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Many of the machines throughout the manufacturing industry communicate their data over the internet using machine tags. These tags represent various parameters or attributes that communicate their state. These could be spindle speeds, alarms, or many other data points. The Tulip platform is designed to work with these signals and let you use them in your applications to improve process visibility and control. This application is a template that you can use when connecting your first machine and is an attempt to share best practices for machine monitoring app development as well as introduces ways to expand the scope of the terminal to connect to other application structures such as andon management and work order tracking. Since every machine needs to be connected individually, this document will walk you through setting up your machine and connecting it to the application.
General Process Overview
This Tulip application relies on an OPC UA server and the machine monitoring features within the Tulip platform to gather and process machine data. The data is displayed from within the Tulip application and can be interacted with by the user.
Getting Started - Application Overview
Before we get into the installation of your machine, let’s take a look at how the application works once your machine is connected. The application is centered around a single screen which displays the terminal and presents multiple opportunities for the users to view machine status and interact.
Since this application relies on the output data from a machine, when the application is first loaded onto your instance there will need to be a number of connections made. This is what the application will look like from within the editor when it is first loaded:
Setup your OPC UA connection:
Select the “Machines” option from the Shop Floor drop down
Choose “Machine Data Sources” from the drop down
On the top right, click the “Create Connector” button
Name your connector and click save. Click on the connector afterwards to configure it.
Enter your OPC UA server URL with the credentials. Some people use Kepware to get their machines connected to the internet. Here is a guide that may help you if you need to get your machine on your network. Tulip Support Page
Once you’ve entered your information press “test” and then “save”
Create your Machine
Select “Machine Library” from the drop down navigation
Click “Create Machine” in the top right
Enter in a name for your machine (this should represent an actual machine, not a group of machines). Choose the OPC UA server from the drop down and press save. For now you can leave “Station” and “Type” blank. We’ll configure those in later steps.
Click “Select Machine Node” and use the drop down menu to navigate the OPC UA server. Clicking on the arrows “>” will allow you to drop into sub-directories and select the machine you are looking for.
These directories will match the setup of your OPC UA server and will allow you to choose which machine you’d like to connect to.
Once you’ve found the directory that matches your machine, click it to highlight it (and all of the tags within it) and press the select button.
All of the tags will be displayed on the right side of the screen. Each of these tags will be named in accordance with how the machine is configured through the OPC UA server. By clicking the drop downs to the right, you can create commonly named attributes across all of your machines that you can use in all of your apps. This is essentially mapping or translating the OPC data to Tulip.
Once you’ve chosen which attributes you would like to consider, press the save button on the top right. You should now begin to see data streaming in from your machine!
Create a Machine Type
Machine types represent groups of machines that understand their attributes in the same way. The machine data may be coming in under different tag names, but after you have mapped these to common attribute names within Tulip they can be understood in the same way. For example, you may have a number of machines that are manually loaded for each cycle. These machines may not be “down” just because the door is open. You may decide to have a combination of factors result in a “down” state and these factors are all shared across the machine type.
Select “Machine Types” from the drop down
Click “Create Type” in the top right hand corner
Name the type of machine on the top left corner - this is representative of a group of machines operating under similar conditions.
In the bottom left, click “Add a machine attribute” and then select from the pop out on the right hand side. You should select any and all attributes that contribute to the state of the machine. Which attributes can best describe whether a machine is “stopped”, “idle” or “running”? Are there other states that you’d like to include? If so, add more states by clicking the + button
In our example, we will just use the “Emergency Stop” attribute. Once you’ve added your attribute(s) it is time to build your state change trigger. Click the “Add trigger” button on the right side of the screen.
In the above example we have created a very simple state change trigger. Your state change logic will be specific to your machine so feel free to adjust this as you learn about your machine and the tags it is producing during normal operation.
Create a Station for your Application
The machine terminal is an application and, as such, needs to be run on a Tulip station like any other application. In this example, each machine needs to have its own application so that the associate can interact with information specific to the machine. You could create other applications that could allow a user to manage multiple machines at the same time but this example is for a single machine terminal.
Select “Stations” from the Shop Floor drop down menu.
Click “Create Station” in the Top right corner
Name your station and assign it to a group if you would like to organize your stations into groups. If your device is already registered then you may assign your device at this time. Otherwise, you may assign your device during registration.
Click the “Edit” button on the top right of the bottom “Configuration” section. This will enable you to give development version permissions to the station. Press “save” afterwards to lock in the new permissions.
Assign Your Machine to its Station and Type
Return to the “Machines” area using the Shop Floor drop down menu. Navigate to the “Machine Library” and select your machine.
Assign your machine to the Station that you’ve just created and to the Type that you created in the previous steps.
Log into your Player and App Editor
Log into your account through your player and choose the Station that you created earlier when registering your device. Once you are presented with the application menu, choose “Machine Terminal”.
You will be presented with the screen to the left. Ensure that the station name being displayed matches the station that you’ve created. This application relies on a Stations table to hold values that support its function. We will discuss that in more detail later on. Press “Yes, Create Station” to continue.
Now that you have your player open to the terminal you will be able to see the application come together in real time as you adjust the editor.
Navigate to the “Machine Terminal” step in the App editor. You will now be clicking on each of the widgets and connecting them to the machine that you’ve set up.
Click on each of the three machine monitoring widgets on the left hand side of the screen and choose the machine type to display on the right hand side. Feel free to play around and display the items that you’d like to see.
Click on the “Select from Existing” buttons on each of the analytics. The buttons are difficult to see on the smaller analytics to the right but they are still able to be clicked on.
Click on “Machine” and then choose your machine. Press the “Create New Analysis” button on the right hand side.
Choose the “Single Number” template option and, from the drop down menu, select which analytic you would like to display.
The calculations for each of these metrics will be populated automatically.
Save the analytic once you have chosen the one you would like to display by pressing the “Save & Close” button on the top right.
Continue this process for the remaining analytics
There are two optional machine triggers that you may elect to use: “Auto increment part counter” and “program save to activity history”. Click to edit these if you would like machine attributes to trigger data manipulations of the activity history record (which can be used for analytics)
The installation is now complete! Feel free to open the *Stations table in the tulip tables drop down menu and add an image for your machine. This image will populate in the top left hand corner of the application.