPC 10000-3 and the base structure is described in OPC 10000-5.

OPC UA specification defines a very wide range of functionality in its basic information model. It is not required that all Clients or Servers support all functionality in the OPC UA specifications. OPC UA includes the concept of Profiles, which segment the functionality into testable certifiable units. This allows the definition of functional subsets (that are expected to be implemented) within a companion specification. The Profiles do not restrict functionality, but generate requirements for a minimum set of functionality (see OPC 10000-7)

4.2.3.2 Namespaces

OPC UA allows information from many different sources to be combined into a single coherent AddressSpace. Namespaces are used to make this possible by eliminating naming and id conflicts between information from different sources. Each namespace in OPC UA has a globally unique string called a NamespaceUri which identifies a naming authority and a locally unique integer called a NamespaceIndex, which is an index into the Server's table of NamespaceUris. The NamespaceIndex is unique only within the context of a Session between an OPC UA Client and an OPC UA Server- the NamespaceIndex can change between Sessions and still identify the same item even though the NamespaceUri's location in the table has changed. The Services defined for OPC UA use the NamespaceIndex to specify the Namespace for qualified values.

There are two types of structured values in OPC UA that are qualified with NamespaceIndexes: NodeIds and QualifiedNames. NodeIds are locally unique (and sometimes globally unique) identifiers for Nodes. The same globally unique NodeId can be used as the identifier in a node in many Servers – the node's instance data may vary but its semantic meaning is the same regardless of the Server it appears in. This means Clients can have built-in knowledge of of what the data means in these Nodes. OPC UA Information Models generally define globally unique NodeIds for the TypeDefinitions defined by the Information Model.

QualifiedNames are non-localized names qualified with a Namespace. They are used for the BrowseNames of Nodes and allow the same names to be used by different information models without conflict. TypeDefinitions are not allowed to have children with duplicate BrowseNames; however, instances do not have that restriction.

4.2.3.3 Companion Specifications

An OPC UA companion specification for an industry specific vertical market describes an Information Model by defining ObjectTypes, VariableTypes, DataTypes and ReferenceTypes that represent the concepts used in the vertical market, and potentially also well-defined Objects as entry points into the AddressSpace.

5 Use cases

The purpose of this specification is to provide structures and mechanisms related to metal forming machines. Accordingly, a number of use cases must be satisfied in this model:

The user would like to identify machines of different manufacturers in a standardized manner (see 7.1).

The user would like to access repetitive forming data and monitor them within a cyclic context (see 7.2).

The user would like to access characteristic forming positions and monitor them in a cyclic context (see

7.3, 7.4 and 7.5).

The user would like to get notified if metal forming specific conditions appear during the process (see 7.8).

The user would like to access process values from various functional working units which are closely related to the forming process (see 7.4).

The user would like to monitor metal forming specific job parameter within a cyclic context (see 10.1).

The user would like to receive specific information about forming parts (see 10.2).

Note that the main purpose of the metal forming specification is to provide the information in a structure, optimized for repetitive metal forming specific processes.

6 Metal Forming Information Model overview

Based on the modelling concepts this chapter introduces the “OPC UA Information Model for Metal Forming”. The model is based on the OPC UA model of machine tools, an instance of the Machine Tools specification can be used to describe the metal forming machines with their processes. This Information Model provides the ObjectTypes as illustrated in Figure 8. There are ObjectTypes used for structuring different functional working units, like the ProcessWorkingUnitType and FormingProcessWorkingUnitType and ObjectTypes which instances are part of them, like the FormingPositionsType and CyclicProcessValueType. In addition, there are extensions of the 8:BaseToolType (FormingToolType) and the 8:MultiToolType (FormingMultiToolType). Furthermore, this Information Model specifies types for condition reporting (FormingConditionClassType).

An example of a 8:MachineToolType instance with a Metal Forming extension is shown in Figure 9. Only the 8:MonitoringType and the 8:EquipmentType of the 8:MachineToolType are considered, as this is the relevant part of the extension. The example contains metal forming data and process data. A more detailed description of the data and process values is given in the object types (see clause 7). The example displays a metal forming machine with a cooling unit and a slide. The cooling unit is described in more detail by the ProcessWorkingUnitType. The slide is defined more closely by the FormingProcessWorkingUnitType in its position and processes. In the 8:EquipmentType in the example, two specific metal forming tools are defined by the FormingToolType and the FormingMultiToolType.

7 OPC UA ObjectTypes

7.1 MachineTool Extension

A metal forming machine is described by an instance of the 8:MachineToolType defined in OPC 40501-1 Machine Tools and has various extensions for the metal forming specific values and process data. The 8:MachineToolType Instance can be extended by the following points through metal forming specific objects types (see Figure 10). The object type 8:ElementMonitoringType from the 0:BaseObjectType instance is extended by the Metal Forming ObjectTypes ProcessWorkingUnitType (7.4) and FormingProcessWorkingUnitType (7.5). The ObjectType 8:BaseToolType is supplemented by the ObjectTypes FormingToolType (7.6) and FormingMultiToolType (7.7). The example in Figure 9 also shows an extension of the 8:MachineToolType. To identify machines of different manufacturers, the information in the 2:Identification component of the 8:MachineToolType can be used.

7.2 CyclicProcessValueType ObjectType definition

The CyclicProcessValueType (see Figure 11) is a subtype of the 7:ProcessValueType and is used if the monitoring of dependent on repetitive processes inside a run is done. Therefore, it is important to remind the differences between a job order, run and cycle defined in the Metal Forming terms 3.2. The CyclicProcessValueType describes a machining cycle of a forming process.

The CylicProcessValueType is formally defined in Table 15.

CyclicProcessValue describes the transactional context between the 6:AnalogSignal, 7:ProcessValueSetpoint and the CycleCount. The DataType CyclicProcessValueDataType is defined in 10.1. The corresponding TypeDefinition CyclicProcessValueVariableType is defined in 9.1.

7.3 FormingPositionsType ObjectType Definition

The FormingPositionsType (see Figure 12) defines characteristic positions of a forming process and is formally defined in Table 16. For each cycle, the selected positions will get the ActualValue, Setpoint, EURange, EngineeringUnits and corresponding CycleCount as a CyclicProcessValueType, defined in 7.2. Figure 13 shows a hydraulic press machine with a cushion, indicating the positions of the characteristic points of a forming process.

TDC is defined in the Metal Forming terms 3.2.1.

Start defines the starting point of a forming process, which can be different to TDC.

Touch defines the position where the workpiece and tool have their first contact.

BDC is defined in the Metal Forming terms 3.2.1.

Retract defines the position where workpiece and tool separate from each other.

7.4 ProcessWorkingUnitType ObjectType Definition

The ProcessWorkingUnitType (see Figure 14) provides an instance of a unit which is part of the forming and / or production process and is formally defined in Table 17.

<ProcessValue> describes the monitoring of a signal from the corresponding working unit. Since there are more than one monitoring signals available per working unit, the 7:ProcessValue is defined as an optional placeholder. The 7:ProcessValueType is defined in OPC 40001-2.

<CyclicProcessValue> is of type CyclicProcessValueType, which is a subtype of 7:ProcessValueType and is representing process values and a transactional context between the 6:AnalogSignal, 7:ProcessValueSetpoint and the actual cycle count of the last cycle. The CyclicProcessValueType is formally defined in 7.2.

4:MachineryItemState represents the current state of the working unit.

7.5 FormingProcessWorkingUnitType ObjectType Definition

The FormingProcessWorkingUnitType (see Figure 15) represents a forming related working unit process, which needs to describe the actual forming position(s) of the last cycle, next to the processing parameters defined by the ProcessWorkingUnitType in Table 17. Therefore, FormingProcessWorkingUnitType is a subtype of ProcessWorkingUnitType and is formally defined in Table 18.

FormingPositions is representing an ObjectType, including a definition of optional positions which are most used in forming processes. The TypeDefintion for the FormingPositionsType is done in 7.3.

7.6 FormingToolType ObjectType Definition

The FormingToolType (see Figure 16) is a subtype of the 8:BaseToolType and provides metal forming specific tool parameter in the Location Object. Therefore, the Location Object is overridden and adjusted with metal forming specific tool parameters. The FormingToolType is defined in Table 19.

The components of the FormingToolType have additional subcomponents which are defined in Table 20.

The 8:Location parameter, formally defined in OPC 40501-1 UA for MachineTool, indicates, where the tool is located.

Orientation indicates the mounted direction of the tool if there are several possibilities (e.g. “Front” or “Back” at bending machines) to align the tool at the tool holder.

Position is a parameter which describes the absolute position of the central tool axis in dependency to the central middle axis of the complete tool holder. This is necessary if the machine consists of several stages or if the is mounted asymmetric in dependency to the central middle axis of the complete tool holder.

The Position parameter is extended by an 0:EngineeringUnits property as well as an 0:EURange property describing detailed static information.

describes a hydraulic press machine with three stages, the absolute Positions as well as the corresponding unit (mm) and the low (red) and high (green) limits of each tool in the current stage.

The Stage parameter indicates on which stage the current defined tool is located.

The 8:PlaceNumber and the 8:Name are used like in the 8:BaseToolType.

7.7 FormingMultiToolType ObjectType Definition

The FormingMultiToolType (see Figure 19) provides an optional placeholder for FormingToolTypes and is formally defined in Table 21.

The optional placeholder <FormingTool> Object contains information about the individual forming tools within the multitool.

7.8 FormingProcessConditionClassType ObjectType Definition

The supertype FormingProcessConditionClassType (see Figure 20) is a subtype of the ProcessConditionClassType and describes condition which can appear during the forming process, formally defined in Table 22.

7.9 AllowableTiltingExceededConditionClassType ObjectType

The AllowableTiltingExceededConditionClassType is an abstract ObjectType which should be caused when the allowable tilting of the machine limits is exceeded. The tilt is related to the punch of the hydraulic press machine as shown in Figure 21.

The AllowableTiltingExceededConditionClassType is formally defined in Table 23.

7.10 BreakthroughTonnageExceededConditionClassType ObjectType

The BreakthroughTonnageExceededConditionClassType is formally defined in Table 24.

7.11 CorrectionValueOutOfRangeConditionClassType ObjectType

The CorrectionValueOutOfRangeConditionClassType is an abstract ObjectType which should be caused when the correction value of the machine limits is exceeded. In this context, correction values mean dynamically adjusting values during production process, to get a better production quality. EXAMPLE: immersion depth control

The CorrectionValueOutOfRangeConditionClassType is formally defined in Table 25.

7.12 EccentricLoadExceededConditionClassType ObjectType

The EccentricLoadExceededConditionClassType is an abstract ObjectType which should be caused when the eccentric load of the machine limits is exceeded. Eccentric load describes the value of the forming force acting off-center as shown in Error! Reference source not found. for a hydraulic press machine.

The EccentricLoadExceededConditionClassType is formally defined in Table 26.

7.13 OverloadTriggeredConditionClassType ObjectType

The OverloadTriggeredConditionClassType is an abstract ObjectType which should be caused when the overload of the machine limits is triggered. The overload refers to a situation where the press machine is subjected to a force or load that exceeds its normal operating capacity.

The OverloadTriggeredConditionClassType is formally defined in Table 27.

7.14 PositionOutOfRangeConditionClassType ObjectType

The PositionOutOfRangeConditionClassType is an abstract ObjectType which should be caused when the operating range of the machine is exceeded. The position out of range generally refers to a situation where the position of a part or tool is exceeded by the normal operating range of the press machine.

The PositionOutOfRangeConditionClassType is formally defined in Table 28.

7.15 ProcessForceExceededConditionClassType ObjectType

The ProcessForceExceededConditionClassType is an abstract ObjectType which should be caused when the process force of the machine is exceeded. The process force is the force that is applied to the material being formed by the press.

The ProcessForceExceededConditionClassType is formally defined in Table 29.

8 OPC UA EventTypes

8.1 CyclicEventType

This CyclicEventType is used to display information about the current production process. The CyclicEventType is triggered after a new value in the CycleCount is available. It purposely contains a consistent snapshot of the properties and components of the corresponding CurrentProcessValue which is connected with the event. For each cyclically CurrentProcessValue there is a corresponding CyclicProcessEvent needed.

This CyclicEventType is formally defined in Table 30.

All Variables and Objects of the CyclicEventType in Table 29 are described in 7.1.

9 OPC UA VariableTypes

9.1 CyclicProcessValueVariableType ObjectType Definition

9.1.1 Overview

The CyclicProcessValueVariableType is a subtype of 0:BaseVariableType. It is used to represent the process value in context to the current cycle count.

The CyclicProcessValueVariableType is formally defined in Table 31.

The CyclicProcessValueVariableType has no other explicitly defined References.

10 OPC UA DataTypes

10.1 CyclicProcessValueDataType

This structure contains the actual value and setpoint of the corresponding process. To create a transactional context, there is an additional cycle counter, which represents the actual cycle count of the current forming process. The Boolean value indicates if the cyclic process measuring is active. The structure is defined in Table 32.

Its representation in the AddressSpace is defined in Table 33.

The CyclicProcessValueDataType has no other explicitly defined References.

10.2 CyclicPartInformationDataType

This structure contains the current serial number or part id of the last produced part and the corresponding cycle count. The structure is defined in Table 34.

Its representation in the AddressSpace is defined in Table 35.

The CyclicPartInformationDataType has no other explicitly defined References.

11 Profiles and ConformanceUnits

11.1 Conformance Units

This chapter defines the corresponding Conformance Units for the OPC UA Information Model for Metal Forming.

11.2 Profiles

11.2.1 Profile list

Table 37 lists all Profiles defined in this document and defines their URIs.

11.2.2 Server Facets

11.2.2.1 Overview

The following sections specify the Facets available for Servers that implement the Metal Forming companion specification. Each section defines and describes a Facet or Profile.

11.2.2.2 MetalForming Basic Server Profile

Table 38 defines a Profile that describes the minimum required content and address space functionality any Metal Forming server shall at least provide.

11.2.2.3 MetalForming Monitoring Server Facet

Table 39 defines a Facet that describes the that describes the additional monitoring information.

11.2.2.4 MetalForming Production data access Server Facet

Table 40 defines a Facet that contains enhanced information about the data access to the process on the MetalForming server compared to the MachineTool Basic Server Profile.

11.2.2.5 MetalForming Production Server Facet

Table 41 defines a Facet that contains enhanced information about the process on the MetalForming. This can be used in addition to the MachineTool Basic Server Profile, MachineTool Production Server Facet and the MachineTool Production Plan Server Facet.

11.2.2.6 MetalForming Tool Server Facet

Table 42 defines a Facet that contains the information about tools (sensors) in the MetalForming.

12 Namespaces

12.1 Namespace Metadata

Table 43 defines the namespace metadata for this document. The Object is used to provide version information for the namespace and an indication about static Nodes. Static Nodes are identical for all Attributes in all Servers, including the Value Attribute. See OPC 10000-5 for more details.

The information is provided as Object of type NamespaceMetadataType. This Object is a component of the Namespaces Object that is part of the Server Object. The NamespaceMetadataType ObjectType and its Properties are defined in OPC 10000-5.

The version information is also provided as part of the ModelTableEntry in the UANodeSet XML file. The UANodeSet XML schema is defined in OPC 10000-6.

Note: The IsNamespaceSubset Property is set to False as the UANodeSet XML file contains the complete Namespace. Servers only exposing a subset of the Namespace need to change the value to True.

12.2 Handling of OPC UA Namespaces

Namespaces are used by OPC UA to create unique identifiers across different naming authorities. The Attributes NodeId and BrowseName are identifiers. A Node in the UA AddressSpace is unambiguously identified using a NodeId. Unlike NodeIds, the BrowseName cannot be used to unambiguously identify a Node. Different Nodes may have the same BrowseName. They are used to build a browse path between two Nodes or to define a standard Property.

Servers may often choose to use the same namespace for the NodeId and the BrowseName. However, if they want to provide a standard Property, its BrowseName shall have the namespace of the standards body although the namespace of the NodeId reflects something else, for example the EngineeringUnits Property. All NodeIds of Nodes not defined in this document shall not use the standard namespaces.

Table 44 provides a list of mandatory and optional namespaces used in a Metal Forming OPC UA Server.

Table 45 provides a list of namespaces and their indices used for BrowseNames in this document. The default namespace of this document is not listed since all BrowseNames without prefix use this default namespace.

13 (normative)Metal Forming Namespace and mappings

NodeSet and Supplementary Files for Metal Forming Information Model

The Metal Forming Information Model is identified by the following URI:

http://opcfoundation.org/UA/MetalForming/

Documentation for the NamespaceUri can be found here.

The NodeSet associated with this version of specification can be found here:

https://reference.opcfoundation.org/nodesets/?u=http://opcfoundation.org/UA/MetalForming/&v=1.0.0&i=1

The NodeSet associated with the latest version of the specification can be found here:

https://reference.opcfoundation.org/nodesets/?u=http://opcfoundation.org/UA/MetalForming/&i=1

The supplementary files associated with this version of specification can be found here:

https://reference.opcfoundation.org/nodesets/?u=http://opcfoundation.org/UA/MetalForming/&v=1.0.0&i=2

The supplementary files associated with the latest version of the specification can be found here:

https://reference.opcfoundation.org/nodesets/?u=http://opcfoundation.org/UA/MetalForming/&i=2

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