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