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)
Overview 1.1 - 3Industrial Automation 2013
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
Overview 1.1 - 4Industrial Automation 2013
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
Overview 1.1 - 5Industrial Automation 2013
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
Overview 1.1 - 6Industrial Automation 2013
Technical necessity of automation
• Processing of the information flow
• Enforcement of safety and availability
• Reduction of labor costs
Overview 1.1 - 7Industrial Automation 2013
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
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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
Overview 1.1 - 9Industrial Automation 2013
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
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Plant Automation
All automation systems share a common structure
They differ in the type of plant controlled, quantity of information, geographical distribution
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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
Overview 1.1 - 12Industrial Automation 2013
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….
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Four distinct businesses
automation equipment (control & command)
engineering & commissioning
primary technology(mechanical, electrical)
maintenance& disposal
offered by different companies
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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
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Research and Development
The components and tools are developped
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Design
From the customer’s requirement specs to the system design
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Programming and engineering
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Factory Acceptance Test
The client verifies that the system is ready
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Commissioning on site
hard work …
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Maintenance…