Production data acquisition
Bidirektional ProductionDataAcquisition: Bi-PDA
The production data acquisition system is a highly adaptable scripting environment that allows us to record current plant data and enables the communication between external data sources and the control system.

Data is recorded using an SQL database and can be exported periodically as CSV or XML files.

The BiPDA system works closely with both OPICOM and the reporting system to provide the operator with the necessary data and information, exactly where it is needed.

what - how - when - from where - how


The range of data collected can include sensor data, weighing data, order data and laboratory data. Usually, this data is retrieved from the PLC, which uses a driver to read it out directly via TCP, on request. This communication with the PLC ensures high-quality data recording.


We use a standardised Siemens communication protocol and a data server we programmed in-house to read data from the PLC, prepare it for a specific customer and store it in a database in an organised manner. Right from the concept phase, we can take customer requirements into account, allowing us to design and prepare the tables for superordinate merchandise management systems and interfaces. If other networked systems are to be accessed alongside the PLC, customer-specific interfaces (micro-services) can be programmed so that certain events trigger read-out and archiving.


Cyclical and event-triggered data recording is the most important capability of any production data acquisition system.
An operating hours meter could be recorded cyclically (daily), for instance. Certain events are natural triggers, including the start and end of an order and all key process points in between (batch storage or weighing, for instance).
Guaranteed PLC seek times of 100 ms allow data recording in almost real time. A standard case achieves seek times of 300–500 ms (parametrisable solution), taking into consideration the communication load on the PLC.

From where

A standardised interface driver and the scripting solution in ESA BiPDA allows data to be gathered from three different database systems (MS SQL, Oracle, MySQL).


How is the data presented to the customer?
Operational data can be displayed to the end user by means of a customised report or the customer can pick up the data in the ERP. Alternatively, the data can be actively exported to pre-defined tables in the interface databases. Communicating with ERP systems (SAP, Axapta, Navision or customised ERP solutions) via standardised interfaces is an integral part of our work.