Lecture 2 Industrial Netw ork 1 INDUSTRIAL AUTOMATION • The term industrial automation covers a range of systems used to improve the productivity, safety or product quality of an industrial concern. • Grouped into the two categories of process industries or continuous process industries, such as electric power systems and other utilities, and discrete manufacturing industries, • There are several models of industrial automation systems in common usage. One of the more well known is the Computer Aided Manufacturing (CIM) 1 pyramid model, in which the system is viewed as a series of layers, ranging from low-level data acquisition and control functions to high-level functions such as plant and process management
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Lecture 2 Industrial Network 1
INDUSTRIAL AUTOMATION• The term industrial automation covers a range of
systems used to improve the productivity, safety or product quality of an industrial concern.
• Grouped into the two categories of process industries or continuous process industries, such as electric power systems and other utilities, and discrete manufacturing industries,
• There are several models of industrial automation systems in common usage. One of the more well known is the Computer Aided Manufacturing (CIM) 1 pyramid model, in which the system is viewed as a series of layers, ranging from low-level data acquisition and control functions to high-level functions such as plant and process management
Lecture 2 Industrial Network 2
CIM PYRAMID
Sensors and Actuators
Process Control
Process Monitoring
Plant and Process
Management
Lecture 2 Industrial Network 3
INDUSTRIAL AUTOMATION• A conventional automation system used for control of
an industrial plant consists of sensors connected to the plant, data acquisition devices, interface racks, actuators, cables and wires for transmission of analogue quantities, microprocessor-based controllers and a platform for operator intervention.
• The controllers, which are required to operate online in real time, are usually connected to plant equipment through relatively short-length cables/wires or optical fibres, designed with consideration of signal distortion, noise interference and cable reliability.
• The network would be very complex, as a huge number of cables and wires are used for a variety of purposes.
Lecture 2 Industrial Network 4
Automation Applications
Power generation hydro, coal, gas, oil, shale, nuclear, wind, solar
Distribution electricity, water
Process paper, food, pharmaceutical, metal production and processing, glass, cement,chemical, refinery, oil & gas
Ansaldo ITEmerson US Fisher Rosemount General Electric USHitachi JPHoneywell USRockwell Automation US Allen Bradley, Rockwell,..Schneider Electric FR Télémécanique, Square-D, ...Invensys UK Foxboro, Siebe, BTR, Triconex,…Siemens DE Plessey, Landis & Gyr, Stäfa, Cerberus,..Yokogawa JP
€ 80 Mia / year business (depends on viewpoint),growing 5 % annually
Lecture 2 Industrial Network 6
Expectations of automation
• Energy, material and time savings• Quality improvement and stabilisation • Reduction of waste, pollution control• Compliance with regulations and laws, product tracking• Increase availability, safety• Fast response to market• Connection to management and accounting
• Automation of engineering, commissioning and maintenance• Software configuration, back-up and versioning• Life-cycle control• Maintenance support
-> Acquisition of large number of “Process Variables”, data mining
Personal costs reduction
Process Optimisation
• Simplify interface• Assist decision• Require data processing, displays, data base, expert systems
-> Engineering Tools
Lecture 2 Industrial Network 7
Process Industry Application: Water treatment plant
S
M.C.C.
Control Room
Sub Station
SCADA
Bus Monitor
JB JB
RemoteMaintenance
System
Ethernet
Segment 1
Segment 2
Segment 3
Segment 4
FB ProtocolConverter
PLC
Digital Input/Output
PID
PID PID
PID PID
H1 Speed Fieldbus
LAS
JB JB
AI AI AI AI AI
AI AI AI AI AIAI AI AI
AI AI AI
AI
AO AO
AO
AO
AO
AO
DI
S SSSAI
AO
AI
Japan
Malaysia
Numerous analog inputs (AI), low speed (37 kbit/s) segments merged to 1 Mbit/s links.
source: Kaneka, Japan
Lecture 2 Industrial Network 8
Flexible Automation
Robots
ConveyorASRS
CNC Machines
Lecture 2 Industrial Network 9
Large control system hierarchy (1)
Group control
Unit control
Field
Sensors& actors A V
Supervisory
Primary technology
Workflow, order tracking, resources
SCADA =Supervisory ControlAnd Data Acquisition
T
Production planning, orders, purchase
1
2
3
4
0
Planning, Statistics, Finances5
(manufacturing) execution
enterprise
administration
Lecture 2 Industrial Network 10
Large control system hierarchy (2)Administration Finances, human resources, documentation, long-term planning
Enterprise Set production goals, plans enterprise and resources, coordinate different sites, manage orders
Manufacturing Manages execution, resources, workflow, quality supervision, production scheduling, maintenance.
Supervision Supervise the production and site, optimize, execute operationsvisualize plants, store process data, log
operations, history (open loop)
Group (Area) Controls a well-defined part of the plant(closed loop, except for intervention of an
operator)Coordinate individual subgroups, Adjust set-points and parameters, Command several units as a whole
Unit (Cell) Control (regulation, monitoring and protection) part of a group (closed loop except for maintenance)Measure: Sampling, scaling, processing,
calibration.Control: regulation, set-points and parametersCommand: sequencing, protection and
interlocking
Field data acquisition (Sensors & Actors*), data transmission
no processing except measurement correction and built-in protection.
.
Lecture 2 Industrial Network 11
ANSI/ISA 95 standard
Source: ANSI/ISA–95.00.01–2000
the ANS/ISA standard 95 defines terminology and good practices
Enterprise Resource Planning
Manufacturing Execution System
Control & Command System
Business Planning & LogisticsPlant Production SchedulingOperational Management, etc.
Lowest levels (closest to the plant) are most demanding in response time. Quantity of raw data is very large.Processing is trivial (was formerly realized in hardware). These levels are today under computer control,except in emergency situations, for maintenance or commissioning.
Lower Levels
Higher Levels
SCADA level
Presentation of complex data to the human operator, aid to decisions (expert system) and maintenance.Requires a knowledge database in addition to the plant's database
When ascending the control hierarchy, data are reduced: higher level data are created (e.g. summary information)Processing and decisions becomes more complicated (requires using models).Timing requirements are slackened. Historical data are stored
Lecture 2 Industrial Network 15
Complexity and Hierarchical level
MES
Supervision
Group Control
Individual Control
Field
Site
Command level
Complexity Reaction Speed
ERP
days
months
minutes
seconds
0.1s
0.1s
Lecture 2 Industrial Network 16
INDUSTRIAL NETWORK
• The main difference between an office grade network and an industrial network is the robustness or the hardness of the component it use.
• Office networks are usually in an environmentally controlled space with little variation in temperature or humidity. But in the industrial arena things are different.
• For a factory environment the bus topology is popular.
The central computer only monitors and forwards commands to the PLCs
plant
Lecture 2 Industrial Network 27
plant
Decentralized Control System (DCS)
engineeringworkstation
operatorworkstation
data logger
controller controller controller controller
field bus
control bus
all controllers can communicate as peers (without going through a central master), restricted only by throughput and modularity considerations.Note: Honeywell's "DCS™" stands for "Distributed Control System", it is not a decentralized control system, but a control system for the process industry.