![Advanced Control Systems
Objective: Process control
information system Automating
the Plant Operations
In producing the required output
of the product with minimal A PLC [or] A
ADC
DAC
Sensors & Control
quality variation SCU DCS [or] Valve
Optimal consumption of raw PC Based
material and energy
Maximum efficiency
Improved Productivity
Efficient Monitoring and Control Control
Scalable and Robust Station
Types of Automation Systems
Programmable Logic Measured Variable Controlled Variable
Controller [PLC], Process
Distributed Control System
[DCS] and
PC Based Control System](https://image.slidesharecdn.com/whyrthplcv2-130123042655-phpapp01/85/Why-rthplc-v2-2-320.jpg)
![TECLEVER’s offerings
PC Based Control System Framework
Features
X86 Based system with Medium to High processing power based on
requirement
Real time Linux based environment for Hard Real time application
Developed mostly with FOSS components
Easy integration with any OPC based SCADA packages
Custom Web based control for non critical process monitoring
Standardized driver modules for various Data acquisition cards. [Possible
to have different vendor cPCI/PXI cards]
Possible to have both Data acquisition and control in a single controller.
Possible to configure a High reliable redundant system
Standard Software oriented environment for SCADA and User control
program
Developed a User Control program framework where support for traditional
Ladder or FBD based development is enabled](https://image.slidesharecdn.com/whyrthplcv2-130123042655-phpapp01/85/Why-rthplc-v2-6-320.jpg)
![Controller/Data Acquisition Module
Optional redundancy management for any single point of failure
Possible to have multiple thread User control program
Standard ethernet based communication to and from DAQ system and
server.
High speed operational cycle [Possible to have as small as 10msec]
Able to handle very large number of channel systems](https://image.slidesharecdn.com/whyrthplcv2-130123042655-phpapp01/85/Why-rthplc-v2-9-320.jpg)
Why rthplc v2
- 1. Industrial Automation PC Based Control System Overview
- 2. Advanced Control Systems Objective: Process control information system Automating the Plant Operations In producing the required output of the product with minimal A PLC [or] A ADC DAC Sensors & Control quality variation SCU DCS [or] Valve Optimal consumption of raw PC Based material and energy Maximum efficiency Improved Productivity Efficient Monitoring and Control Control Scalable and Robust Station Types of Automation Systems Programmable Logic Measured Variable Controlled Variable Controller [PLC], Process Distributed Control System [DCS] and PC Based Control System
- 3. Architecture of Traditional PLC PLCs were designed to eliminate the Input Sensing Load electro mechanical relays. Devices Devices Input Output PLC Module Module Advantages Programming language is based on relay wiring symbols familiar to most plant electrical engineers. Man High reliability and minimal Machine Interface maintenance Small physical size Ability to connect to the computer Control systems in the plant. Station Moderate to low initial investment.
- 4. Architecture of DCS DCS is a derived version of Input Sensing Control multitasking and multi loop controller Devices Valves used for process control. Field Isolators Analog Transmitter Devices Advantages Compact to contain ON/OFF C controllers P Link P A A D D Digital S Mod I O I O Devices u Control algorithm changes do not call Motor for hardware changes LEDs Reduced complexity and easy expandability PCServers with High speed of the control processing Propitiatory Software Continuous trend data available Sequential, batch and feed back control are possible
- 5. Architecture of IndustrialEmbedded PC Based Control System PC Based Control System provides homogeneous environment Advantages PC Software oriented environment Based Standard development tools based control Control software and application software Plug In Not device specific, so no issues in handling Cards the devices from different vendors More reusability since software based Ethernet to other PC’s Simulation environment for cross checking Reduced Hardware cost Profibus, Interbus etc Provide a Open Control System E/ E/ A A Options with Fieldbus CANopen. Modbus, PROFIBUS, PROFINET, Interbus, Ethernet Powerlink, EtherCAT, EthernetIP, DeviceNet, ControlNet, Foundation Fieldbu
- 6. TECLEVER’s offerings PC Based Control System Framework Features X86 Based system with Medium to High processing power based on requirement Real time Linux based environment for Hard Real time application Developed mostly with FOSS components Easy integration with any OPC based SCADA packages Custom Web based control for non critical process monitoring Standardized driver modules for various Data acquisition cards. [Possible to have different vendor cPCI/PXI cards] Possible to have both Data acquisition and control in a single controller. Possible to configure a High reliable redundant system Standard Software oriented environment for SCADA and User control program Developed a User Control program framework where support for traditional Ladder or FBD based development is enabled
- 7. User Control Program Development environment is based on Open Source Framework for writing control program Compliance to IEC 61131, PLCOpen and CanOpen standards Any existing application compliance to this can be easily ported to our development environment. Supports programming in LD/FBD/ST/IL/SFC Compiles ST/IL/SFC code into ANSI-C code. All POU parameters and variables are accessible through nested C structs Able to generate application code for different RTOS/Linux environments Enabled to work on a single Configuration file across controller/ Monitoring software and Use Control program development. So seamless integration of User control program into system control application
- 8. Controller/Data Acquisition Module Standard driver support for DAQ cards in Hard Real Time OS Any cPCI or PXI based card will be supported for the control requirement So no vender specific looking is required Control System configuration thru configuration file, enables to use the same application across different control requirement Diagnostic information for monitoring purpose Failure handling for any application problem thru a text based script Distributed engineering unit conversion to avoid load at monitoring server Configurable mode to send RAW value to monitoring station for calibration
- 9. Controller/Data Acquisition Module Optional redundancy management for any single point of failure Possible to have multiple thread User control program Standard ethernet based communication to and from DAQ system and server. High speed operational cycle [Possible to have as small as 10msec] Able to handle very large number of channel systems
- 10. SCADA Server/ Operator Station Supports any standard OPC communication supported SCADA packages Optional Web Based Monitoring system for monitoring SCADA System configuration thru configuration file SNMP based Network Diagnostic information for monitoring purpose Offline GUI for any specific reporting requirements Support for 10msec data logging Redundancy management at OPC communication and Application server levels
- 11. Case Study
- 12. Test Facility Control System
- 13. Project Description The objective of this project is to design, develop and install a PC based control system. A PXI/cPCI based control system with SCADA running in PC and Server in distributed configuration is proposed for designing the control system. The control system acquires the data from field control elements then processes the data in real time and generates output. The normal cycle time of the system is 10msec. The acquired data and generated output are used for online monitoring and controlling the test system. The data is logged at both the server and controller for offline analysis. Data exchange between all the subsystems is through Dual redundant Ethernet. Redundancy management at controller, server for fail-safe mode of operation
Editor's Notes
- #3: Prior to the PLC, every hard-wired panel was just a collection of basic components and a host of wires.
- #4: It's not quite that simple. Changing the workings of a PLC is often a long and difficult task in which not only a few rung have to be changed, but more often a lot of rungs. These rungs have a tendency to influence each other, so you have to look out for these effects too. A big advantage in this is that you can make changes off-line, whereas rewiring is always online. Think at what this means for you production line.With PLCs, whether by accident (AB does not store rung comments with the program) or design (OEM lock) the designer of the machine can effectively seal you out of the process. You could have the best electrician in the world, but if the ladder code is not accessible, he is faced with a "black box" that he can do little more than guess at. He might be able to look at peripheral sensors and other equipment and sensors and guess at what he thinks should be happening, but he will have no clue as to what is really going on.When something goes wrong, all they can do is call out the PLC OEM tech or your SI and shell out the bucks.Ladder logic is an analog of relay logic, but statement list is a far cry from relay logic, symbolically. The learning curve on PLC's is longer than relay logic. You need to know everything you know for relay logic in ADDITION to whatever you need to know about PLC's.One last disadvantage is the lack of support for legacy PLC's. Think about converting programs in 20+ years because the old PLC is no longer made, and the code is no longer usable in its present form. I've not yet encountered this with PLC's, but I've gotten it with enough other (computers, drives, etc) equipment.http://www.plctalk.net/qanda/showthread.php?t=11438 2-B ? ----+----] [----+------------( )---- | | | | | 2-B |+----] / [----+
- #6: High Availability , Reliability, Scalability ISA S84 standard: http://www.triconex.com/NR/rdonlyres/6155344E-58C4-4852-B420-D72CCC327C92/0/PCSTechnicalPaperANSIISAS8401HowThisStandardWillAf fectYourBusiness.pdfTMR control system: http://www.triconex.com/us/eng/triconexProducts/tricon/default.htmhttp://www.plctalk.net/qanda/archive/index.php/t-13453.html
- #12: Prior to the PLC, every hard-wired panel was just a collection of basic components and a host of wires.