Industrial Automation Automation Industrielle Industrielle Automation

1.1 Automation Overviewautomación - vista generalAutomation -vue d'ensembleAutomation - Übersicht

Industrial AutomationAutomation IndustrielleIndustrielle Automation

Overview 1.1 - 2Industrial Automation 2013

Definition

Automation (automation, Automation):

1) set of all measures aiming at replacing human work through machines(e.g. automation is applied science)

2) the technology used for this purpose(e.g. this company has an automation department)

Automation (automatisation, Automatisierung)

1) replacement of human work through machines(e.g. the automatisation of the textile factory caused uproar of the workers)

2) replacement of conscious activity by reflexes(e.g. drill of the sailors allows the automatisation of ship handling)

automation and automatisation are often confounded: in English, it is the same word.(they are related like electricity and electrification)


Automation as a hierarchy of services

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


Automation and living beings

Automation =the neural system

Enterprise

Trends & History = Brain

Display and react = Cortex

Communication networks = Neurons, spine

Controller = Ganglions

Sensors & Actors = Sensory cells & muscles

Society

Physical plant = Skeleton


Automation as a computer network

DB, Historians,

Optimizers, MES

Plant Network

OPC Server

Operator Workplaces

Power ManagementSubstation AutomationLV Electrification

ProcessInstrumentation

Fieldbus

Control Network

Protection & Control

Instruments

IEC 61850 station busController

HART mux

OPC Server OPC Server

Power generation

Internet

ProfinetHart


Technical necessity of automation

• Processing of the information flow

• Enforcement of safety and availability

• Reduction of labor costs


Expectations

• 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 (SAP™)

• Automation of engineering, commissioning and maintenance• Software configuration, back-up and versioning• Life-cycle control• Maintenance support

Asset Optimisation (gestion des moyens de production)

-> Human-Machine-Interface (HMI)

-> Acquisition of large number of “process variables”, data mining

Personnel costs reduction

Process Optimisation

• Simplify interface• Assist decision• Require data processing, displays, data base, expert systems

-> Engineering Tools


Data quantity in plants

Data reduction and processing is necessary to operate plants

information flow to the operators: ~ 5 kbit/s.human processing capacity: about 25 bit/swithout computers, 200 engineers (today: 3)

Electricity distribution network

three times more points than in conventional power plants Nuclear Power Plant

10'000 points, comprising 8'000 binary and analog measurement points and 2'000 actuation point 1'000 micro-controllers and logic controllers

Coal-fired power plant today

100 measurement and action variables (called "points")analog controllers, analog instrumentsone central "process controller" for data monitoring and protocol.

Power Plant 30 years ago

100’000 - 10’000’000 points


Contents

1 Introduction

1.1 Automation and its importance

1.2 Examples of automated processes

1.3 Types of plants and controls

1.3.1 Open loop and closed loop control

1.3.2 Continuous processes

1.3.3 Discrete processes

1.3.3 Mixed processes

1.4 Automation hierarchy

1.5 Control System Architecture


Plant Automation

All automation systems share a common structure

They differ in the type of plant controlled, quantity of information, geographical distribution


Automation Systems - World Players

Largest Company Based Major mergers

ABB CH-SE Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-BaileyAlstom-Schneider-Areva FR-GB Alsthom, GEC, CEGELEC, Telemécanique,..Emerson US Fisher, Rosemount General Electric USHitachi - Yokogawa JPHoneywell USRockwell Automation US Allen Bradley, Rockwell,..Invensys UK Foxboro, Siebe, BTR, Triconex, Wonderware…Siemens DE Plessey, Landis & Gyr, Stäfa Controls, Cerberus,..

€ 80 Mia / year business(depends on viewpoint),

growing 5 % annually


Terms

plant: the object of automationF: site, usine, centrale (électricité)D: Prozess, Werk, Fabrik, KraftwerkE: planta, fabrica, instalación

general contractor: organizes the suppliers of the different components.

turnkey factory: the client only hires consultants to supervise the contractorincreasingly, the general contractor has to pay itself by operating the plant.increasingly, the suppliers are paid on results….


Four distinct businesses

automation equipment (control & command)

engineering & commissioning

primary technology(mechanical, electrical)

maintenance& disposal

offered by different companies


Life-phases of a Plant (Example: Rail Vehicle)

Maintenance(entretien, Unterhalt)

Start on service

Recycling(Recyclage, Wiederverwertung)

Out of service

Commissioning(mise en service, Inbetriebnahme)

Sleeping Wagon XL5000Engineering(bureau d’étude, Projektierung)

Equipment Production(production, Herstellung)

air conditioning brakescontrolEquipment Design(développement, Entwicklung)

brakes

brakes

replacement

Manufacturers

Assembler (ensemblier)

Client, Service

car body design by assembler


Research and Development

The components and tools are developped


Design

From the customer’s requirement specs to the system design


Programming and engineering


Factory Acceptance Test

The client verifies that the system is ready


Commissioning on site

hard work …


Maintenance…

Documents

Industrial Automation Automation Industrielle Industrielle Automation