Retailer Trends in Distributed Controls and Electronics · A Unifying Layer for Centralized & Distributed Systems •Enterprise software is required---independent of the control architecture
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Retailer Trends in Distributed Controls
and Electronics
E360 Forum • Houston, TX • October 25, 2018
Ron Chapek
Director, Product Management — Enterprise Software
Emerson
John Wallace
Director of Innovation
Emerson
Discussion Topics
IntroductionWhat’s the
difference?
Distributed
vs.
central
(or both)
What do I
need to plan
for in the
future?
Background and
evolution of control
systems
What are the different
architecture “layers” of
a control system?
What are the key
differences and similarities
of the different control
architectures? What
are the benefits?
Is it possible to “future
proof” my systems?
2
Definitions
• Slight differences in meaning across industries
• Generally, BAS implies broader integration, while EMS implies focus on energy management
• Refers to a collection of hardware and software to monitor and control the mechanical, electronic and lighting systems
• Installed at a single site
• For our purposes, these are the same thing
Energy Management
System (EMS)
Building Automation
System (BAS)
Facility Management
System (FMS)
Building
Management
System (BMS)
3
Systems Evolved From “Islands of Control” to Form a Complete
Integrated Control System
• Individual systems tied together
• Information sharing across systems
• Emergence of “supervisory functions”
• Integration/control maturity similar to auto industry evolution
– Communication technologies
– More sensors
– Smarter control
– Use data to drive actions
Supervisory
system
HVAC
LightingREF
Other
Connecting the “islands” into
an integrated control system
Evolution and progress
4
Layers and Functions of a Control System
Remote
Supervisory
Control
• Remote user interface
• Site information
• Data feed
Key elementsArchitecture layer
• On-site user interface
• User management
• Data logging
• Alarming
• Cross-system coordination
• Control algorithms
• Inputs and outputs
• Sensors and transducers
• Equipment interface
Hardware Can Be
Combined or Separated
Site
5
Integration and Communication Capability Key Part of BMS
Benefits• Common user interface across site
• Remote access
• Normalized information (alarms, logs, etc.) using operational visibility
Core
HVACR/L
BMS
Supervisory layer
normalizes information
to provide alarms,
data logs, etc.
53%
6%
41%
HVAC REFR OTHER
Third
Party
Devices
70%
27%
3%
ECHELON MODBUS BACNET
By protocolBy type
Third Party Device Statistics
Note: Statistics based on Emerson’s E2 support
Water heaters, energy
meters, car chargers,
breaker panels, etc.
6
Distributed Control Systems — The Technical Definition
7
Source: Wikipedia https://en.wikipedia.org/wiki/Distributed_control_system
John’s definition:
push control intelligence
down to the “edge” while
pushing monitoring and
supervisory functions “up”
Distributed vs. Central: A Familiar Example
8
Centralized control
• Control algorithms run in centralized E2
• I/O boards utilized for inputs, relays
Distributed control
• Control algorithms run in distributed controllers
• Communication to E2 or Site Supervisor for
supervisory functions
John’s definition:
push control intelligence
down to the “edge” while
pushing monitoring and
supervisory functions “up”
Comparison of Refrigeration Control Architectures
Floorplan
Refr.
controls
• Control elements centralized at refrigeration
rack or electrical panel
• “Home runs” for sensors
• “I/O” boards for control
• Control elements at case
• Communication “daisy chain” to EMS
• Complete control at refrigeration case
• Case electronics for control
Case
controls
Case
controls
Refr.
controls
Centralized control architecture Distributed control architecture
Case
controls
9
Distributed Control Benefits
• OEM/equipment providers can factory install and test to deliver a complete working system
• Broader integration delivers more value to end user
• Reduced field wiring and startup time
• Technology flexibility allows best “fit” solution
• Additional sensors provide more data for remote troubleshooting
• Lifecycle cost advantage
Lifecycle cost considerations for distributed case control
Sensors feed data analytics to facilitate cost optimization
11
Planning for the Future: Newer Systems Need Flexibility and
Advanced Control to Create Smarter Buildings
• “Traditional” control architecture
expanding to enable more value
• Flexibility provided by add-on “apps”
which facilitate customized solutions
• Site control provides macro-level
control, coordination of equipment on a
cross-site basis (i.e., HVAC/R) and
data aggregation
• Transactive services provide
opportunity to utilize “smart grid” as
well as other cloud-based services
(i.e., renewable integration, etc.)
12
Supervisory
Equipment control
Site control
Transactive
services
Apps
Remote Cloud services Transactive
services
Distributed controllers
Advanced BMS
Future Case Example: Using Data and Machine
Learning to Optimize Site Control
13
Supervisory
System Collects
Performance
Data From
Equipment
Controls
Selected Data
Provided to
Cloud-Based Service
Cloud-Based
Data Analysis and AI/Machine Learning
Optimized
Performance
Model
Site-Level Control
Updated Automatically to
Optimize Performance
Integration Between Site Controls and Cloud-
Based Services Key to Performance OptimizationSite-Level Control and
Supervisory System
Model Created
Based on
Site/Enterprise Data
Discussion Summary and Questions
14
• Global trends driving distributed control architecture transition
• Hybrid systems (i.e., case controllers with centralized rack control) are common and familiar
• Benefits include factory test, reduced startups and potentially lower lifecycle costs
• System integration capabilities as well as domain expertise keys to seamless transition and creation of integrated solution
• Advanced capabilities (cloud, transitive, machine learning, etc.) drive need for advanced, flexible BMS which can be utilized with distributed controls
• Closely coupled integration between site and cloud creates opportunities for optimization
John’s definition:
push control intelligence
down to the “edge” while
pushing monitoring and
supervisory functions “up”
Enterprise-level
Software
Enterprise-level SoftwareMacro Trends for Multisite Retail
• Adoption of cloud-based building/asset/energy solutions
• Deployment of IP-enabled devices (IoT)
• Exponential increase in data volumes
• Aggregation of multiple, previously disparate data sources
• Adoption of Master Data Management/MDM
• Proliferation and adoption of dashboarding, analytics and reporting apps
• Rapid customization of user-experience (Persona-specific)
• Integration of refrigeration/HVAC/lighting with other enterprise platforms
• Need for a single platform with a single user-interface (Common UI/UX)
• Future-proofing platforms to meet rapidly-morphing requirements
Trends are Increasing the Need for Enterprise-level Software
Enterprise-level SoftwareProblem/Solution Statement
• Enterprise software provides data-driven, persona-specific solutions that actively monitor & control site-level assets across their enterprise from a central location.
– Value is delivered by providing real-time visibility, management, analysis/reporting plus ADMIN and other system-level functions
• Controller Access Control
• Controller Backup/Firmware Management
• Alarm/Setpoint/Energy Management
• Refrigerant Compliance
• Maintenance Management
“I Need Help Getting and Staying Ahead of My Complex Enterprise….”
Enterprise-level SoftwareA Unifying Layer for Centralized & Distributed Systems
• Enterprise software is required---independent of the control architecture
– Data is aggregated locally (site) where real-time control is executed and then moved to the cloud
– Non-real-time analysis/reporting is executed at the Data Management/Presentation layer
• Same-day and day+1
– Predictive maintenance with root-cause identification
• Weekly/monthly
– Trend analysis
• Year/multi-year archiving
– Modeling & audit/compliance
Value Originates at the Device/IoT-layer & Delivered at the Presentation-layer
Enterprise-level SoftwareVisualizations are Solution-specific
• Provide only required information
– Apply comprehensive filtering criteria
• Time, data-type, asset-type, location, limits, etc.
• Provide highly graphical, intuitive views
– Expand adoption to include non-domain experts
• Complete specific use-cases
– Color-coded map-view of sites with two-click navigation to ID root-cause
• Include prescriptive corrective action(s)
The User-experience Now Tailored to Specific Personas/Tasks
Enterprise-level SoftwarePerformance/Responsiveness at-Scale
• Centrally manage 10s/100s/1000s sites
– Simultaneous updates (500 sites)
• Global device completed in hours not days
• Push menu changes to smart kitchen devices
• Make as-needed firmware updates
– Load graphics e.g. floor-plans in seconds
• Near real-time updates for critical values e.g. case temperatures
– Actively manage site/asset-level alarms
• Automatically prioritize and triage events
– Faster root-cause analysis and resolution
• Requires integration with service software
Complete Global Changes in Hours Instead of Days
Enterprise-level Software Example Three: Setpoint Benchmarks & Changes
Maintaining Setpoints Optimizes Asset Performance & Energy Savings
Advisory Status Map provides global and
regional views of alarming sites helping
to identify problem sites/assets.
Color coding of site active alarms
provides indication of alarm intensity.
Snapshot summary of site Active and
Return-to-Normal Advisory counts with
links to Advisory details or Device UI.
1
2
3
1
2
3
Enterprise-level SoftwareExample One: Advisory Status Map
At-a-Glance Overview of Enterprise Status/Health
Site floor plan provides simple
view of cabinets location and
current temperatures and status.
1
2
3 Click on cabinet color to view
graphical details of coil, fans,
doors live state and values.
Click on temperatures provides
quick graph and details of alarm
and defrost settings.
Enterprise-level Software Example Two: Floor Plan with Link to Asset Data
1
3
2
Identify, Diagnose and Resolve Asset-level Issues--Faster
Enterprise-level SoftwareOpen Architecture “At the Top”
• Leverage APIs to provide specific data for analysis & reporting plus niche applications– What points?
– What rate?
– What throughput?
– What priority?
• Governed/managed data access – Control remains the highest priority
– System stability trumps data-transfer
• Microservices execute on separate servers – Enterprise application is mission critical
(requires dedicated resources)
Sharing Data at the Enterprise-layer Provides Low-Risk Data Access
Microservices (API) Architecture
• ISO27001 Certified Data Center
• Full Disaster Recovery Capabilities
• 24x7x365 System Monitoring/Incident Resolution
• 24x7 Incident Response
• Enterprise Crisis Management Plans In-place
• Security Team CISSP Certified
• Network Team Cisco Certified
• Web Application Firewall
• Hardware and Operating System Updates
Off-premise Data/System Hosting Increasingly Adopted
Enterprise-level SoftwareSecure Cloud-based Systems/Hosted
Questions?
DISCLAIMER
Although all statements and information contained herein are believed to be accurate and reliable, they are presented without guarantee or warranty of any kind, expressed or
implied. Information provided herein does not relieve the user from the responsibility of carrying out its own tests and experiments, and the user assumes all risks and liability for
use of the information and results obtained. Statements or suggestions concerning the use of materials and processes are made without representation or warranty that any such
use is free of patent infringement and are not recommendations to infringe on any patents. The user should not assume that all toxicity data and safety measures are indicated
herein or that other measures may not be required.
Thank You!
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