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Reporting is an important part of any automation system. It allows for retrieving information on production. Some reports are mandatory while some are for the company’s own benefit. Ordinarily reports are used to provide information of the company’s performance, or to explain any given trend that has occurred. Forming a report is a multi-phase process consisting of data collection from the field, decision-making algorithms, databases, communication, and finally the report formulation. Main challenge of this study is to find a method for extracting just the specific process data needed for the reporting. Current approaches for collecting the reporting data are considered inefficient and time consuming. The study is motivated by the need to optimize and standardize the engineering process. The problem is approached by studying theory around the topic. Analy sis and design of the system is done based on the knowledge gained. The solution found is im plemented and demonstrated to prove its effectiveness. Previous implementations are considered and reflected on in the analysis phase. The system is modeled using Unified Modeling Language (UML) and designed using Collaborative Object Modeling and Design Method (COMET). Multiple solutions for the data collection are conceptual ized to find the best fit for the given problem. The benefits of implementing Edge computing as a part of the system are evaluated. As a result of the analysis and design chapter, Siemens’s TIA Portal’s new Cause Effect Matrix (CEM) programming language is chosen to be studied. Benefits of the CEM-based solution are evaluated to be its ease of implementation, universality, scalability, and modifiability. The solution developed is named as Centralized System-Wide Cause Effect Matrix (CSW-CEM) due to its nature. The whole algorithm for tracking the material flow in the system is packed into one centralized CEM. This CSW-CEM models the whole physical system consisting of tanks, valves, pumps, pipelines, and other instrumentation in the automation system. After defining the CSW-CEM itself, an instance of it is attached to each material source in the system. This allows for unambiguous reporting of every transfer in the system, regardless of it being automatic or manual. The findings of this thesis satisfied the requirements set for it. The solution proposal was successfully demonstrated. The CSW-CEM was tested to be able to handle multiple different scenarios that may occur in a real system implementation. Interface to upper-level systems was done with data blocks, written by the PLC configured as an OPC UA server. Communication and the communication interface was demonstrated by reading the data blocks with an OPC UA client. Unplanned advantages were also found in the process of development. These included the possibility to use the CEM language for visualization and routing purposes as well. The original idea of using Edge computing for the report formulation was questioned. Future development of the solution should consider this. |
