Вы находитесь на странице: 1из 55

Electrical Lighting Automation DataComm

Virtualization for Manufacturing


Industries
-PRESENTED BY

Mike Murphy Schaedler Yesco


Tim McCain Rockwell Automation
Experience the Difference!

Agenda
Overview & Drivers
Virtualization for Engineers
Virtualization for Production
Virtualization & Rockwell
Additional Options
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Virtualization Adoption, by Industry


Server virtualization adoption, by industry. (Percent of respondents)
Using server virtualization in a production environment
Using server virtualization, but in a test environment only
Have not yet deployed server virtualization, but plan to
Have not deployed and have no current plans to
Education (N=59)
Manufacturing (N=74)
Health Care (N=51)
Professional Services (N=36)
Government (State & Local, N=48)
Financial (N=79)

30%

46%

Communications & Media (N=27)


Government (Federal, N=28)

36%

21%

Retail/Wholesale (N=25)

36%

20%

Transportation/Logistics (N=20)
0%

10%

20%

11% 4%

30%

40%

21%

21%

28%

16%

20%

30%

20%

30%

50%

60%

9%

15%

41%

44%

10%

19%

23%

48%

14%

25%

11%

50%

14%

12%

22%

53%

11%

20%

8%

61%

8%

8%

12%

71%

70%

80%

90%

100%

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Virtual Machine Deployment Projection

Source: IDC
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

What is Virtualization?

Traditionally the OS and its applications


were tightly coupled to the hardware they
were installed on
Virtualization breaks the link between
operating system and physical hardware

Application

Application

Application

Hypervisor
Operating
System

This allows the ability to change hardware


without replacing the OS or applications
Additionally multiple instances of an OS
with independent applications can now run
on the same hardware

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Increased Application Longevity


Typical computer refresh cycle is 3-5 years
Typical Industrial control system refresh is15 to 20
years
Computer replacements typically require software
upgrades which are expensive and difficult
Virtual hardware exposed to the guest OS does not
change when physical hardware is replaced
Each virtual hardware version is supported for three
major releases of vSphere

APP

APP

APP

OS

OS

OS

HW 8
HW10

HW 8
HW10

HW 8
HW10

VMware
VMwareESXi
ESX
ESX5.x+2
5.x+3
5.x+1
5.x

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Server Consolidation
Many physical servers
- Under utilized
- Requiring maintenance
- Generating heat
- Consuming energy
Fewer physical servers

More efficiently utilized


Easier to maintain
Generating less heat
Consuming less energy

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Agenda
Overview & Drivers
Virtualization for Engineers
Virtualization for Production
Virtualization & Rockwell
Additional Options
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Hosted (aka Desktop) Virtualization


Hosted or Desktop

Application

App

App

OS

OS

Hypervisor

Hypervisor runs as an application on


another OS such as Linux or Windows
Advantages:
Low cost
Self administered
Independent of IT management and
controls

Host Operating System

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

VMware Player Overview


Free solution built on the same
hypervisor technology as VMware
Workstation
Allows basic creation, modification
and use of one or more virtual
machines
Similar in functionality to Windows
Virtual PC and WindowsXP mode
for Windows 7
Aimed at end users that need multiple
OS or software versions with limited IT
support.

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

VMware Workstation Overview


Easily and quickly build and run multiple VMs
Snapshot capabilities to allow rapid recovery from
botched upgrades or destructive tests
Basic server functions, for sharing VMs with a team
of engineers
Integration with VMware vSphere
Aimed at developers and engineers that need to build a
multi tiered application in a test environment, then
seamlessly migrate to a production server cluster.

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Workstation vs. Player


Workstation

Support for VM groups


Basic VM sharing / serving
support
Integration with VMware vSphere
Snapshots create restore
points for destructive tests

Player

Free for noncommercial use


Basic virtual machine creation
and management
Common hypervisor technology
with Workstation

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Agenda
Overview & Drivers
Virtualization for Engineers
Virtualization for Production
Virtualization & Rockwell
Additional Options
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

13

Server (aka Bare Metal) Virtualization


Hypervisor replaces host operating system
and manages host hardware and resources
Advantages:
Reduced host maintenance
Improved host reliability
Reduced security surface area
Data center level vendor support

Bare Metal or Server


App

App

App

OS

OS

OS

Hypervisor

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

VMware vSphere Overview


Combines multiple servers and storage units into a
pool of resources that can be divided between
applications
Provides central management for servers and their
applications
Advanced high availability and disaster recovery
features
Intended to provide a highly available, always on back
end for server applications and desktops. Can segment
hardware into multiple priority groups allowing
development testing and production to share the same
hardware.
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Centralized management (servers)

Monitor all host servers and virtual machines


Deploy new VMs from template
Attached to the console session to manage installed applications
Shutdown / reset problem VMs
(optional) Backup and restore virtual machines with integrated
addons

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Manageability: vMotion
Migrate a running VM from one physical server to
another

Resource Pool

VMware ESXi

VMware ESXi

VMware ESXi

Operating Server

Operating Server

Operating Server

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Manageability: Distributed Resource


Scheduler
Management server monitors host load and virtual
machine placement vs. defined rules.
Either suggests or automatically executes vMotion
operations

Resource Pool

VMware ESXi

VMware ESXi

VMware ESXi

Operating Server

Operating Server

Operating Server

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Reliability: High Availability


Hosts monitor each other and their virtual machines
for failure
Failed virtual machines automatically restarted where
resources are available.

Resource Pool

VMware ESXi

VMware ESXi

VMware ESXi

Operating Server

Failed Server
Operating
Server

Operating Server

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Reliability: VMware Fault Tolerance


Virtual machines execute simultanously on two
physical servers
Bumpless failover in the event of a HARDWARE
falure

No Reboot
Seamless Cutover

VMware ESXi

VMware ESXi

VMware ESXi

OperatingServer

OperatingServer
Failed Server

OperatingServer

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

VMware View Overview


Central management for both engineering and
operations clients
Rapid deployment of new desktops and updates
Run virtual machines on production server cluster,
or on engineering laptop
Client can run on a range of devices from desktops
to tablets
End user focuses on using the applications rather
than managing his virtual machine library
Aimed at systems that could benefit from centralized
management
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Client Virtualization
Centralized Virtual
Desktops

Extend server virtualization benefits to clients:

Software independence from hardware


Lower Administration and Support Costs
Rapid Desktop Deployment
Leverage VM Availability Features
Centralized disaster recovery
Integrated Secure Remote Access
Offline Mode

VMWARE VIEW
SECURITY SERVER

Remote Client

VMWARE
VIEW MANAGER

Thin Client
Desktop
Laptop
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Centralized management (clients)


View status of current clients
Reset problem clients
Provision new systems
Rapidly deploy tested patches
or software updates
Entitle or revoke user access

VMware View VDM can also be used to


manage access to Microsoft Terminal
Services

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

VMware View vs. Workstation


VMware View

Production Environments
Centralized management
Composer functionality for rapid patch
and update deployment
Securely provision environments for
contractors and vendors
Thin client support

Workstation

Development for SI/Engineers


Decentralized management
Lower hardware costs for small
deployments
Broader OS support

Execution occurs in the data


center not at the client endpoint
Offline mode support

Allows disconnect use of desktop


for traveling users
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Typical Hardware Architecture


In the data center
Storage Array (iSCSI, FC, NFS)
2-5 Physical Servers
Redundant Gigabit Switches
In the office and on the shop floor
legacy desktops
ruggedized laptops
solid state thin clients
Tablets (iPad / Android)

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Server Considerations
CPU
2 CPU sockets with 4-8 cores each
Consolidation Ratios of 8 20 VMs per Server

Memory
32-128GB physical RAM per server
Suggested initial allocations
Operator Workstations: 2 GB
Engineer Workstation: 4 GB
HMI/Historian Server: 4 GB
Monitor actual memory usage and adjust allocations up
or down depending on actual application usage
Number of Servers

For redundant systems, 3 physical servers is a suggested minimum, allowing for full
application redundancy during infrastructure maintenance periods.
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Storage Considerations
Storage Options

Fibre Channel
NAS
iSCSI
Direct Attached SAS
Virtualized SAN

Selection Factors
Capacity / Price / Performance
Disk types (SCSI, ATA, FC, SATA)
Access Time; IOPS; Sustained Transfer Rate
Reliability (MTBF)

Virtual machine performance is highly dependent on I/O


throughput of the storage array
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Networking
Virtualization requires additional networks to manage and isolate information traffic

VM Network(s)

Ie./ Assembly Line 1 VLAN, Assembly Line 2 VLAN, DMZ


Management / vMotion
Storage Network (If applicable)
Fault Tolerant Network
So how many NICs do I need on my server?
2 per traffic type.
For a system with iSCSI, Fault Tolerance and a DMZ: 10

Gigabit Switches are required, 10GbE switches may be used


Networks should be isolated by VLANs
The NICs connected to the Servers act as Trunks into your vSwitches

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Agenda
Overview & Drivers
Virtualization for Engineers
Virtualization for Production
Virtualization & Rockwell
Additional Options
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

29

FactoryTalk System Example

Active Directory

Asset Centre

FactoryTalk Directory

Primary HMI

Secondary HMI

Historian

VantagePoint

Batch

Engineering Workstations

Operator Workstations

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

FactoryTalk System Example

Active Directory

Asset Centre

FactoryTalk Directory

Primary HMI

Secondary HMI

Historian

VantagePoint

Batch

Engineering Workstations

Operator Workstations

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Rockwell Virtualization Progression


November 2009 RA Products Supported with Vmware

Design &
Configuration

Quality &
Compliance

Production
Management

Asset
Management

Data Management

Performance &
Visibility

RSLogix 5
RSLogix 500
RSLogix 5000
RSLogix Architect
RSNetworx
RSLinx Classic &
Enterprise
Factory Talk Gateway
FactoryTalk View SE & ME
RSView32
FactoryTalk View Studio

FactoryTalk Batch
FactoryTalk Transaction Manager
FactoryTalk Metrics
FactoryTalk AssetCentre
FactoryTalk Vantage Point
FactoryTalk ProductionCentre
FactoryTalk Historian SE & Classic
Emonitor

Not SoftLogix!

Official statement of support: RA Knowledgebase Article 42682


Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Rockwell Automation and VMware


Solution Provider
Combine Rockwells industry
expertise with VMware
technology to provide design,
plan and deployment services
for VMware based virtual
infrastructure
Technology Alliance Partner
Allow Rockwell Automation to
directly leverage the VMware
resources needed to deliver
enhanced value to shared
customers.

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

33

Rockwell Virtualization Progression

2010

2011

2012

2013

November 2010 RA Announces VMware Ready Software

RSLinx Classic
RSLinx Enterprise
RSLogix 5000
FactoryTalk View SE
FactoryTalk View Studio
FactoryTalk Batch
FactoryTalk AssetCentre
FactoryTalk Vantage Point
FactoryTalk Historian SE
Factory Talk Gateway

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Rockwell Virtualization Progression

2010

2011

2012

2013

FY 2011 Network and Security Services Group expands


consultant services to Virtualized Systems

ASSESS
MANAGE / MONITOR

Capacity Planner
Infrastructure Design
Hardware Procurement
System Validation
And much more

HOURLY CONSULTING
DESIGN/PLAN
AUDIT

IMPLEMENT

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Rockwell Virtualization Progression

2010

2011

2012

FY2012 - Virtual Appliance Development

2013
Virtual Appliances
PASS

vApp

OS

Process Automation System


Server

vApp
vApp

OS

OWS

OS

Operator Workstation

Plant Enet

EWS

Engineering Workstation

App
vApp
vApp

OS

vApp

OS

vApp

OS

vApp

OS

vApp
vApp

OS

OS
OS

Process Control Enet

with Virtual Appliances

vApp

vApp

vApp

System Elements as standard products Reduced validation Costs!


Pre-installed & Pre-configured Reduced Engineering Costs!
Hardware Independent Increased Product Lifecycle!

OS
OS

OS

AS Batch

Application Server
Batch Management

AS Information
Application Server
Process Information

AS Asset Centre
Application Server
Asset Centre

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

PlantPAx Virtual Image Templates v3.00


Provide customer value by reducing Total Cost of Ownership

Templates provide a drop in solution for customers existing IT


architecture
Open Virtual Format (OVF) Format - Can work with any Virtual offering

VMware ESXI officially Supported and Recommended!

Virtual Templates
PASS

Process Automation System


Server

Plant Enet

App
vApp
vApp

OS

vApp
vApp

vApp

OS

vApp

OS

OS

Operator Workstation

vApp
vApp

OS

OS

OWS

vApp

OS

OS

EWS

Engineering Workstation

OS

Process Control Enet

Virtual Templates offer

System Elements as standard products Reduced validation Costs!


Pre-installed & Pre-configured Reduced Engineering Costs!
Hardware Independent Increased Product Lifecycle!

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

37

Whats Provided?
When the templates are ordered the customer receives

The 3 core PlantPAx system elements as Images on a USB Hard-Drive (HDD)


with all required Rockwell Software preinstalled, but NOT activated.

3 Microsoft Operating System Full Packaged Product (FPP) Licenses

The end-user must convert the FPP to a Microsoft Volume License within 90 days

Templates require a Microsoft Volume License to run

Customers should contact their Microsoft Rep. to convert the licenses

Activating the Templates


EWS Order
OWS Order
PASS Order

9528-EWSLICENE
9528-OWSLICENE
9528-PASS100ENE

9528-PAXVTENE

9528-PASS250ENE
9528-PASSUNLENE
*PASS Activation based on HMI display count of 100, 250, or Unlimited
*Activations are in increments of 1 per image. Order 1 for each image required
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

38

Rockwell Virtualization Progression

2010

2011

2012

2013

2013 Industrial Data Center


Offering a single SKU* that can be combined
with the PlantPAx Virtualized System

*A turnkey solution is available through our


NSS (Network Services) business today.
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

System Architecture
PlantPAx Virtualization Infrastructure

New Rockwell Automation Industrial Data Center


Essentials Option
Supports 15-20 virtual machines
Support for VMware HA and application
redundancy
Essentials+ Option
Supports up to 50 virtual machines
Support for VMware HA, FT, and application
redundancy

Virtualized system infrastructure preconfigured


and supported by Rockwell Automation
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Whats the value of pre-configured?


System Design

Industrial Network Architecture Design


Product Selection Generate BOM for enclosure, servers,
storage, switching, cables, Cable Interconnect design
Generate all system drawings and documentation

System Fabrication

Load BOM into ERP/Business system and generate all POs


Receive Product - open, check against order, inspect,
receive in system, dispose Packaging

Build Cabinet

Install all HW
Install all cables and wire markers
Perform functional test (Green lights)
Burn in system

Time Estimates
Design time
15 16 engineering days,
assumes CCNA (Cisco
Certified), VCP (VMware
Certified), and storage
experienced engineer with final
approval from IT.
Fabrication/test time;
7 8 days assumes trained
technician level experienced
employee.

Additional value of standard system

The design has been Thermally Validated can improve system reliability by more than
20 percent
The Cabinet would meet applicable global standards (i.e. UL 508A )
Bundle would include either a 1 day or 3 day onsite start-up assistance package
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

41

Industrial Data Centers

Essentials

Essentials +

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

42

The Power of Collaboration

Bundle includes:

Servers and switches from Cisco


Cables, patch cords, cable management, testing,
validation, and assembly from Panduit
Storage from EMC
Virtual System Licenses from VMWare
PlantPAX Virtual Image Templates from Rockwell

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

43

Agenda
Overview & Drivers
Virtualization for Engineers
Virtualization for Production
Virtualization & Rockwell
Additional Options
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

44

Fault-Tolerant Servers
for Automation and MES

Resilient Servers
Duplex Hardware Components

Embedded I/O

PCI
Embedded I/O

Automated Uptime
Layer
Fault Detection &
Isolation

Automated Uptime
Layer
Fault Detection &
Isolation

Purpose build to provide Uptime


unachievable by standard servers

CPU
Chipset
Memory
CPU
Chipset

Lockstepped CPUs

Multi-path I/O

PCI

Memory

Manage like single x86 server


Ideal for mission critical apps in
the data center or remote sites

Multi-Path IO Devices
Fault Detection
&
Isolation

PCI

Enet

PCI

Fibre Channel

Stratus Direct
Attach Storage

Fault Detection
&
Isolation

Embedded IO
Network Switch

Bonding

Enet

Bonding

Network Fault Tolerance

Fibre Channel

Standard Intel PROSet teaming


Single virtual interface to the kernel
One MAC address
Avoids software handling of failures

Embedded IO

Storage Fault Tolerance

RAID1 internal disks


Multi-path to external HW RAID

47

Leveraging the ftServer for


Virtualization and Consolidation
App2
OS
App 1

VM1

VM2

VM3

App 1

App2

DB

OS

OS

OS

DB
Server 2

OS

Server 1

OS

Virtualization Layer
99.999+%
uptime

Server 3

The Cost of Server Sprawl

The Benefits of Consolidation

Initial Hardware, software, and


installation costs

Fewer servers, easy provisioning,


better DR options

Recurring costs for administration


and support and utilities

Plug-and-play operational simplicity


and administration

Downtime and repair

No downtime or data loss


48

Stratus Confidential

Product Specifications
2700
Low-end system

4700
Mid-tier system

6400
High-end system

1-socket

2-socket

2-socket

Quad-core 1.8 GHz


6.4 GT/s QPI

Quad-core 1.8 GHz


6.4 GT/s QPI

Octa-core 2.6 GHz


8.0 GT/s QPI

10 MB Shared

10 MB Shared

20 MB Shared

34.1 GB/s

68.2 GB/s

85.3 GB/s

8 DIMM Slots

16 DIMM Slots

16 DIMM Slots

32 GB

256 GB

256 GB

Note: All I/O options


specified in logical
count, physical count is
2 times numbers
specified
Processors
CPU
QPI Performance
CPU Cache
Memory Bandwidth
Memory Slots
System Memory
Embedded

PCI Slots Embedded


PCI Slot Expansion

SAS, 2x ENET (10/100/1000) ,


3x USB2.0 (rear), 1x USB2.0 (front), 2x COMM, VGA, BMC, DVD R/W (front)
2 x PCIe

2 x PCIe

4 x PCIe

Not Available

2 x PCIe Gen 2

Included

8 x 2.5 SAS Disks

RAID 1 Disk (Internal)


Form Factor

4U Rack

4U Rack

4U Rack

49

Automated Uptime Layer

ActiveService Architecture at Work

Call
Home
Two-way
Customer
Assistance Center

Next Day
Delivery
Service

1. Unit fails - system isolates fault


and continues operation with
redundant unit
2. Call home technology reports fault
opens support issue with the Stratus
Customer Assistance Center (CAC)
3. CAC contacts customer to confirm
issue and initiates shipment of
replacement part
4. Customer receives and replaces part system synchronizes with
replacement and continues operation

Welcome to ThinManager Platform 6

Platform Management Tool


XLi Compatible
Office Clients

IP Cameras

Industrial
Thin Clients

ThinManager
iPad & iPhone

VMware
Virtualization

Remote Desktop
Services

ThinManager Model
ThinManager provides Centralized Configuration, Management, and
Security of Servers, Clients, Applications and Users in Terminal
Services or VDI based Networks.
ThinManager ensures your applications are securely available to the
people that need them, when they need them, regardless of system
conditions.

Thank you for attending!

Questions?

Tim McCain

Information Solutions Regional Manager

tjmccain@ra.rockwell.com

Mike Murphy

Industrial Automation Software Specialist

mmurphy@sydist.com

Follow ROKAutomation on Facebook & Twitter.


Connect with us on LinkedIn.
www.rockwellautomation.com
Rev 5058-CO900C

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Electrical Lighting Automation DataComm

ENJOY the EXPO!


Please complete your survey!
Schaedler Yesco Expo 2014
The Premier Electrical Tradeshow in Central PA!
A Two-day, Jam-Packed Schedule!
Over 100 Booths from Leading Manufacturers!

Experience the Difference!