July 7, 2016

Zumbach Measuring Instruments now with OPC UA Standard

OPC UA Industry 4.0


Prepare your dimension, profile and diameter measurement field data for new Industry 4.0 services. Instruments with the new OPC UA standard meet the technical requirements for intelligent data networking.
ZUMBACH has equipped its powerful measuring instruments with OPC UA which ensure a simple, scalable and secure information exchange between different production line systems – regardless of platform or manufacturer.

Transparent data management – simple monitoring in real-time

One software enables all M2M (machine to machine) or M2H (machine to human) measurement data obtained to be interconnected on one output platform, collected, displayed and analysed. The OPC UA standard facilitates horizontal AND vertical integration across various levels of the automation pyramid. This means that the requirements for industry automation along with future semantic communication scenarios from Industry 4.0 and the Internet of Things (IoT: Internet of Things) have already been met.



Data output, diagnosis and reactive actions occur on one platform. The transparency generated shortens the reaction times in case of deviations and ultimately results in important quality gains.

ZUMBACH has it today, everyone else will have it tomorrow

OPC has the broadest circulation in the field of automation, but is technologically industry-neutral and can be run on all operating systems. Communication between plant equipment takes place reliably, securely and independent of the manufacturer. As one of the first equipment manufacturers for inline measurement and monitoring, ZUMBACH integrated OPC UA into its PC-based stems with host communications protocol (e.g. in the PROFILEMASTER® profile measuring systems series, in measurement systems for hot rolling mills and STEELMASTER cold processes as well as in the USYS IPC series for universal data recording, processing and display systems and many more). The OPC UA server is also available for installation on your server/PC or a small IPC pre-configured by Zumbach for gauges with microprocessor and host communication protocol (ODAC® laser diameter measuring instruments, MSD diameter and ovality measuring systems, spark testers, computer interface boxes, and more) For information on additional devices that support OPC UA, please refer to our OPC UA data sheet.



OPC UA: Milestone of standardization for Industry 4.0

“OPC United Architecture (OPC UA) is the data exchange standard for secure, reliable, manufacturer and platform-independent communication. It enables data exchange between products from different manufacturers across any operating system. … With the introduction of service-oriented architectures (SOS) in industrial automation systems starting in 2007, the OPC UA architecture enabled a scalable, platform-independent solution that combines the benefits of web services and integrated security with one uniform data model.”

(Thomas J. Burke, President and Executive Director OPC Foundation).






Standardisation achieved with the OPC UA is a milestone in the development of processes within Industry 4.0. Devices communicate with one another and respond as a network. In certain applications, OPC UA has the potential to replace the existing variety of industrial Ethernet protocols with a direct connection between field devices and the application.

Starting in the mid-90s, industry and other market segments supported the development of the OPC standard. Broad approval from representatives in research, industry and related organizations shows that as a data and information exchange standard for the Industry 4.0 project, OPC UA is a key technology.

OPC UA meets the requirements of Industry 4.0

Independence of the communication technology from manufacturers, industries, operating systems,
programming language; supported by all well-known SCADA (as client) and PLC control manufacturers (mainly as server). First clouds with corresponding interface.

Scalability for full interconnection, from the smallest sensor via embedded devices and PLC controls to PC and smart phones as well as mainframe computers and cloud applications.

Security of transmission as well as authentication on user and application level.

Uniform, flexible, transparent and efficient data transport across established
standards (SOA via TCP/IP) with optimised binary protocol or with HTTP/HTTPS web services; visualisation support from various suppliers.

Information model of real products and their production steps thanks to fully interconnected,
object-oriented concept for name space and meta data.

Compliance testing thanks to IEC-62541 standard, tools and test labs.


OPC Unified Architecture


Zumbach develops for Industry 4.0

As it moves toward the use of self-optimising systems as modular production equipment, OPC UA with its flexible features is the basis for further development in the Industry 4.0 environment. For future modular and scalable production equipment, we expect that the use of OPC UA will simplify the process of connecting such equipment to overriding systems (MES, ERP).

As the trendy catchphrase of the hour. Industry 4.0 describes the 4th industrial paradigm change in history and leaves us hopeful for major innovations in data processing. The large volumes of data that have brought about computerisation with big data will soon be networked based on intelligent production technologies. In the age of Industry 4.0, production processing systems will be able to self-regulate themselves.


As a developer and manufacturer of measurement and control solutions for industrial applications, ZUMBACH is busy working on new data transmission and networking solutions, especially when it comes to recording and displaying measurement values from different measuring devices (display), transmitting data to one customer server and its further processing in reports and statistics.

The following systems form the basis to do this in today’s industrial landscape:

1. 1. M2M – machine to machine communication based on recognised standards
2. 1. M2H – machine to human communication based on platform-independent display devices and one standard software

In M2M communication, ZUMBACH also uses special field buses and real-time Ethernet. Standards as well as actions required by certification lead to the necessary reliability and performance capability.

M2H, in contrast, focuses on web server applications that are already offered in numerous systems and will be used universally in the future. Thanks to shared industrial interoperability standards and in this context, OPC UA also offers a strong foundation for efficient M2H solutions.

Learn more on Industry 4.0


The Industry 4.0 approach and its innovation cycle go above and beyond this traditional view:

Industry 4.0 is characterised by the search for new services that are based on collected data. The process of collecting data to develop a new service is illustrated in the Industry 4.0 Innovation Cycle that involves the following phases: “Product Features,” “Data Analytics” and “New Services”.


In the first Product Features phase, the conditions for information processing must be established. A product can only be used in the Industry 4.0 environment if it has sensors and a system available for information processing and is equipped with a suitable application software; another option is the use of actuators. In addition, the product requires a network interface that can establish a wireless or wired network connection for the product in the field.

ZUMBACH instruments equipped with the “OPC UA Data Access” feature now already support this basic requirement and cover the broad basis of applications. Depending on need, this basic functionality can be enhanced to include additional security functions (encryption and authentication certificates instead of only “basic user authentication”), object-orientation and other features (results, methods, alarms and historic access).

If the measuring instruments generate precise data, the second phase involves assessing and deriving general scenarios from the plethora of information (big data). Based on these data, scenarios and innovative approaches aimed at improvement can be developed. Accordingly, the knowledge generated from data analysis decisively supports the development of new, useful services.

 This is therefore the ideal time to work with you together to define further features across your entire company so you are well-equipped for the future.

 Become part of this process and tell us what your I4.0 focus is for the future.

OPC Questionnaire Industry 4.0


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