Extending the functionality of topologies of Web-oriented control systems for technological objects based on “Open User Communication”

Authors

DOI:

https://doi.org/10.15587/1729-4061.2025.348728

Keywords:

Open User Communication, OUC topology, SCADA, PLC Simatic-S7, OUC simulation model

Abstract

This study focuses on the information processes involved in the interaction between components of WEB-oriented control systems based on the “Open User Communication” (OUC) technology. The task addressed related to the violation of data consistency across different topology levels in process control systems during cyclic server requests, the need for batch transmission of heterogeneous data types, the unification of equipment, and the technical validation of solutions.

A system topology has been designed using a SCADA (Supervisory Control and Data Acquisition) system, a server PLC (Programmable Logic Controller), and four terminal PLCs with integrated OUC in the “TIA Portal” environment. This topology allows for data consistency between the server and terminal PLCs by transmitting heterogeneous data formats within a single frame using dynamic data-slice selection.

Hardware tools and application software were developed in the Function Block Diagram (FBD) language of the IEC 61131-3 standard to implement “Open User Communication” with transmission capacities of up to 8192 bytes per frame.

To study information processes, a simulation model of interaction between the server and terminal PLCs based on OUC was built and tested using virtual PLC simulators with dynamic data-slice adjustment. The transmission of 12 different data formats (a total of 332 bytes) was tested using the “TSEND_C” and “TRCV_C” instructions under a “monitoring-on” mode.

GRE tunneling protocol parameters were configured to enable simultaneous data exchange between the server and terminal PLCs via “Open User Communication”, alongside PLC programming via “S7-Communication”.

Based on the proposed solutions, a WEB-oriented data acquisition system for technological facilities of municipal water-supply enterprises was developed and validated under industrial conditions

Author Biographies

Leonid Zamikhovskyi, Ivano-Frankivsk National Technical University of Oil and Gas

Doctor of Technical Sciences, Professor, Head of Department

Department of Information and Telecommunication Technology and Systems

Mykola Nykolaychuk, Ivano-Frankivsk National Technical University of Oil and Gas

PhD, Associate Professor

Department of Information and Telecommunication Technology and Systems

Ivan Levytskyi, Ivano-Frankivsk National Technical University of Oil and Gas

PhD, Associate Professor

Department of Information and Telecommunication Technology and Systems

References

  1. Basics of Open User Communication: S7 1200, S7 1500, S7 1500T (TIA Portal V20) (2024). Siemens. Available at: https://docs.tia.siemens.cloud/r/en-us/v20/editing-devices-and-networks/configure-networks/communication-via-connections/working-with-connections/using-open-user-communication-s7-1200-s7-1500-s7-1500t/basics-of-open-user-communication-s7-1200-s7-1500-s7-1500t
  2. Products for Totally Integrated Automation: Catalog ST 70 (Catalog No. E86060-K4770-A101-C2-7600) (2025). Siemens. Available at: https://support.industry.siemens.com/cs/attachments/109744167/simatic-st70-complete-english-2025_1.pdf
  3. Reyes Domínguez, D., Infante Abreu, M. B., Parv, A. L. (2024). Main Trend Topics on Industry 4.0 in the Manufacturing Sector: A Bibliometric Review. Applied Sciences, 14 (15), 6450. https://doi.org/10.3390/app14156450
  4. Villar, E., Martín Toral, I., Calvo, I., Barambones, O., Fernández-Bustamante, P. (2024). Architectures for Industrial AIoT Applications. Sensors, 24 (15), 4929. https://doi.org/10.3390/s24154929
  5. Alsabbagh, W., Langendöerfer, P. (2022). A New Injection Threat on S7-1500 PLCs – Disrupting the Physical Process Offline. IEEE Open Journal of the Industrial Electronics Society, 3, 146–162. https://doi.org/10.1109/ojies.2022.3151528
  6. Gautam, M. K., Pati, A., Mishra, S. K., Appasani, B., Kabalci, E., Bizon, N., Thounthong, P. (2021). A Comprehensive Review of the Evolution of Networked Control System Technology and Its Future Potentials. Sustainability, 13 (5), 2962. https://doi.org/10.3390/su13052962
  7. Yadav, G., Paul, K. (2021). Architecture and security of SCADA systems: A review. International Journal of Critical Infrastructure Protection, 34, 100433. https://doi.org/10.1016/j.ijcip.2021.100433
  8. Schäffer, E., Penczek, L. N., Bartelt, M., Brossog, M., Kuhlenkötter, B., Franke, J. (2021). A Microservice- and AutomationML-based Reference Architecture for an Engineering Configurator Web Platform. Procedia CIRP, 103, 274–279. https://doi.org/10.1016/j.procir.2021.10.044
  9. Busboom, A. (2024). Automated generation of OPC UA information models – A review and outlook. Journal of Industrial Information Integration, 39, 100602. https://doi.org/10.1016/j.jii.2024.100602
  10. Tusa, F., Clayman, S., Buzachis, A., Fazio, M. (2024). Microservices and serverless functions—lifecycle, performance, and resource utilisation of edge based real-time IoT analytics. Future Generation Computer Systems, 155, 204–218. https://doi.org/10.1016/j.future.2024.02.006
  11. Zhukabayeva, T., Ahmad, Z., Adamova, A., Karabayev, N., Abdildayeva, A. (2025). An Edge-Computing-Based Integrated Framework for Network Traffic Analysis and Intrusion Detection to Enhance Cyber-Physical System Security in Industrial IoT. Sensors, 25 (8), 2395. https://doi.org/10.3390/s25082395
  12. Ji, T., Xu, X. (2025). Exploring the Integration of cloud manufacturing and cyber-physical systems in the era of industry 4.0 – An OPC UA approach. Robotics and Computer-Integrated Manufacturing, 93, 102927. https://doi.org/10.1016/j.rcim.2024.102927
  13. Nazarenko, I. V., Nikolaychuk, M. Ya., Ferenets, V. D., Sukhanov, D. Ye. (2014). Construction and modeling of unified control systems of actuating mechanisms for objects of gas-transport system. Eastern-European Journal of Enterprise Technologies, 1 (2 (67)), 41–48. https://doi.org/10.15587/1729-4061.2014.21204
  14. Zamikhovskіy, L., Levytskyi, I., Nykolaychuk, M. (2021). Designing a system that removes metallic inclusions from bulk raw materials on the belt conveyor. Eastern-European Journal of Enterprise Technologies, 3 (2 (111)), 79–87. https://doi.org/10.15587/1729-4061.2021.234235
  15. S7-1200 Programmable controller: System manual (V4.7, A5E02486680-AQ) (2024). Siemens. Available at: https://support.industry.siemens.com/cs/document/109977302/s7-1200-programmable-controller?dti=0&lc=en-US
  16. SCALANCE X-200: Operating instructions (BA_SCALANCE-X-200_76) (2024). Siemens. Available at: https://cache.industry.siemens.com/dl/files/056/109955056/att_1266072/v1/BA_SCALANCE-X-200-2023_76_en-US.pdf
  17. SIMATIC NET S7 1200 telecontrol / SIMATIC CP 1243-7 LTE (2025). Siemens. Available at: https://support.industry.siemens.com/cs/document/109995459/simatic-net-s7-1200-telecontrol-simatic-cp-1243-7-lte?dti=0&lc=en-US
  18. Industrial Ethernet / PROFINET: Networking manual. System Manual, 07, C79000-G8900-C242 (Doc. No. SYH_IE-Net_76) (2019). Siemens. Available at: https://support.industry.siemens.com/cs/attachments/27069465/SYH_IE-Net_76.pdf
  19. SIMATIC STEP 7 Basic/Professional V20 and SIMATIC WinCC V20 (2024). Siemens. Available at: https://support.industry.siemens.com/cs/document/109977280/simatic-step-7-basic-professional-v20-und-simatic-wincc-v20?dti=0&lc=en-US
  20. S7-PLCSIM online help (Version 21, Doc. No. A5E46238743-AJ) (2025). Siemens. Available at: https://support.industry.siemens.com/cs/document/109997161/s7-plcsim-online-help
  21. Basic examples for Open User Communication (OUC): ISO on TCP, TCP, UDP (2021). Siemens. Available at: https://support.industry.siemens.com/cs/document/109747710/basic-examples-for-open-user-communication-%28ouc%29?lc=en-cy
  22. S7 1500 / S7 1500T motion control overview: Function manual (Version 7.0, Doc. No. A5E03879256 AH) (2022). Siemens. Available at: https://support.industry.siemens.com/cs/attachments/109812056/s71500_s71500t_motion_control_overview_function_manual_en-US_en-US.pdf
  23. Open User Communication with TSEND_C and TRCV_C: SIMATIC S7 1200 CPU (Version 2.1) (2018). Siemens. https://support.industry.siemens.com/cs/attachments/67196808/net_s7-1200_isoontcp_en.pdf
  24. Zamikhovskyi, L., Nykolaychuk, M., Levytskyi, I. (2024). Organizing the automated system of dispatch control over pump units at water pumping stations. Eastern-European Journal of Enterprise Technologies, 5 (2 (131)), 61–75. https://doi.org/10.15587/1729-4061.2024.313531
  25. Zamikhovskyi, L., Zamikhovska, O., Ivanyuk, N., Mirzoieva, O., Nykolaychuk, M. (2025). Development of an anti-surge protection system for gas pumping units based on hardware and software vibration monitoring tools. Eastern-European Journal of Enterprise Technologies, 4 (2 (136)), 117–132. https://doi.org/10.15587/1729-4061.2025.337736
Extending the functionality of topologies of Web-oriented control systems for technological objects based on “Open User Communication”

Downloads

Published

2025-12-31

How to Cite

Zamikhovskyi, L., Nykolaychuk, M., & Levytskyi, I. (2025). Extending the functionality of topologies of Web-oriented control systems for technological objects based on “Open User Communication”. Eastern-European Journal of Enterprise Technologies, 6(2 (138), 94–115. https://doi.org/10.15587/1729-4061.2025.348728

Issue

Vol. 6 No. 2 (138) (2025): Information technology. Industry control systems

Section

Industry control systems

License

Copyright (c) 2025 Leonid Zamikhovskyi, Mykola Nykolaychuk, Ivan Levytskyi

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

The consolidation and conditions for the transfer of copyright (identification of authorship) is carried out in the License Agreement. In particular, the authors reserve the right to the authorship of their manuscript and transfer the first publication of this work to the journal under the terms of the Creative Commons CC BY license. At the same time, they have the right to conclude on their own additional agreements concerning the non-exclusive distribution of the work in the form in which it was published by this journal, but provided that the link to the first publication of the article in this journal is preserved.

A license agreement is a document in which the author warrants that he/she owns all copyright for the work (manuscript, article, etc.).
The authors, signing the License Agreement with TECHNOLOGY CENTER PC, have all rights to the further use of their work, provided that they link to our edition in which the work was published.
According to the terms of the License Agreement, the Publisher TECHNOLOGY CENTER PC does not take away your copyrights and receives permission from the authors to use and dissemination of the publication through the world's scientific resources (own electronic resources, scientometric databases, repositories, libraries, etc.).
In the absence of a signed License Agreement or in the absence of this agreement of identifiers allowing to identify the identity of the author, the editors have no right to work with the manuscript.
It is important to remember that there is another type of agreement between authors and publishers – when copyright is transferred from the authors to the publisher. In this case, the authors lose ownership of their work and may not use it in any way.