How do you bring IT and OT together? It's a question that must be answered by any company hoping to realize the visions of Industry 4.0. A puzzle – so far – without a real solution. But B&R is breaking down the barrier between the two worlds, giving machine builders access to one of the world's largest software ecosystems.

exOS bridges the divide between IT and OT to get the best out of each domain.

A team is only ever as good as its members. But simply sitting the best and brightest from individual fields around a table will only get you so far. To achieve the best results, you must also allow each team member to use the tools and methods they are most comfortable working with. In practice, that's often easier said than done.

To leverage the full potential of the Industrial IoT, machine builders need interdisciplinary teams that bring together experts from both domains. All too often, this becomes a conflict between two different worlds. While OT experts are well versed in machine design, PLC programming and commissioning, their IT colleagues are more at home using high-level programming languages like C++, Python or JavaScript and working with open-source software and Linux. Until now, there has been no platform where both groups could pool their expertise.

Exploring new horizons

The challenge is to overcome the obstacles that stand in the way of harmonious, effective IT/OT collaboration. Traditionally, the two domains have existed more or less as parallel universes. "But with the rise of the Industrial IoT, the time has come to change that," says Stefan Schönegger, IoT specialist at B&R. "In order to integrate advanced database systems, machine learning, artificial intelligence and IoT algorithms directly into machines, we need to erase the lines between IT and OT."

The biggest obstacle is that today's control systems don't support the full bandwidth of high-level programming languages the way a Linux environment would. As a prerequisite for true IT/OT connectivity, control systems must therefore be given the ability to access and understand Linux software.

Optimally combining IT and OT

This is exactly where B&R comes in – with its new enhanced crossover Operating System, or exOS for short. "exOS bridges the divide that has traditionally separated IT and OT, and finally gives machine builders an ideal connection between the two worlds," says Schönegger. "With the ability to use any Linux software in the B&R system, they now have access to one of the world's largest software ecosystems."

exOS gives every Linux engineer the freedom to develop, compile and debug code in their preferred environment. Then, the Linux application can be easily integrated into the control system and used hand-in-hand with B&R's real-time operating system, Automation Runtime. "When developers are able to work in a familiar environment, like Eclipse or Visual Studio, they can make the best use of their knowledge and experience," explains Schönegger. "And that's a huge advantage."

With exOS, B&R gives control systems the ability to access and understand any Linux software. This gives every Linux software developer the freedom to develop, compile and debug their code using their preferred programming environment (IDE).

One central engineering tool

Developers simply import their completed Linux application into the B&R system as an exOS package. From that point on, they can use Automation Studio as a central engineering tool. Managing and debugging software solutions becomes simple and straightforward. No other tools are required. "What that means is that the developer creating the Linux software and the engineer commissioning the machine can each work in the environment they're used to," notes Schönegger, "because they have exOS bringing it all together seamlessly."

Efficient maintenance

In addition to streamlined development and commissioning, another hallmark of an intelligent machine is that maintenance can be performed quickly and easily. In the event of a malfunction, service technicians need to locate the problem and contact the machine builder as quickly as possible.

exOS offers extensive diagnostic functions. The B&R system provides the user with a complete log of all error messages from both the Linux application and the controller operating system. Hardware components are also easy to replace.

The machine is back up and running again in minutes without any reprogramming. "exOS makes maintenance much more efficient and significantly reduces downtime," says Schönegger. Not only is it easy to replace hardware when necessary, any updates to the machine software can also be installed, for example via remote access.

Developers simply import their completed Linux application into the B&R system as an exOS package. This lets them use Automation Studio as a central engineering tool.

Future-proof solution

B&R's crossover solution offers numerous integrated functions that make it easier to implement hybrid solutions combining machine control and Linux applications. The integrated functions are executed symmetrically in Automation Runtime and Linux. "exOS uses technology and tools from the B&R system and integrates the Linux application into the B&R engineering environment. All the freedom of Linux remains," says Schönegger.

Features include uniform project management for Linux and real-time applications in Automation Studio as well as automatic transfer of Linux applications from Automation Studio to the controller and the Linux environment. exOS also includes a user-friendly API for high-performance data exchange. The API ensures easy, buffered process data communication between the controller operating system and Linux, consistently in the millisecond range.

exOS offers numerous integrated functions that make it easier to implement hybrid solutions combining machine control and Linux applications.

Scalable for any application

To use exOS, machine builders only need one Automation PC or Panel PC from B&R. "Automation Runtime and Linux run on the same device, and the Linux application is executed hand in hand with cyclic control applications. This is useful in applications like automated guided vehicles (AGVs)," says Schönegger. Such systems are often based on the open-source robotics platform ROS. In ROS, dynamic path planning is executed in Linux, while motion control tasks are handled in Automation Runtime. With exOS, the two can be optimally synchronized in a hypervisor configuration and installed on one Automation PC.

A single Automation PC or Panel PC from B&R is all that is needed to implement exOS. The Linux application runs hand in hand with cyclic control applications on one device.

IT and OT hand-in-hand

As a flexible crossover solution, exOS breaks down longstanding barriers between IT and OT to create common ground for effective collaboration. "With this move, B&R opens up one of the world's largest software ecosystems – where the best of both worlds can contribute to convergent, adaptive machine concepts," says Schönegger. OEMs can fully leverage the know-how of their developers and engineers in both domains and implement innovative machine concepts for smart factories.

Author: Carola Schwankner, Corporate Communications Editor, B&R

exOS applications

Optimized machine processes

exOS helps optimize machine processes by executing machine learning algorithms directly at the edge. Machine and device data can easily be accessed and collected from the machine controller. A TensorFlow ML model can run in Linux on an Automation PC 2200 that at the same time is handling machine control in Automation Runtime. exOS combines the two in a hypervisor configuration, making it fast and easy to get everything integrated and connected.

Simplified quality control

With exOS, production data for quality control can be stored directly on industrial automation hardware in highly developed database systems. The database, for example MongoDB, runs in Linux, while the machine control software runs in Automation Runtime. exOS combines the two in a hypervisor configuration on a Panel PC.

"In order to integrate advanced database systems, machine learning, artificial intelligence and IoT algorithms directly into machines, we need to erase the lines between IT and OT," says Stefan Schönegger, VP of Product Management for Controls, Machine Vision and Networks at B&R.

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