Automatic Journey ?
Automatic Journey ?
1
HOW AN AUTOMATION SYSTEM
CHANGES THE WORLD
❑ MANUAL CONTROL
❑ PNEUMATIC CONTROL
❑ ELECTRICAL HARD WIRED LOGIC CONTROL
❑ ELECTRONIC CONTROL USING LOGIC GATES
❑ PLC control
❑ SCADA
❑ DCS ( Distribution control system)
❑ EXPERT PROCESS OPTIMIZATION (Rule based Fuzzy system)
❑ Robotics in Process & quality control
❑ Industries 4.0–IVth Industrial Revolution (Smart factory)
❖ Cloud competing
❖ AI ( artificial intelligent)
❖ MI ( machine learning )
❖ IOT sensors
❖ EDGE Computing (extension of cloud computing)
MANUAL CONTROL
All the actions related to process control are taken by the operators
(Human interface)
Drawbacks:
❑ No records/History of operation
PNEUMATIC CONTROL
Industrial automation, with its machine and process control, had its origin
in the 1920s with “Pneumatic Controllers”.
Drawbacks:
• Bulky and Complex System.
• Involves lot of rework to implement control
logic.
• Longer Project time .
• performance based on quality of air
• Difficult maintenance and troubleshooting.
ELECTRICAL HARD WIRED LOGIC
CONTROL
❑ The contactor and relays together with
hardware timers and counters were used in
achieving the desired level of automation.
❑ Bulky Panels.
❑ Complex wiring.
PLC HARDWERE
PLC PANEL
PROGRAMMABLE LOGIC CONTROLLERS
(PLC)
PLC- Programmable Logical Controller : Programmable Logic
Controller (PLC) is a digital computer used for the automation of various
electro-mechanical processes in industries. PLC consists of a microprocessor
which is programmed using the computer language.
❑ Alarms
❑ Device connectivity
❑ Database connectivity
BENEFITS OF SCADA:
❑ Continuous monitoring of dynamic process value.
❑ Process graphics
HMI-HUMAN MACHINE INTERFACE
• Human Machine Interface (HMI) systems use to communication
between machines and to the human operator.
❖
▪
The DCS concept increases
▪
Reliability
▪
Reduces installation costs by more communication protocol
▪
Remote monitoring and supervision
▪
Distributed process with common network & server
Area wise signal processing near to equipment & communicated on network by
using STAR /RING Tropology
DCS
WITHOUT SERVER/CLIENTARCHITECTURE
DCS
TYPICAL BLOCK DIAGRAM FOR DATA PROCESSING & CONTROL
24 V
DIGITAL
Power Supply
INPUT /OUTPUT
BOARD
+5V
Regulated
INPUT/OUTPUT ANALOG supply
DAQD
CURRENT TERMINAL PROCESSOR BOARD
VOLTAGE BOARD
RTD
DATA
BASE-1
( Battery PROCESSOR
ALGORITHM Back-1 Up) BOARD
CAT HOLD PROCESSOR
STATION
DATA
BASE -2
FIRE WALL
OFFICE
LAN
SER. CCTV
Ethernet Ring
WORK STATION
• Make : Dell
• Model: Dell Precision T3630
• Processor Intel Xeon E-2124, 3.4 GHZ
• Memory : 8x DVD+/-RW Drive
• Hard Disk : 1 TB
• Operating : Windows 10 Pro English 64bit
DCS- DISTRIBUTED CONTROL SYSTEM
HART Protocol
(Hybrid Both Digital & Analogue)
DCS- DISTRIBUTED CONTROL SYSTEM
Profibus –PA & DP connection diagram
IOT -TRANSMITTER
connection diagram
DCS- DISTRIBUTED CONTROL SYSTEM
MODBUS –CONNECTIVITY
DCS- DISTRIBUTED CONTROL SYSTEM
Ethernet connectivity :Ethernet protocol is the traditional
technology for connecting devices in a wired local area network
(LAN) or wide area network (WAN) enabling them to communicate
with each other via a protocol -- a set of rules or common network
language.
The basic idea of its design is that multiple computers have access
to it and can send data at any time.
Advantage
• relatively low cost;
• backward compatibility;
• generally resistant to noise;
• good data transfer quality;
• speed;
• reliability; and
• data security -- common firewalls can be used
DCS- DISTRIBUTED CONTROL SYSTEM
2. Server-client relationships.
10. Alarms.
❑ CLOUD COMPUTING
❑ VIRTUAL TWINS,
❑ AUGMENTED REALITY,
❑ AUTONOMOUS ROBOTS,
❑ CYBER-PHYSICAL SYSTEMS.
What is the Internet of Things (IoT)?
• COLLECT AND SHARE DATA ABOUT THE WAY THEY ARE USED
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CONNECTING IOT SENSORS AND WIRED SENSORS
• Sensors in an Industry 4.0 system can be connected in various ways for data
transfer from the machine to the computer
• The sever can be on premise, meaning within the physical boundaries of
the organization, or on the cloud .
• There are a variety of connection options depending for IOT sensors, sensors
❑ with wired LAN
❑ sensors with WiFi LAN.
• ON-PREMISE SYSTEM:
❑ The sensors on machines send data to a server within organization.
❑ The connection between sensors and the server can be wired or WiFi LAN.
❑ Users can see reports if they are on the same LAN, from within the shop
floor.
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CONNECTING IOT SENSORS AND WIRED SENSORS
Cloud based system: The sensors on machines send data to a Cloud server
outside your organization.
The connection between sensors on the machine can be direct IOT, via
In the wired or WiFi LAN systems, you need LAN cabling, switches, access
points, repeaters, etc. In the on premise system, you additionally need a
server within the organization
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CLOUD BASED SYSTEMS -IOT DIRECT TO
CLOUD
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ON-PREMISE SERVER SYSTEMS
Wi-Fi LAN
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ON-PREMISE SERVER SYSTEMS
Wired LAN
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Industry 4.0 Solution – Mobile App
Key Features
❑
❑ Connect to Individual Plant DCS or Historian using OPC UA or OPC DA
❑
❑ Comprehensive Industrial IoT Platform for consolidated data aggregation and KPI Derivations.
❑ Secured access to various groups for relevant KPIs based on access control.
❑
❑ Each Plant can access to only own data
❑ Corporate Team can access multiple plants
❑ No of plant - 14
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❑ No. Control system 34 ( all Dalmia power & cement plant)
EDGE COMPUTING FOR IOT DEVICES
• Edge computing is a extension of cloud computing
• that brings computation and data storage closer to the location where it is
needed, to improve response times and save bandwidth.
• Edge allow data from IOT devices to be analysis at the edge of network
before being sent to data center or cloud
❑ Speed
❑ Security.
❑ Scalability
❑ Versatility.
THANKS