The SCHMIDT Technology PRC4000 6-axis ServoPress controller is an "open source" logic and servo control unit that provides sequencing, calculating, process monitoring, SPC, and motion control, as well as a built-in HMI. This controller also contains an OPC server that is used as an interface to allow for real-time exchanging of data with OPC clients. By using an OPC interface, any word or Boolean information can be easily exchanged between the SCHMIDT controller and another PC-based control, HMI, or PLC.

In a recent medical application, the PRC4000 ServoPress controller was required to provide force data to a GE Intelligent Platforms (GE Fanuc) PLC that was functioning as a master controller on an assembly line. This application also required the involvement of providing status of force monitoring, sequence information, and real-time access to additional force and position data from two ServoPress modules.

Since SCHMIDT does not support a direct driver link to a GE Intelligent Platforms (GE Fanuc) PLC, SCHMIDT engineers decided to review Kepware's OPC server suite (KEPServerEX) as well as Kepware's OPC system bridging software package (LinkMaster). KEPServerEX would provide the Ethernet connection to the GE Fanuc PLC, and LinkMaster would bridge or "link" the OPC data between the SCHMIDT OPC server and KEPServerEX. During the development stage of this project, the fully functioning 2-hour demo packages of KEPServerEX and LinkMaster were downloaded from the Kepware website.

It is important to note that, during this process, SCHMIDT engineers did not have a GE PLC
in-house to test the data transfer. However, they did have several Allen Bradley Micrologix PLCs on hand. Because KEPServerEX also provides connectivity to Allen Bradley PLCs, the SCHMIDT team was able to install the KEPServerEX OPC server suite and the LinkMaster application on the PRC4000 controller. They used Kepware's Allen Bradley DF1 connectivity to communicate directly to the PLC through a serial port. Next, LinkMaster was quickly configured to acquire the data to/from the SCHMIDT OPC server, and map the integer and Boolean data directly to available Integers and bits within the AB PLC. Due to the reliability and ease of use of the in-house evaluation system, SCHMIDT engineers made the decision to use Kepware's solution at the customer site. Kepware's OPC server provides a single consistent interface to a variety of industrial protocols. This made the transition from the in-house AB to the on-site GE connectivity fast and easy. KEPServerEX with GE connectivity and the bridge application LinkMaster were installed on the PRC4000 controller allowing a successful and seamless exchange of data through the on-board Ethernet port.

This fast, easy, and reliable solution provided by LinkMaster prompted a final configuration featuring the use of LinkMaster to transfer data and status/control bits between three PRC4000 controllers and the GE PLC.