manoj99

Hello Dan, Thanks a ton for your response. I really appreciate it.    Analog sensors connect to the conversion device directly.  The conversion must have I/O capable of handling the analog signals. You are absolutely correct. Yes these are Analog Sensors and they connect to conversion device directly. The conversion device does have I/O capability, however, it has been designed to export is Output to the Application Software only.  The reason for me to ask this question was the fact that I am an IT guy and have never worked with PLC/Scada or for that matter any electro-mechanical device in past. So this is a completely new scenario to me. However, your response has certainly provided me some ammunition to research and explore some new ideas. My main problem is, that the current scenario, "Sensor >> Conversion Device >> Analysis and Monitoring Application" is an integrated and proprietary Application Software + Hardware . Therefore, it can neither be changed/modified nor can be removed as my client won't allow that. I have to design a solution keeping in mind the fact that the data will have to be exported by Application Software to PLC rather than coming from Conversion Device to PLC directly or via an OPC Server. And PLC/Scada needs to accept this incoming data from Software itself.   So the communication will remain in the following way: Sensors Connected to H/W which need to be monitored <-------> Conversion Device - which converts the raw data generated by Sensors and convert them into software readable format <-------> Application Software to analyze the data and generate reports, sound alarms etc. <-------> PLC/Scada The only point of consolation for me is that the Application Software does have the facility to export data using Modbus/OPC protocol.  Now, I will have to find the way to make PLC accept this data either by installing an OPC Server in-between this Application and PLC and make them talk, or by some other mechanism.  And to answer your questions given under "Direction" heading: PLCs make real time decisions on input data and change their outputs for control purposes - turn on a motor, generate an alarm, that kind of stuff.   What data analysis is needed beyond what a PLC does? Well, the idea behind having this Application Software is to know in advance what type of problem may arise in Motors in future by analysing the data generated by functioning of Bearings and other components, thereby preventing unplanned downtime and ensuring 100% availability and functionality of plant. The data is generated by changing conditions of lubrications/temperatures/Sounds/vibrations produced by motors and other critical components of plant. PLC can generate alarm or make real time decisions, but idea behind implementing this application software + hardware combination is to predict the break-down well in advance and to avoid them completely. This is the job of this combination.  Generally, the people who sell the high value data analysis software make it quite clear about what is needed as input for the software and what it needs to run with.   Isn't this clear for your analysis software? This is "Hardware+Software" combination is a Real-Time Online Temperature/Velocity/Sound/Vibration Monitoring and Analysis application. The main purpose of my client behind using this application was prevention of Any unplanned downtime by getting to in advance about any problem that may come in Motors due to wear and tear. As written above, the data needed by this Application is the data collected from the changing conditions of lubrications/tempeartures/Sounds and also the amount a& type of Vibrations produced by Motors in whole as well as its components like Bearings, Blades, Belts etc separately. Hope that explanation helps.    Many Thanks Manoj

I have a Vibration monitoring software+Hardware combination. This combination can visually be shown as following:                 Sensors Connected to H/W which need to be monitored   Conversion Device - which converts the raw data generated by Sensors and convert them into software readable format   Application Software to analyze the data and generate reports, sound alarms etc.     <-------> <------->                           Brief Description: Sensors: are connected to H/W (motors, turbines, etc) to collect different type of data like sound, temperature, RPM etc Conversion Device: It is an electronic device which receives raw data from sensors and convert this raw data into a format which can be read and understood by the Application software. Application Software: is the one used for analysing this data generated by Conversion device. This software, based on the analysis, raise alarm, generates multiple different type of reports etc.   I now have a client which needs the post-analysis data generated by software to be exported to a PLC/Scada device using either “Modbus RTU” or “OPC” protocol. My problem is that I have never done this before. I, therefore, have a few queries: 1.      What is the step-by-step procedure to follow? 2.      Is it possible at all? 3.      Do we have any programming language available to program a PLC/Scada device in such a way that it accepts data generated by a software via Modbus RTU or OPC? If yes, then I would greatly appreciate it if I can be given the same. 4.      Are their any free PLC/Scada simulator software available to test communication between software and PLC /Scada? If yes, then kindly let me know. Please do let me know in case if I am missing something, or if am going in a completely wrong direction.