1. Overview Industrial Automation rtPAC Systems

2. Process Control Basic Process Control Concept A measurement of the state or condition of a process A controller calculating an action based on this measured value against a pre-set value [set point] An output signal resulting from the controller calculation which is used to manipulate the process action through some form of actuators. The process itself reacting to this signal, and changing its state or condition. 3. 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 DAC AA Process Controlled VariableMeasured Variable 4. 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 Load Devices PLC Input Sensing Devices 5. 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 P S PCServers with Propitiatory Software Control Valves Isolators Input Sensing Devices Link Mod C P u A I A O D I D O Digital Devices Motor LEDs 6. Architecture of IndustrialEmbedded PACs Plug In Cards PAC E/ A E/ A Ethernet to other PCs 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 7. TECLEVERs 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 8. 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 9. 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 10. 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 11. 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 12. Case Study 13. Test Facility Control System 14. 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