🌐 Networked Industrial SCADA System (Python + OPC UA)

📌 Project Overview

This project demonstrates a real-world industrial Client–Server SCADA architecture where a Python-based HMI communicates with a remote PLC through Kepware OPC UA over LAN.

The system is built across two separate physical machines to replicate an actual factory environment where the control room and machine network operate independently.

This is not a simulation-only UI — it performs real-time read/write communication with PLC logic through industrial protocols.

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🏗 System Architecture

Machine	IP Address	Role	Software
PC 1 (Server)	192.168.0.20	PLC + OPC UA Server	CODESYS SoftPLC + Kepware
PC 2 (Client)	192.168.0.10	SCADA/HMI	Python (PySide6)

Data Flow

Python HMI → OPC UA (TCP/IP) → Kepware → PLC PLC → Kepware → Python HMI (Feedback)

Operator commands and setpoints are written to the PLC via OPC UA, and live machine data is read back into the HMI for monitoring and visualization.

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🖥 Screenshots

1. HMI Dashboard (Running on Client PC)

2. Kepware & PLC Status (Running on Server PC)

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🚀 Features

Real-time Control

• Start / Stop / Reset motor from remote HMI
• Setpoint writing to PLC (PV update)
• Bi-directional OPC UA communication

Live Monitoring

• Process value & count monitoring
• Motor status & limit indicators
• PLC online/offline detection

Visualization

• Real-time trend chart (CV tracking)
• Dynamic alarm/status messages
• Industrial UI design (PySide6)

Network Architecture

• Two-PC industrial setup
• OPC UA over LAN
• Firewall & port configuration (Port 49320)
• Remote PLC control from separate machine

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⚙️ Requirements

Server PC

• CODESYS SoftPLC running
• Kepware OPC UA configured
• OPC UA port open (default: 49320)

Client PC

Install dependencies:

pip install PySide6 opcua qt-material

🧱 Logical System Architecture

graph TD
    PLC["PLC / Controller"] -->|"OPC UA / Modbus TCP"| OPC["Kepware OPC UA Server"]
    OPC -->|"TCP/IP"| HMI["Python HMI (PySide6)"]
    HMI -->|"Write Commands"| OPC
    HMI -->|"Read Live Data"| OPC
    HMI -->|"Log Production Data"| DB[("SQLite Database")]
    HMI -->|"Visualize"| UI["Operator Dashboard"]
    HMI -->|"Generate Reports"| RPT["PDF & Excel Reports"]
    DB -->|"Dataset for Future"| AI["AI / Analytics Layer"]
    HMI -->|"MQTT (Future)"| CLOUD["Cloud / Remote Monitoring"]

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🔌 Network Topology (Physical Setup)

graph TD
    subgraph Server_PC ["🖥️ PC 1 (Server Room)"]
        IP1[("IP: 192.168.0.20")]
        PLC["CODESYS SoftPLC"]
        KEP["Kepware Server"]
        PLC <-->|"Internal Memory"| KEP
    end

    subgraph Client_PC ["💻 PC 2 (Control Room)"]
        IP2[("IP: 192.168.0.10")]
        HMI["Python HMI (PySide6)"]
    end

    KEP <==>|"OPC UA / TCP (Port 49320)"| HMI

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