Hierarchical control and industrial automation
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This document discusses hierarchical control and industrial automation. It begins by defining automation as using control systems like computers to reduce human intervention in industrial processes. It then outlines the main expectations from automation systems. The document goes on to describe various applications of automation and the typical pyramid structure used in industries. It also provides details on the key building blocks of automation systems, including sensors, PLCs, DCS, SCADA, MES and ERP systems. It discusses the interactions between these different levels and components.
Hierarchical control and industrial automation
- 1. Hierarchical Control and Industrial Automation Prof. Arpit Jain arpit.eic@gmail.com +91-8650304041
- 2. Automation • Automation is the use of control systems such as computers to control industrial machinery and processes, reducing the need for human intervention.
- 3. Expectations from automations High reliability and availability. Fast troubleshooting. Easily configurable. Process optimization. Asset optimization . Flexibility. Able to take each & every decision with minimum assistance from human intervention.
- 4. Applications of Automation Power generation Manufacturing Building Transportation Mining Oil & gas industries Pharmaceutical And many more…..
- 5. The famous Pyramid of Automation This pyramid is considered as reference in industries while developing automation solutions. Manufacturing Execution Supervision (SCADA) Group Control Individual Control Field Primary technology Enterprise
- 6. Detailed structure of control system hierarchy
- 7. A standard functional hierarchy by ANSI/ISA-95
- 8. Building blocks of Automation Sensors and actuators Analog and digital I/O modules DDC direct digital control PLC being replaced by PACs DCS distributed control systems SCADA supervisory control and data acquisition MES manufacturing execution system ERP enterprise resource planning
- 9. Sensors and Actuators • Intelligent sensors • Biosensors • Optical fiber sensors • Expert sensors • Digital actuators Biosensor Motor with built in DAC
- 10. Analog and digital I/O module Analog I/O module Digital I/O module Mixed I/O module Genius I/O module
- 11. Direct Digital control Mainly used for control of critical process parameters
- 12. PLC Programmable Logic Controllers • A programmable logic controller (PLC) or programmable controller is a digital computer used for automation purposes. PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact A typical rack mounted PLC
- 13. PAC Programmable Automation Controllers • PAC has all the capabilities of PLC with some added features like task flexibility, integrated communication interfaces and very high computing power.
- 14. Architecture of PAC Architecture details of SEL-2411 PAC
- 15. Benefits of PAC over PLC PAC support many standard communication protocols PAC can do many tasks simultaneously
- 16. DCS Distributed Control System Architecture of DCS Control room of a DCS system
- 17. DCS system on a plant floor
- 18. SCADA Supervisory control and data acquisition system In early 1970s all instruments were directly wired to the control room
- 19. SCADA Supervisory control and data acquisition system SCADA architecture
- 20. Main functions of SCADA - displays the current state of the process (visualization) - display the alarms and events (alarm log, logbook) - display the trends (historians) and analyse them - display handbooks, data sheets, inventory, expert system (documentation) - allows communication and data synchronization with other centres
- 21. Knowledge management for design and manufacturing
- 22. MES Manufacturing Execution System Manufacturing Execution Systems (MES) manage and monitor work-in- process on the factory floor including manual or automatic labor and production reporting, as well as on-line inquiries and links to tasks that take place on the production floor. Manufacturing Execution Systems may include one or more links to work orders, receipt of goods, shipping, quality control, maintenance, scheduling or other related tasks. Here we are dealing with the Level 3 of ANSI/ISA-95 standard which is shown in figure
- 23. Reasons to implement MES • Automate management of recipes (process manufacturers) • Scheduling, including the management of priorities • Production reporting • Key Performance Indicator (KPI) tracking • Event or exception management • Product or materials tracking • Intelligent decisions to influence production and cost management • Measure and manage operational equipment efficiency, or OEE • Ease management of resources, including inventory and personnel
- 24. Standardized MES architecture by ISA-95
- 25. S95.01 There are eleven generic functions found in an MES suite, which are defined by the S95.01 standard provided by the Instrumentation, Systems and Automation (ISA). These functions are not the be all and end all of MES functionality but are meant to provide a solid category of capabilities. The eleven functions are: Operations/Detailed Scheduling Resource Allocation & Status Dispatching Production Units Document Control Product Tracking & Genealogy Performance Analysis Labor Management Maintenance Management Process Management Quality Management Data Collection Acquisition.
- 26. Link between SCADA and MES systems Plant intelligence links between SCADA and MES
- 27. Benefits of implementing MES
- 28. ERP Enterprise Resource Planning • ERP is an enterprise-wide information system designed to coordinate all the resources, information, and activities needed to complete business processes such as order fulfillment or billing.
- 29. Interactions between ERP and plant floor • Current ERP vendors (SAP) provide over 30 different interactions between plant floor and ERP, some of them are shown below
- 30. Response time and hierarchical level Planning Level Execution Level Control Level Supervisory Level ms seconds hours days weeks month years ERP (Enterprise Resource Planning) DCS MES (Manufacturing Execution System) PLC (Programmable Logic Controller) (Distributed Control System) (Supervisory Control and Data Acquisition) SCADA
- 31. Complexity and Hierarchical levels
- 32. Conclusion • Industrial Automation is a discipline that includes knowledge and expertise from various branches of engineering Industrial Automation Engineers have always drawn new technologies and implemented original or enhanced versions to meet their requirements. As the range of technology diversifies the demand on the innovative ability of these Engineers has increased. Hence in order to survive in today’s competitive manufacturing markets, manufacturing systems need to adapt at an ever-increasing pace to incorporate new technology which can lower the cost of production, while maintaining quality and delivery schedules.