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Survey of Industrial Control Robert Nolan CIS 888.11E Wi01 February 21, 200 Pharmaceutical Chemical Manufacturing Applications Allen-Bradley ABB Automation Foxboro Honeywell National Instruments Siemens Major Companies Types of Industrial Systems Distributed Control Systems (DCS)

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survey of industrial control

Survey of Industrial Control

Robert Nolan

CIS 888.11E Wi01

February 21, 200

CIS 888.11E Wi01

applications
Pharmaceutical

Chemical

Manufacturing

Applications

CIS 888.11E Wi01

major companies
Allen-Bradley

ABB Automation

Foxboro

Honeywell

National Instruments

Siemens

Major Companies

CIS 888.11E Wi01

types of industrial systems
Types of Industrial Systems
  • Distributed Control Systems (DCS)
  • Process Logic Controller (PLC)
  • Hybrid Control

CIS 888.11E Wi01

basic dcs functions
Basic DCS Functions
  • Control loops
  • Execute special programmed logic
  • Monitor inputs
  • Alarm the plant operations
  • Trend, log, and report data

CIS 888.11E Wi01

dcs architecture
DCS Architecture
  • User Interface
  • Plant-Wide Data Highway
  • Communication Modules
  • Controller Modules
  • Local I/O Bus
  • I/O Modules
  • Process Instruments

CIS 888.11E Wi01

process instruments
Process Instruments
  • Measurement
    • Temperature transmitters
    • Flow-meters
    • pH Sensors
  • Control
    • Valves
    • Heating elements

CIS 888.11E Wi01

i o modules
I/O Modules
  • Main interface between DCS and process
  • Convert information to digital form
  • Signal filtering

CIS 888.11E Wi01

local i o bus
Local I/O Bus
  • Bridge between I/O Module and Controller Modules
  • Communication
    • Polling
    • Serial communication

CIS 888.11E Wi01

local i o bus standards
CANopen

ControlNet

DeviceNet

EtherNet

Fieldbus

Interbus

Profibus

Smart Distrib. Sys.

Local I/O Bus standards

CIS 888.11E Wi01

ethernet
Advantages

De facto standard

Readily available

Low cost

Concerns

Nondeterministic

Lack of Industrial grade

Ethernet

CIS 888.11E Wi01

foundation fieldbus
User Layer

Communication Stack

Fieldbus Message Specification

Fieldbus Access Sublayer

Data link layer

Physical layer

Foundation Fieldbus

CIS 888.11E Wi01

foundation fieldbus cont
Foundation Fieldbus (cont.)

Communications Stack

  • Token-passing protocol
  • Link-active scheduler
    • Acts as central arbiter
    • Executes a schedule that allows deterministic control and comm.
    • Distributes time so all devices share the same sense of time

CIS 888.11E Wi01

foundation fieldbus cont14
Foundation Fieldbus (cont.)

User Layer

  • Resource Block
  • Function Blocks
  • Transducer Blocks

CIS 888.11E Wi01

slide15
CAN
  • CAN frames
  • Producer/Consumer network
  • Multicast
  • Non-destructive bitwise arbitration
  • Cost-effective

CIS 888.11E Wi01

devicenet
DeviceNet
  • Built on the CAN protocol
  • Developed by Allen-Bradley
  • Hot insertion

CIS 888.11E Wi01

controller modules
Controller Modules
  • Receives the data
  • Performs process calculations
  • Sends actuator signals

CIS 888.11E Wi01

controller module functions
Controller Module Functions

Control logic

Control interlocks

Sequencing

Batch control

Passing on trends

Passing on report information

  • I/O signal characterization
  • Signal filtering
  • Alarming I/O modules
  • Ranging and engineering units

CIS 888.11E Wi01

communication modules
Communication Modules

Links

  • Data highway to controller modules
  • Data highway to user interfaces

CIS 888.11E Wi01

real time data highway
Real-Time Data Highway

Issues

  • Synchronization
  • Deterministic
  • Token-passing vs. report by exception
  • Variation in protocol types
  • Peer-to-peer vs. collision detection
  • Size and speed

CIS 888.11E Wi01

user interface
User Interface
  • Device to integrate displays and controls for operators

CIS 888.11E Wi01

honeywell s plantscape
Honeywell’s PlantScape
  • Hybrid Control
  • Distributed Server Architecture

CIS 888.11E Wi01

plantscape cont
PlantScape (cont.)
  • ControlNet process control network
  • Ethernet Supervisory network
  • Fieldbus integration module

CIS 888.11E Wi01

processlogix
ProcessLogix
  • ControlNet network
  • Multicast capabilities

CIS 888.11E Wi01

references
References

Fundamentals of Industrial Control, Albert & Coggan, ed., Instrument Society of America, 1992.

http://www.iac.honeywell.com/plantscape/

http://www.ab.com/process/processlogix/networking.html

http://www.ni.com/networks/

CIS 888.11E Wi01