Overview
Industrial Automation PC Based Control System
Advanced Control Systems Objective: Process control
information system Automating the Plant Operations In producing the required
output of the product with minimal quality variation
Optimal consumption of raw material and energy
Maximum efficiency Improved Productivity Efficient Monitoring and
Control Scalable and Robust
Types of Automation Systems Programmable Logic
Controller [PLC], Distributed Control System
[DCS] and PC Based Control System
Sensors & SCU
Control Valve
Control Station
PLC [or] DCS [or] PC Based
ADC
DACAA
ProcessControlled VariableMeasured Variable
Architecture of Traditional PLC PLCs were designed to eliminate
the electro mechanical relays.
Advantages Programming language is based
on relay wiring symbols familiar to most plant electrical engineers.
High reliability and minimal maintenance
Small physical size Ability to connect to the
computer systems in the plant. Moderate to low initial
investment.
Input Module
Output Module
Man Machine Interface
Control Station
LoadDevices
PLC
Input Sensing Devices
Architecture of DCS DCS is a derived version of
multitasking and multi loop controller used for process control.
Advantages Compact to contain ON/OFF
controllers Control algorithm changes do not
call for hardware changes Reduced complexity and easy
expandability High speed of the control
processing Continuous trend data available Sequential, batch and feed back
control are possible
Field Transmitter
Analog Devices
PS
PC\Servers withPropitiatory Software
Control Valves
Isolators
Input Sensing Devices
LinkMod
CPu
AI
AO
DI
DO
Digital Devices
MotorLEDs
Architecture of Industrial\Embedded PC Based Control System
Plug In Cards
PCBased
Control
E/A
E/A
Ethernet to other PC’s
Profibus, Interbus etc
PC Based Control System provides homogeneous environment
Advantages Software oriented environment Standard development tools based
control software and application software Not device specific, so no issues in
handling the devices from different vendors
More reusability since software based Simulation environment for cross
checking Reduced Hardware cost Provide a Open Control System
Options with Fieldbus CANopen. Modbus, PROFIBUS, PROFINET,
Interbus, Ethernet Powerlink, EtherCAT, EthernetIP, DeviceNet, ControlNet, Foundation Fieldbu
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
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
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
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
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
Case Study
Test Facility Control System
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