Industrial Automation Automation Industrielle Industrielle Automation 1.5 Control System Architecture Arquitectura de control Architecture de Contrôle - Commande Leittechnik-Architektur
Dec 23, 2015
Industrial AutomationAutomation IndustrielleIndustrielle Automation
1.5 Control System ArchitectureArquitectura de controlArchitecture de Contrôle - CommandeLeittechnik-Architektur
Control system hierarchy 1.5 - 2Industrial Automation
1.5 Control System Architecture
1 Introduction
1.1 Automation and its importance
1.2 Applications of automation
1.3 Plants and controls
1.3.1 Open loop and closed loop control
1.3.2 Continuous process
1.3.3 Discrete process
1.3.3 Dual plants
1.4 Automation hierarchy
1.5 Control System Architecture
Control system hierarchy 1.5 - 3Industrial Automation
Principle
The control system is a communication system consisting of controllers and links.
The structure of the control system should reflect the structure of the plant
Ideally, each unit of the plant should have its own controller, interacting with the controllers of the other, related units, mirroring their physical interaction.
Example: Airbus: a wing is delivered with its own computers.
Control system hierarchy 1.5 - 4Industrial Automation
System Architecture
Conceptual model presenting•Structure•Relationships •Behavior
Including•Description of most important elements of system•Mapping of functionality onto hardware and software components•Description of top-level human interaction with components
Goal:•support reasoning about elements, structure and behavior•guide for implementation
Control system hierarchy 1.5 - 5Industrial Automation
Example: Power plant control - 1980 (!)
Control systems still look similar
Control system hierarchy 1.5 - 6Industrial Automation
Buses and processors in industrial plants
PLC nodes(multi-processors)
fieldbus (30m..2 km)
Operator panelMimic board
plant (Werk, usine)
P
disk
processor pool
transducers
controlstations
plant network (500m .. 3 km) – includes control network
valve thermo-couple motor
Process pictures
Process Data Base
Logging
position
backplane bus
node bus
workstation bus
instrument bus(mimic board)
sensor bus
directly coupled input/output
open network, WAN
station
P P C
I/O MEM I/O
P P C P
MEM BC
station
M
sensor bus (0,5.. 30 m)
Control system hierarchy 1.5 - 7Industrial Automation
Example: Production management system
transportationcell control
manufacturingcell control
scheduling maintenance quality control
plant network
floor network
productionplanning
robotcontroller
enterprise network
millingmachine
rail-guided vehicle
cell
Control system hierarchy 1.5 - 8Industrial Automation
Plant with process (e.g. chemical) and electrical (substation) parts
horizontal communication
CN Connectivity Server (and router)
IEC 61850 connectivity server
plant networkEngineering
bay bus
substation networkprocess network
interface
SAN IEDs
CI871
Aspect Servers
controller
PIPB
PIPB
PIPB
PIPB
PIPB
PI = Process Interface MU = Merging Unit
PIPN
PIPN
PIPN
PIPN
PIPN
PIPI
PIPI
PIPI
PIMU
PIMUProfibus
Engineering
Engineering
Profinet RSTP
LANs are separate: there is no IP routing between
them
vertical communication
Workplaces
horizontal communication
Control system hierarchy 1.5 - 9Industrial Automation
Example: Newspaper Printing Architecture
Each level has its own bus !
MPS = Managed Print Services
Control system hierarchy 1.5 - 10Industrial Automation
Example: ABB Industrial IT (redundant system)
3rd partycontrollers,servers etc
Serial or fieldbus
engineeringworkplace
Field Bus
Firewall
Plant Network / Intranet
Field Bus
Plant Network (Ethernet)
3rd party application server
applicationserver
aspectserver
Workplaces(clients)
Enterprise Optimization
(clients)
MobileOperator
connectivityserver
Control Network (Ethernet)ProgrammableLogic ControllerAC 800C
RedundantAC 800M
touch-screen
sensor network
Control system hierarchy 1.5 - 14Industrial Automation
Centralized (Hierarchical) Control Architecture
Sensors, Actors
PLCsGroup
Control
Group
Control
Group
Control
Central Computer
(Mainframe)
Classical, hierarchical, centralized architecture.
The central computer only monitors and forwards commands to the PLCs
plant
Control system hierarchy 1.5 - 15Industrial Automation
plant
Decentralized Control System (DCS)
engineeringworkstation
operatorworkstation
data logger
controller controller controller controller
field bus
plant bus
all controllers can communicate as peers (without going through a central master), restricted only by throughput and modularity considerations.
hierarchical(vertical communication)
peer-to-peer (horizontal communication)
Control system hierarchy 1.5 - 16Industrial Automation
Hierarchies are simple and traditional
Control system hierarchy 1.5 - 17Industrial Automation
but Distributed Control Systems reflect a more complex world....
Control system hierarchy 1.5 - 18Industrial Automation
Assessment
1. What is a bus and why do we have more than one kind of them in a plant?
2. Name the parts of a typical hierarchical control system its busses and controllers
3. How does the network hierarchy relate to the plant control hierarchy?
4. What is the difference between a centralized and a decentralized control system ?What are the (dis)advantages of the two approaches?