PC Cascade 4.0 is a modern platform for building HMI and dispatching systems

Modern automated process control systems (APCS) cannot be imagined without SCADA/HMI software systems. They provide communication between technological equipment and humans, allow monitoring of the state of production facilities, perform dispatch control, keep an archive of technological parameters, and analyze the efficiency of production processes. In the context of industrial digitalization, the requirements for such systems have significantly increased. In addition to displaying information to the operator, modern platforms must support distributed architecture, handle large data streams, integrate with corporate information systems, and have high reliability and scalability.

One of such domestic platforms is the software complex KASKAD 4.0. Unlike most classical SCADA systems, the KASKAD architecture is built around an object data model and the microservice principle of software construction. Thanks to this, the platform allows you to create both small local HMI and large dispatching complexes with tens of thousands of data points and a large number of simultaneously working operators.

The main feature of KASKAD is that the system does not treat process signals as a set of independent tags. The platform is based on an object model that combines data points, parameters, properties, and graphical representation of equipment into a single logical structure. This is what sets KASKAD apart from many traditional SCADA systems.

CASCADE PC Architecture

The Cascade 4.0 architecture is based on the microservice principle. Instead of a single monolithic application, it uses a set of independent managers, each of which performs a strictly defined function. This approach significantly improves system reliability, simplifies maintenance, and enables horizontal scaling.

The main managers are:

  • Manager Management Console;
  • Gateway;
  • Handler;
  • HDB (Historical Database);
  • Data Point Configurator;
  • User Interface (UI).

Each manager is a separate software process. They exchange messages and technological data. This ensures that the failure of one component does not cause the system to shut down completely.

For example, if the user interface is closed, the gateway will continue to exchange information with the controllers, and the archive manager will continue to store historical data. Once the client is restarted, the operator will immediately see the current status of the equipment.

This architecture is significantly superior to classic SCADA systems, where all functions were performed by a single running process.

Gateway — technology data exchange center

The Gateway Manager is responsible for interacting with external sources of information.

It is he who exchanges data with:

  • programmable logic controllers;
  • input/output devices;
  • intelligent sensors;
  • industrial meters;
  • OPC UA servers;
  • MQTT brokers;
  • Modbus TCP and Modbus RTU devices.

Gateway can be compared to the communication center of the entire system. Its task is not to process data, but only to receive and transmit it to the internal managers of Cascade. Once a new value is received, it is passed to the Handler.

Handler — the core of information processing

Handler is one of the most important components of Cascade. This is where the main logical processing of information takes place.

After getting the new Handler value:

  • defines the parameter change;
  • checks the quality of the data;
  • updates the corresponding DataPoint;
  • notifies the user interface;
  • transfers information to the archive;
  • checks the alarm conditions;
  • it sends updates to all connected clients.

Thus, the Handler is the central dispatcher of the system. It ensures the coordinated operation of all other managers.

HDB — Historical Database Manager

Any industrial system must store the history of changes to its technological parameters.

In Cascade, this task is fully assigned to the Historical Database Manager.

After receiving information from the Handler, the archive manager records the data in the historical database.

Based on the accumulated data, the:

  • trends;
  • reports;
  • statistics;
  • change logs;
  • analysis of equipment operation.

Separating the archiving functions from the controller exchange allows you to significantly improve the system's performance.

CASCADE Object Model

The most important feature of the platform is the use of an object-based data model.

In many SCADA systems, the basic unit is a tag.

Cascade uses a significantly higher level of abstraction, DataPoint.

A DataPoint is a software object that describes some essence of a technological process.

It can be a pump, a fan, a gate valve, an electric motor, a tank, a heat exchanger, a temperature sensor, a room, or a power line. For example, a pump is not considered as several independent tags, but as a single object.

Inside it are the parameters:

Pump_1

├── State

├── Current

├── Temperature

├── Pressure

├── Runtime

├── Alarm

└── Mode

In this way, DataPoint combines all the information related to a single process object. This approach greatly simplifies the development of large projects. Instead of working with thousands of individual tags, engineers work with logically complete objects.

Para is the heart of the object model

If DataPoint is an object, then Para is a separate parameter of that object. It is Para that contains the actual technological data.

For example:

DataPoint «Pump»

has Para:

  • State;
  • Speed;
  • Current;
  • Voltage;
  • Alarm;
  • Runtime;
  • Pressure.

Each Para has its own set of properties. These include:

  • meaning;
  • data type;
  • unit of measurement;
  • quality;
  • Time of change;
  • time of receipt;
  • access rights;
  • possibility of archiving;
  • belonging to worries.

Thus, Para is significantly superior to a regular SCADA tag. In fact, Para is a full-fledged software object with its own state and set of characteristics.

When the Para value is changed, the processing chain is automatically triggered:

PLC

↓

Gateway

↓

Handler

↓

Para

↓

HDB

↓

GEDI

↓

Operator's screen

Therefore, a change in one parameter is instantly reflected in the mnemonic, in the trends, in the archive, in the alarms, and in the reports.

Data Point Configurator

A specialized configurator is used to create a DataPoint. It is the engineering part of Cascade, where the entire project structure is created. The engineer forms the enterprise object tree.

For example:

Company

└── Boiler room

      ├── Pump No. 1

      ├── Pump No. 2

      ├── Boiler

      ├──Fan

      └── Heat exchanger

Each object automatically contains a Para. set, which significantly reduces the amount of manual project configuration.

GEDI — graphical development environment

One of the most powerful components of the platform is the GEDI editor.

GEDI (Graphic Editor) is designed to create human-machine interfaces. Unlike conventional graphic editors, GEDI works directly with the Cascade object model.

Graphical elements do not contain their own data. They only display the status of the corresponding Para.

For example, the pump image can simultaneously display the status color, rotation speed, temperature, motor current, operating mode, and emergency status.

Each of these parameters is associated with a specific Para DataPoint. When the value changes, the Handler automatically notifies GEDI. The editor only updates the screen elements that have actually changed.

This mechanism significantly improves the performance of the user interface.

Dynamic properties of objects

GEDI supports a large number of dynamic properties.

These include color changes, transparency changes, size changes, position changes, object rotation, blinking, animation, text display, and image changes.

All dynamic properties receive information directly from Para. This mechanism allows you to create very informative mnemonic diagrams.

Archiving and trends

Each Para can be configured to be archived. When the value is changed, the Handler sends information to the HDB manager.

After being added to the historical database, the following become available:

  • plotting graphs;
  • analysis of changes;
  • emergency search;
  • generating reports;
  • hardware performance analysis.

Since it is Para that is being archived, the history automatically preserves the entire project's object structure.

Alarms and events

Each Para is capable of generating events.

After the alarm occurs, the system:

  • displays a message;
  • saves the event;
  • records the time of occurrence;
  • controls the confirmation by the operator;
  • saves the confirmation time.

This way, a complete equipment log is generated.

System scalability

One of the main advantages of Cascade is its scalability.

A small object can run on a single computer. A large enterprise can distribute managers between multiple servers.

At the same time, the object model remains unified, and the operator does not notice the distribution of components.

Advantages of the object model

Using DataPoint and Para provides several advantages over the traditional tag model:

  • logical unification of equipment parameters;
  • simplification of project development and maintenance;
  • reuse of object templates;
  • a unified approach to archiving, alarms, and visualization;
  • reducing the likelihood of design errors;
  • convenient scaling of large projects.

It is the object model that allows you to work effectively with tens of thousands of technological parameters while maintaining an understandable project structure.

Conclusion

The KASKAD 4.0 software package is a modern domestic platform for building HMI, SCADA, and dispatching systems based on a microservice architecture and an object-oriented data model. Unlike traditional SCADA systems, where the main element is a separate tag, KASKAD uses the concept of DataPoint, a software object that combines related equipment parameters. Inside each object, there are Para, which are full-fledged parameters with their own values, data quality, timestamps, archiving settings, and alarm participation. Thanks to support for modern industrial protocols, a scalable architecture, advanced visualization tools, and deep integration of the object model with the user interface, KASKAD can be effectively used both in small local automation facilities and as part of large distributed control systems.