AI 120 Examples

Automation Examples1.2Exemples de sites automatissBeispiele AutomatisierungssystemeProf. Dr. H. KirrmannEPFL / ABB Research Center, Baden, SwitzerlandIndustrial AutomationAutomation Industrielle Industrielle Automation2008 March HK

*1.2 Automation ExamplesIndustrial Automation

Examples of Automated Plants1 Introduction1.1Automation and its importance1.2Applications of automation 1.3Types of Plants and Control1.3.1Open Loop and Closed Loop Control1.3.2Continuous processes1.3.2Discrete processes1.3.3Mixed processes1.4Automation hierarchy1.5Control System Architecture


Carstraditional: appliances control (windows, seats, radio,..)motor control (exhaust regulations)critical new applications: ABS (anti-skip) and EPS (stability), brake-by-wire, steer-by-wire (X-by-wire) increased safety ?extreme price squeezing2001 US model: 19% of the price is electronics, tendency: +10% per year.


Rail vehiclesdisplay unitvehicle control unitDU TCU DU TCU VCUradio linkthere are more than 20 interconnected computers on a locomotivebrakessignalingtraction control unitdiagnosticsenergyBenefits: reduce operation costs, faster diagnostics, better energy management, automatic train control. VCUSBB 460


Airplanesavionics:flight control (safe flight envelope, autopilot, engineer)flight managementflight recording (black boxes, turbine supervision)diagnosticsfly-by-wirehigh reliability


Launch vehiclesserial data buses ( 23 shared, 5 dedicated )GPC 5IOP 5GPC 4IOP 4GPC 3IOP 3GPC 2IOP 2GPC 1IOP 1Intercomputer (5)Mass memory (2)Display system (4)Payload operation (2)Launch function (2)Flight instrument (5;1 dedicated per GPC)Flight - critical sensor and control (8)Control PanelsCPU 1CPU 2CPU 3CPU 4CPU 5


Robotsextension limited to 2-3 m (portal robots 10-20m)frequent reprogramming for new tasks, toolingsimple embedded computer, hierarchical control


Substationsprotection (Lines, transformers, generators) very high speed responsecontrol (remote or local) to guarantee power flow, safe operation (interlocking)measurement (local and remote), electricity bill, power flow in grid


Pharmaceutical IndustryInventoryRecipe managementPackagingSamplingTracking & tracingComply with government rules:Typical of batch processes.


Manufacturing


Flexible Automationnumerous conveyors, robots, CNC machines, paint shops, logistics.Download from production management, connection to administration


Warehousesextreme dependency on theavailability of the controlsystem

Connection to * supply chain management, * order fulfilment* customer relationship and * commercial accounting (SAP)


Printing machinestasks of control system:motor control (synchronisation of the printing cylinders)ink and water controlpaper web control (reelstands (Rollenwechsler, bobines), web tension, emergency knife)interface to operator (commands, alarms)production preparation and statistics - up to the press roomvery high requirements on availability: two hours delay and the production is lost.


Oil & Gas, petrochemicals"upstream": from the earth to the refinerydown-sea control

"downstream": from the oil to derived productsspecial requirement: extreme explosive environmentdistributionspecial requirement: high pressure, saltwater, inaccessibilityexplosive environment with gas. special requirement: environmental protectionSwitzerland: Colombey, Cressier


Chemical industrye.g. LONZAlogistics,local control of reactorsCharacterized by batches of products, reuse of production reactors for differentproduct types (after cleaning).


Process IndustryMetals and MineralsGlass productionChemical .Process Industry = industries de transformation, Verfahrenstechnik(one of the many meanings of process)CementContinuous flow of materials, often 24 hours a day


Steel millsparticularity: synchronization of the motors in the rolling mill


Cement WorksControl tasks: Oven rotation and temperature controlfuel supply, silos,transport belts,grinding mills,pollution monitoring,quality supervision,filler stations,...

Switzerland is leading nation in Europe(Holcim, Jura, )The rotating oven is the heart of the cementprocess: the grinded kilnis burnt and comesout as chunks later reduced to powder.


Mining


Building Automationbasics: fire, intrusion, climate, energy managementHVAC = Heat, Ventilation and Cooling = air conditioningvisitors, meeting rooms, catering,.low price tag


Automation of Building GroupsEPFL


Airportslarge building automation system: fire, security access, energy, lighting, air conditioning, communications, traffic control luggage control inZurich-Airport


Traffic controlfireintrusionenergywaterventilationpollution monitoringcameraslight controltraffic jams prevention,....(Tunnel Letten near Zurich)


Harboursfrom ship planningto crane manipulationand stock control


Water treatment(fresh and waste water)

manage pumps, tanks, chemical composition, filters, movers, quality... auxiliaries: methane electricity generation


Power plantstasks: fuel supplyprimary process control (steam, wind)personal, plant and neighbourhood safetymonitoring environmental impactelectricity generation (voltage/frequency)energy distribution (substation) 24 / 365 availabilityHydro - river- dams- storage damsThermo- coal- gas- atom - solar - wasteAlternative- wind- photo-voltaic


Waste treatment, incineratorsraw material supplyburning processsmoke cleaningenvironmental controlco-generation process (steam, heat)ash analysisash disposal


Power transmission networkPower Plant Centrale,Kraftwerkswitchyard, postes HTSchaltfeldSSRegional

Control CenterRegional Control CenterPPSubstation

(Unterstation, sous-station)SSSSPPSSPPSYSYPPHuge number of "points" (power plants, transformers, breakers, substations)lying 2km to 2000km apart.All time-critical operations executed locally in the substations and power generation units.

International Control CenterNational

Control CenterSSSubstation


Swiss electricity interconnection network


Pipelinesparticularities: long-range communication system, safety, explosive environment


AssessmentName the applications you remember and indicate at least one task for thecontrol system

What could be the order behind the plant types that were presented ?


2001 US Cars: 19% is electronics

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