Tools in the DCS

Reliability and safety in the manufacturing process of the DCS. In addition to industrial control systems of the specific installation tools that are reliable, then. The design must also consider safety and limit the loss of production from various accidents or errors within the limited scope of most.


Control system to limit damage caused by defects or failure of K Engineering to hand within the limit.
Control systems to provide backup for control Vice hand control staff are able to control the manufacturing process to replace the main control section that has been able to do damage to normal soon.
Control system must provide protection system that pungent, Chen M for control staff can be ordered to stop and cancel all or part of the production process immediately all safety procedures.
Control system must be self-monitoring system for checking the accuracy of the operation was.

DCS increased the Church’s message holds and safety performance of industrial process control as follows.

Distribution of access equipment and process control of the DCS group were sub-divided the responsibility to monitor and supervise the manufacturing process of industrial indoor keeping the reliability of control systems are increasingly included.

Storage and backup program for performance instead of process control unit of the DCS by the fact type of sleep per Tile Wall internal memory storage of the program will function.

Installation provision for control instead of performance and process control unit connected to the process and the damage can not function normally. Tool control is acting.

Check the DCS system to check the performance of the tools within the system control and monitoring of contact with other tools connected to the DCS to perform with the accuracy at all times. Self-inspection system, and DCS has also instructed the alternate control tools that can come if DCS duty to replace the main control the damage as soon as detected. Disorders of the tool. The process can be carried out successfully with from time to time.

Read more »

Architecture DCS

DCS architecture of each manufacturing company may have different structures according to the design of each manufacturer’s production company, but DCS all companies have to share equipment in the DCS of a functional and operational responsibilities are Engine unit (module) always consists of the DCS Although each manufacturer has a different name, but must consist of DCS units are similar tools.

1. Unit connected to the process (process interface module) is a device interface between DCS and process to receive the signal measured by the production process to the DCS and control signals from the DCS to the manufacturing process. Processing units connected to basic unit consists of DCS analog input (analog input module) unit analog output (analog output module) unit digital signal (digital input module) and digital transmission unit (digital output module).

2. Unit process (process control module) is the main equipment of DCS for process control. By the data processing unit connected to the process to calculate the value of the control signal and send it back to the process units connected to process control unit connected again to contact the unit processes, process control networks. DCS sub-low speed control of the basic process consists of the DCS control and direct digital control stick and fire.

3. Unit Contact and staff functions (operator interface module) and the Laboratory of Engineers (engineerint workstation) is a device interface between DCS and power users, engineers and general staff DCS may spin contact and enter Ki Operation of employees and Engineering is the second set of equipment or devices sharing a single set of contacts and act as a unit’s operating staff and engineers. Unit contacts and skills last year’s Operation staff serves as staff, equipment Nื contact for monitoring and process control. Unit Ki Operating Engineers serves as the DCS equipment fitted to the Engineer for the structure of control systems and equipment connected to the DCS system. Of the details and the order of the graphics for the employees. Shows the trend of record-keeping process history. And warning events of DCS.

4. Unit connected to the network. (Communication module) device is a device for connecting all parts of the DCS network communication. Unit connected to the network initially will link DCS process control equipment with equipment and laboratory staff to contact.

5. Storage and historical processes (process data and history module) as storage devices for process control of the DCS and the history of the process data storage and historical process of the DCS are often installed with the unit interface and operation of employees and engineers. However, DCS may be separate storage devices, and historical processes are independent devices connected to their network communications. Storage devices include basic DCS Nื types of magnetic data storage (magnetic disk) and magnetic tape (magnetic tape).

6. Unit connected to a computer network (computer network interface module) is a device connected to the network of the DCS network of other computers for data collection and management control system, DCS can connect to a computer outside the system DCS. The devices use a Nื contact and connection of the unit’s operating staff and engineers. Or connect directly by the DCS network devices connected to computer networks.

7. Unit connected to the instrumentation sub (subsystem interface module) is a device connected to the DCS tool in an external control system, DCS, such as PLC, gas chromatography graph (gas chromatograph) devices to send and receive data remotely. (remote input / output device) and other tools to control the processor’s own DCS can interact with other tools in the control system via the network sub-unit connected to the process, or connected to the network communication of the DCS directly using sub-unit connectivity tools, as well as connect to other network computers.

8. The power unit (power supply module) is equipped with the power to all devices of the power of the DCS equipment. Served eliminate noise and adjust the power off to suit various devices of DCS and store energy reserves for DCS.

Read more »

What is DCS?

DCS (distributed control system) which comes from the DCS Distributed Control System includes the main control section, which is similar to the PLC, but bigger talent than Either control, Batch, Sequencial, Analog Control and Advance Contol and user interface which is similar to Scada, including the history, History, and other stores.

Because the control system in the first session will be used as a control Relay system. But soon evolved into PLC by language programming of PLC, it has all five languages: Ladder (LD), Instruction List (IL), Sequence Function Chart (SFC), Structure Text (ST) and Function Block Diagram. (FBD) to operate through a graphic that PLC will be connected to other devices is the MMI (Man Machine Interface) or sometimes referred to as HMI (Human Machine Interface), which in the PLC, most will not have built-in by the HMI. can display the value and status of the process and can Operate HMI, which is in part to show the important Historical Report, Alarm Message, Trend.

DCS is a system that evolved after the PLC will be the language used to write different. Depending on the brand. While there are some basic PLC logic in actual use in controlling large the process relatively static (such as process oil and gas) it is more stable than, and DCS will include Graphic, Trend, Historical, Alarm Message. included in the self.

Read more »

The IIntelligent Motor Control Centers (MCCs)

Advances in MCC technology enable the delivery of detailed diagnostics to help improve productivity and maximise asset availability. A new white paper, produced by Rockwell Automation, explains how advanced intelligent motor control centers (MCCs) provide process application users with critical information that ultimately helps minimise and prevent downtime

The white paper outlines industry drivers and the evolution of MCCs, including technology considerations, configuration methods, networking advantages, as well as benefits gained from real-world application examples. It describes the technology behind these capabilities, including advanced monitoring and sensing devices, and built-in network connectivity that allows access to process data from virtually every corner of the plant.

Distinguishing itself from a standard unit, the intelligent MCC integrates three major system components – communications, hardware and software. While early versions of MCCs with communication networks contained variations of these elements, today’s solutions leverage a harmonised design that deliberately integrates these elements into a unified solution.

Furthermore, with a lower installation cost than traditional MCCs, plus the protective, monitoring and troubleshooting advantages, integrating intelligent MCCs presents a major opportunity for manufacturers to capture and use equipment and process data to improve productivity and maximise asset availability.


For a copy of the white paper go to: http://samplecode.rockwellautomation.com/idc/groups/literature/documents/wp/mcc-wp001_-en-p.pdf

Read more »

Conventional Motor Control Centres (MCCs)

Conventional low-voltage Motor Control Centres (MCCs) are ubiquitous in the oil and gas sector and in general, meet industry requirements for safe, reliable and efficient operation. So, are there any real benefits to be gained by choosing the new generation of Intelligent Motor Control Systems (IMCSs) for future projects? The answer is undoubtedly yes except, perhaps, for the most undemanding of projects.

In a conventional MCC, the power switching and protection components that make up the individual starters are linked to the device that provides the control functions – most often a PLC, with conventional cabling. In addition, the functionality of the components used, such as the protection devices, is defined within those devices. If additional information is required from the starters as an aid to managing the plant or for measuring and controlling energy usage, extra components have to be added, along with even more cabling to the PLC.

In an IMCS the power switching devices are controlled by a Smart Control Unit (SCU) that also monitors the motor operating parameters, such as voltage and current. The protection functions are implemented in the SCU, which communicates with the PLC via a data connection, eliminating much of the conventional control system cabling, replacing it with just a handful of network cables.

Also, because the protection functions of the starter are now defined by software in the SCU, decisions about these functions do not need to be finalised until after the motor control system has been built. This is a useful feature in oil and gas applications, where late changes to plant configurations and specifications are common.

The functionality of the starters in the IMCS can also be changed easily and quickly even after the plant has been put into service, providing flexibility. Finally, since the SCU directly monitors the operation of the motor and the starter, it can provide almost any operational data needed for plant management, energy reduction or maintenance purposes directly, without the need to install additional equipment.

There are, however, still those who have reservations about the adoption of IMSCs There are essentially two reasons for this. The first is that some of the earliest IMCS implementations were ill-conceived and failed to deliver on their promises. These issues have now been addressed – the technology has matured.

The second is that there are some applications where conventional MCCs are still the best option, though these are reducing in numbers. Typical of these are simple installations where there is no requirement to collect data for onward transmission to a supervisory system and where the likelihood of modifications being needed during the life of the equipment is small. In such cases, a conventional MCC may well be adequate.

Read more »

Integrated Safety And Regulatory Control

Addressing functional safety and regulatory control in a single system has been a challenge for many years – even more so when systems are destined for use in a hazardous area.

A technical solution from Siemens is said to offer these combined capabilities delivering benefits such as a simplified safety verification process, tangible cost savings and scalability Ian Curtis, safety consultant for Siemens Industry Automation, explains.

The functional safety and hazardous area protection world’s are often closely associated. However, when it comes to meeting the requirements of these two complementary yet distinct disciplines in a distributed I/O system, there are many technical challenges to overcome.

A range of SIL 3 capable failsafe I/O modules for the Siemens ET200iSP hazardous area remote I/O station gives users the potential for new safety system architectures which boast simplified engineering and a reduction in the total lifecycle cost for automation and safety.

Early process automation systems were typically distributed but, ironically, with the advent of the Distributed Control System (DCS), system architectures actually became much more centralised. In recent years, there has been a shift back toward a more distributed approach. This same trend has been reflected, albeit to a lesser extent, in distributed safety within the process industry but the recent addition of capability for integrated failsafe I/O in the hazardous area looks set to accelerate this trend.

Given the conservative nature of the industry there are still many users who prefer to stick to a centralised approach, particularly when intrinsic safety requirements are involved. The traditional practice of putting the controllers and I/O in the safe area and using IS barriers, is well understood and still in common use. However the tough economic climate of the last few years has increasingly prompted end users and OEMs to assess and adopt new concepts such as distributed failsafe systems which can actually solve many problems.

The scalability of these distributed systems, particularly those that combine control and safety in the same infrastructure, means they can also be used cost effectively for small process units, OEM skids or rotating equipment with smaller I/O counts.

The distributed approach reduces the need for multi-core cables carrying I/O signals; this means reduced installation effort; reduced risk of wiring errors and simplified bus connection of I/O stations.

SIL3 capability in a Zone 1 hazardous area is a step change that will strengthen the success of distributed I/O systems and really open up new possibilities. Users from the oil and gas industry, chemical industry, and other major hazard industries will look to benefit from the ability to combine configurations that include non-fail-safe modules, such as standard inputs/outputs and relay modules, alongside failsafe modules. Another key benefit is the potential for cost saving through the elimination the ex-barriers, less wiring and space optimisation.

Many OEM suppliers are also exploiting the possibilities of distributed automation in hazardous areas, particularly when they market their products to target emerging markets. If the end customer's employees lack expertise, the use of a centralised configuration often leads to wiring errors - and a lengthy commissioning phase.

When the ET200 iSP remote I/O station is located directly at the machine, or process skid, commissioning is straightforward and the space savings are considerable. As complicated and space-consuming as the earlier approach was – with remote I/O cables, terminals, and ex-barriers – this marshalling effort can now be completely eliminated. It is also easier to achieve the redundancy required in many applications: The ET 200iSP is connected via RS485-iS in hazardous areas. The path from the CPU in the control room to the field can also be redundant. Digital and high availability requirements are covered thanks to bus use.

Because of an increasing popularity with the OEM market, if an end user doesn't start out with distributed safety as a strategy for their plant they often “inherit” it as process skids and OEM type equipment come equipped with their own safety systems.

The first large customers for the ET200 iSP F-modules have been from the oil and gas industry. They have used the fail-safe modules in water-oil separating equipment and tank farms. Other early adopters have come from the chemical industry. Offshore projects generally also lend themselves to distributed safety and the combination of failsafe and hazardous area capability afforded by these new modules will be attractive for such applications.

Read more »

Wireless Level Switch

Emerson process Management reports that intelligence inside its switches are now also able to distinguish between material build-up on the fork and a high product level, reducing the need for inspection in the field. Electronic Device Description Language (EDDL) is used to enable the level switches to be configured and monitored from the same device management software as a plant’s other intelligent devices such as pressure and temperature transmitters.

Adding hardwired level switches into an existing plant can be costly due to the cost of laying and connecting new cabling, as well as possibly additional cable trays, system input cards, and system tag license costs.

Many tanks around the plant will not originally have been fitted with instrumentation connected to the control system. Similarly, coolant and lubricant level in various assets have not been monitored continuously. Using wireless technology this type of information can now be better utilised.

Wireless level switches overcome the limitations of hardwiring. They can communicate using the IEC 62591 (WirelessHART) protocol and can be deployed without running cable or using up spare wires and system input cards. Because there are no wiring connections to be made, commissioning is also easier.

A wireless level switch will share the same network infrastructure as other wireless transmitters, with information transmitted via the same gateway. One gateway can support up to 100 IEC 62591 transmitters. Once a gateway is in place, plant personnel can expand the network at will, enabling level switches to be installed on points previously not monitored by the control system, to enhance operation and worker safety.

Because IEC 62591 devices all use the same common application protocol, devices and gateways from different manufacturers should work together seamlessly, self-organising to form a mesh network where each device maintains communication with multiple neighbours – establishing multiple communication paths and relaying data even from the most remote devices all the way to the gateway. If devices are added or removed, the network is able to automatically adjust its communication path, without interrupting data flow.

Modern DCS will have native support for wireless. However, older control systems can also make use of wireless level switches, or other IEC 62591 transmitters, using a wireless gateway that converts the signal to Modbus/RTU, Modbus/TCP, or OPC. Wireless support on the control system engineering console is not required as the network setup is done through a web server embedded in the gateway and devices are configured through intelligent device management software. No additional software needs to be loaded onto the control system or other PC for operations or security. All that is required are the existing HART configuration tools, including asset managers and hand-held configurators, to bring the network online.

A vibrating fork level switch operates on the principle of a tuning fork. An internal piezo-electric crystal oscillates the external fork at its natural frequency. The frequency changes depending on the medium in which it is immersed and these changes can be monitored. Unlike many other level switch technologies, the vibrating fork technology does not have parts that can get stuck and therefore is less prone to failure.

With a simple on/off signal from a hardwired float level switch it was not possible to tell the difference between a stuck switch and an actual high-level condition. Similarly, it was not possible to tell if the level switch was damaged or had failed and the signal was therefore invalid. For this reason, technicians are periodically required to go to the field to perform checks just to be sure, often to find nothing wrong.

With intelligent devices, however, changes in frequency are used to detect high or low level, as well as media build-up on the fork, external damage to the fork, internal damage to the piezo, and excessive corrosion.

Having such intelligence in the field can reduce the necessary trips to the field for inspection purposes, as many suspected problems can be remotely verified from the control room, and cleaning or service scheduled accordingly.

Remote set up
Remote setup is a relatively new development in level switches. Manufacturers can now use EDDL to define how a device is to be displayed in the system. This technology is used for continuous devices such as transmitters and positioners as well as with discrete devices such as level switches, on/off valves, and electric actuators.

The use of EDDL enables IEC 62591 level switches to be set up and checked using the same intelligent device management software as the other devices in the plant. The information from level switches can be displayed side-by-side with information from wireless transmitters for pressure, temperature, and other process parameters. They are displayed the same way as FOUNDATION fieldbus and PROFIBUS devices.

Systems based on EDDL are said to make managing the mix of devices easier, eliminating the errors and learning curve associated with using different software or different driver for each one. Manufacturer know-how, in the form of text and illustrations, is brought into the system through the EDDL file.

A device overview page will clearly indicate the process state as ‘wet’ or ‘dry’ and this is accompanied by device health status, which will indicate the validity of the information. Because the operator is able to tell the difference between media build-up on the fork and an actual high level they can act accordingly.

Material build-upon the fork can be detected in its early stages and flagged as an advisory alarm, so that cleaning can be scheduled before build-up accumulates to the point where it causes a false process state indication. As a supporting troubleshooting tool, the fork’s frequency is also displayed as a dynamic needle gauge with a colour band on the scale to distinguish normal from abnormal operation. The health of the internal power module is also indicated.

EDDL is key to interoperability, providing complete access to all device functionality through a hierarchical menu structure. The EDDL file from the device manufacturer is copied onto the system to tell it how to interface with the device. Unlike other device integration technologies, no software installation skills or license key management are required.

Each version of each device from every manufacturer has a unique EDDL file. There are no shared files, ensuring that the addition of a new device will not overwrite another. Because EDDL is a compressed text file, independent of the Windows operating system, existing device files are not made obsolete by new Windows versions. Conversely, new device files do not force a Windows upgrade for the system.

Time delay can be configured to minimise false switching due to turbulence or splashing, such as in the presence of agitators. To set the delay time on traditional level switches they must be opened up and a potentiometer adjusted by screwdriver. This is inconvenient in the field and exposes electronics to potentially harsh environments. With a WirelessHART vibrating fork level switch, the delay time and other settings can be checked and adjusted remotely from the control room, with the EDDL technology enabling the device management software to maintain a single audit trail for all devices, including level switches where configuration changes are logged.

Read more »

SCADA Virtualisation

Virtualisation for SCADA systems brings many benefits such as time and cost savings, greater levels of security and operational efficiency advantages. Tony Chapman from Siemens Industry Automation highlights some of the key areas where SCADA virtualisation can add real value.

As automation solutions become increasingly complex, it follows that the effort required to maintain both hardware and software will also increase. PCs must be provided with suitable specification and operating systems to support the applications. Whilein operation, these systems must be constantly reviewed and updated normally through the application of security patches, updates and service packs. This will apply to every installed system and application program during the lifetime of the system.

To reduce the amount of ongoing administration and maintenance effort associated with update issues, the automation world is turning increasingly to virtualisation and the opportunity it provides to decouple applications from hardware.

This creates the ability to centrally manage the application and simplify back up and restoration of the system environment. Client environments can be installed just once and distributed among one or two virtualisation servers using virtual sessions (instances). It is also easier to implement IT security solutions on central virtualisation servers than via numerous client stations. Virtualisation also eliminates the restriction of target devices to a particular hardware, allowing more complex applications to run on simple, low-cost, and robust thin clients.

Virtualisation
A new service pack for Siemens’ Simatic WinCC Version 7 SCADA system promises owners of automation solutions, the means to reduce hardware, administration, and maintenance costs. One of the innovations of the system is the virtualisation option for both WinCC clients and WinCC servers on various hardware platforms. Through this option, owners of medium and large automation solutions, as well as smaller multiple station and single station systems can reduce hardware, administration, and maintenance costs.

The virtualisation is based on VMware ESX(i) 4.1 - one of VMware's globally-established hypervisor applications for virtualisation. It is installed on central (and ideally redundant) virtualisation servers with adequate performance in order to ensure appropriate background allocation of available system resources (CPUs, work memory, storage media, communication, etc.) among the virtual client and server applications.

This type of virtual server can accommodate up to 25 virtual client sessions of different types without these sessions affecting each other – all on a single hardware platform. Access to these virtual client sessions is via Ethernet using a standard Remote Desktop Protocol (RDP) session. This means that there is no longer a need for powerful client side hardware, which opens the door for the use of simple, compact, and low-cost thin clients, such as robust PDAs or panels without rotating parts, e.g., with Solid State Disk (SSD), for operator control and monitoring in the field.

As a result, it is much easier to choose a client and to use clients in harsh industrial environments, including hazardous areas. If a failure occurs, it is possible to use a thin client with higher or lower screen resolution without making any additional settings, which minimises downtimes.


Consolidation reduces costs
The ability to operate several WinCC servers and/or client sessions on a central platform (also away from the field level) reduces PC hardware and network components, as well as acquisition costs and ongoing operating costs for power/maintenance/spare part considerations. The number of client sessions is limited only by the performance capability of the virtualisation server and not by the SCADA system.

One advantage of virtualisation is that the operating system and automation application no longer has to be individually installed and maintained on every client. Virtualisation reduces this to a one-time installation or a central updating of the VMware and of a small number of different client sessions on the server. The latter can be easily replicated so that the benefits increase with the number of clients. Backups and systems restores are made centrally and in a short time. In addition, it is possible to migrate existing, completely configured systems to a new hardware platform without a time-consuming installation process.


Protection from malicious software
Every inadequately protected operator control station having a USB port, floppy disk drive, or hard disk drive is potentially vulnerable to a certain degree to malicious software and requires more effort in this regard than a virtual system solution. This is because the lack of interfaces in simple thin clients makes them generally less vulnerable to malware than "fully-fledged" PCs. Providing security at a central location requires less effort, quite apart from the fact that the operating systems of professional server solutions, which frequently are not Windows-based, are generally at a lower risk.

Certain hardware and software errors can cause the PC system itself to fail, thus rendering operator control clients inoperable. This calls for a replacement, which is not always possible without interrupting the active process. In virtualised solutions, it is possible to achieve high levels of availability – even when system components require replacement – through the use of RAID systems. Software can be updated during operation, clients can be added to or removed from the system, and the switchover from one client to the other can take place within a few seconds. In addition, a configurable alarm management function is available which notifies the operator in the event of system errors or when critical system loads are reached. All of this contributes to high availability and productivity.

Read more »

An alternative to DCS or PLC/SCADA?

Traditionally, users have had a choice between a DCS or a PLC/SCADA approach when selecting a control system for use in process control applications. Richard Sturt, Rockwell Automation business development manager, process Industries, believes that Rockwell can offer a solution for users needing elements of both of these approaches.

A key benefit of traditional DCSs was that the suppliers took a ‘systems approach’ and it was designed for large scale applications. Much of the work of integrating different parts of the system was taken care of by the DCS vendor by using a single database for the complete system.

The DCS approach is to configure the system using standard control objects and faceplates, reducing engineering and providing standardisation. Most DCSs also offer fieldbus communications, tools for process optimisation and asset management packages to improve maintenance. More recently DCS suppliers have introduced more scalable solutions for smaller applications

However, there are a number of potential shortcomings in the DCS approach. Many process plants have a large number of OEM packages that need to be integrated with the overall process control system and it is unlikely that the OEM will use a DCS for their control system. In some manufacturing processes there is a requirement for different types of control; process, discrete, high speed, drive control, motion control or machinery safety. The DCS is not designed to cope with these types of applications and, if a manufacturing process covers multiple disciplines, the DCS will only ever be suitable for part of the system.

DCS has, traditionally also been an expensive product to support throughout its life. Annual licensing and support costs can become a significant part of the overall cost of ownership. The majority of DCSs are engineered and supported by the original manufacturer and are not freely available though other channels, leaving the end user reliant on its DCS vendor.

Most DCSs had closed and proprietary system architectures. More recently suppliers have adopted more open standards but, in many cases, this approach has limitations which often makes it complicated to integrate with MES and other business systems.

The PLC/SCADA approach
Although PLCs were originally developed for discrete applications, most cover a wide range of applications. The term Programmable Automation Controller (PAC) is now used to describe many products to distinguish them from older systems that were focused on discrete logic. This flexible approach offers multiple programming languages, open communications, and scalability for different applications. There are many systems integrators able to integrate PLC/PAC technology, often with specific industry or application knowledge. This approach is also ideal for OEMs who can select a cost effective product to meet their requirements.

Although PLCs and PACs have become more powerful they still have a number of features that are missing when compared to the DCS approach.

A typical PLC/SCADA system has at least two databases. The user has to configure the PLC database and then separately configure the database in the SCADA system. At initial engineering stages there may be an option to import the PLC database into the SCADA system but this will require manual modification as changes are made during commissioning and when enhancements are made. If additional software packages are required they are likely to have their own separate databases too, that will need to be configured.

Another potential weakness is that not all PLCs have features required for demanding continuous process control applications. In some cases they will lack the ability to modify the system on-line or will not include high availability features like redundancy from I/O modules to supervisory systems.

Process optimisation and asset management is another area where traditional PLCs may be lacking compared to a distributed control system.

The best of both worlds
A true ‘Plant-wide Automation’ approach takes the best features from DCS and PLC/SCADA systems and combines them into a single system. It combines the ‘systems approach’ of a DCS and flexibility of a PLC/PAC to provide a solution for multiple applications.

This approach has benefits that can improve plant performance and reduce costs. A single architecture can be selected for any application whether it is continuous process control, high-speed OEM equipment or a small batch reactor. It simplifies integration and reduces engineering costs. The resulting system will have a seamless communications architecture allowing access to plant data for process optimisation, asset management and integration with MES. Support costs will also be minimised by reducing training requirements and the cost of holding spares.

Rockwell Automation has recognised the benefits of combining the features of Distributed Control Systems and PLC/SCADA solutions into a single Plantwide Automation system with its PlantPAx. As part of the companies Integrated Architecture, it allows a single architecture to be used for a wide range of applications, including process, batch, drives, motion and safety.

The importance of being able to address such a wide range of applications is key to a truly plant-wide automation system. Operating any combination of these applications through a purpose-designed single architecture and software environment makes it possible to achieve the benefits of both a DCS and a PLC/SCADA system without many of the traditional downfalls of either. It is this seamless inter-operability that makes plant-wide automation systems so effective.

At the core of the PlantPAx is the single database that is used for the Controller, HMI, Historian, Batch Management, Asset Management and Business Intelligence Tool/Reporting Package. Any data created in the system is instantly accessible to all the software packages that need it and a single security model simplifies the management of user’s profiles.

The key principles behind this solution can help to drive a lower cost of ownership. Using a single architecture reduces initial engineering and integration costs. The process optimisation and business intelligence tools help to maximise plant efficiency.

Read more »

Expansion Advantages of Wireless Controls

Josh Thompson, principal, Point Source, says that wireless networks provide facility managers with a number of options to both save money and expand into areas they might not otherwise have been able to reach. After all, running a wire requires additional materials and a hole in the wall.

"The current cost of materials, conduit and cabling can push the BMS outside of the return-on-investment window. Wireless fixes that in many cases," Thompson says. "In an industrial facility, there are applications where sensors and controls would be desirable, but due to hazard containment, penetration of the hazard space is not possible. Wireless solves this problem."

That concept of reaching the hard-to-reach places also applies to security, says Gislene Weig, associate, Syska Hennessy.

"When they have a problem getting cable to certain locations and they want to put in a camera, then we would use wireless," she says.

There are additional wireless applications in security. RFID systems allow for tracking of inventory or equipment that isn't used in a stationary location. In health care, many maternity areas of hospitals have tracking bracelets that use RFID to ensure that babies stay in the area. If a baby is taken too close to the door, an alarm sounds.

Remote Control

If all you want in the way of remote access to building automation systems is the ability to log in after hours, that doesn't necessarily require a wireless system internally. But remote data collection on a real-time basis is another big plus of wireless systems, says Myers, using the example of a property manager in a multi-tenant building being able to pull electricity use data from a submeter by walking down a hallway, instead of having to enter individual units. Being able to leverage that real-time data is where the real payoff comes in.
"The applications where you can see return on investment would be in your energy management, your lights, your shades, your mechanical, your room on/room off times, your integrated HVAC and electrical scheduling, your peak power scheduling for operating purposes," Thompson says. "That kind of information, that kind of intelligence on the building that is not specifically life critical ... if properly integrated and commissioned, you can see huge ROI very, very quickly just in energy savings."

The growing use of wireless devices has produced, along with gains in flexibility and energy savings, some surprises for facility managers. In one building, Myers says wireless thermostats Velcroed to cubicle walls became a little too popular with staff who worked in the spaces controlled by the movable devices. When they were relocated, they took the thermostats with them.

" When they walked away with the thermostat, it lost touch with the zone it was supposed to be controlling and didn't do anything, basically," he says. "With a couple of these occurrences, they had trouble controlling the temperatures on the floor and couldn't figure out why nothing was working until they realized they were moving with the thermostats."

Read more »

The Greatest Impact On Automation And Controls In The Next Five Years

Software abstraction – Graphical system design is a great example how software abstraction increases the productivity of engineers and scientist from different industries and application areas.

 

Embedded processing – The ever increasing processing performance and the lower footprint of processors enables companies like National Instruments to bring technologies like multi-core processors into the industrial space and create off-the-shelf embedded systems that engineers and scientist can adopt for the most demanding applications.

 

Reconfigurable hardware – With shorter design cycles and increased pressure to innovate, reconfigurable hardware like field programmable gate arrays (FPGAs) provides the industry with a solution to create custom functionality with hardware performance without the investment and effort of designing an ASIC or custom board. Embedded in off-the-shelf systems and programmable with high-level design tools like NI LabVIEW software, these technologies are accessible for engineers and scientists with little embedded expertise.

 

The combination of a real-time processor, programmable logic and modular I/O within one system – National Instruments refers to this technology as RIO technology but we see a wide adoption for this concept in the industry.

 

Proliferation of Sensors - High-performance measurements are the key to solving sophisticated control problems and realizing robust systems. New technologies and the wide use of sensors in commercial products like smart phones or the Wii gaming console (and many others) have been increasing the availability of sensors and reduced the cost. This trend will continue and so we will see a proliferation of sensors in industrial applications.

 

Networking, synchronization and security – The increasing number of embedded and control systems used to solve today’s applications also increases the need for networking, synchronization and security technologies. And while there are a lot of different standards available today, the integration is where we expect a lot of innovation over the next couple of years.

Read more »

Automation Market of National Instruments Products

National Instruments provides products and platforms that enable engineers and scientists to design any system that needs measurement and control, using the graphical system design approach. In this effort, we design products that can be applied across many different industries and application areas. In fact, no particular industry accounts for more than 15% of NI revenue.

 

Industrial automation is of course an important element of the NI business and we have a lot of customers who are using our industrial grade embedded platforms to implement advanced control and monitoring applications; ranging from automated pipeline welding machines to building control and monitoring systems for turbines.

 

National Instruments will continue to invest in products and platforms that can be applied in industrial automation applications. The core strength of the NI graphical system design platform is the combination of productive software and high-performance hardware. In the industrial area these tools are especially beneficial for developing high-performance machines and devices that require advanced sensor feedback, are characterized through challenging control tasks or have quick time to market requirements. Because those kind of advanced applications often require integration into an automation process, National Instruments products can also accomplish lower-speed process automation tasks.

 

Like the PC and smart phone, most disruptive ideas combine existing elements in a way that provide a dramatically better solution. The same phenomenon is true for the smart grid. Embedded reconfigurable instrumentation and control systems powered by NI LabVIEW software are merging with cloud-based networking, analytics and other cutting-edge information technologies. The proliferation of smart networked embedded systems, widely distributed throughout the grid, will revolutionize the way electricity is produced, consumed and distributed.

 

Many of the industry leaders in smart grid technology around the world are using NI technology for designing, prototyping and deploying the embedded systems needed to transform today’s energy networks into smart grids. The Energy Summit at NIWeek 2011 brought in some of those experts to discuss challenges and solutions around smart grid technology.   

National Instruments has some powerful technology all centered around graphical programming using the company’s LabVIEW software. NI products are great for designing, prototyping and deploying embedded systems quickly.  At NIWeek there were many demanding applications demonstrated that were made possible using the high performance capabilities delivered by NI products.

 

Creating industrial control and automation applications is easy and intuitive using LabVIEW.  The drawback is that NI hardware and software has a high price tag compared to typical industrial control and automation products. National Instruments products are like driving a fine sports car - they are responsive and high performance, but expensive.

 

NI is supporting industrial communications with the most recent being EtherCAT.

 

In demanding industrial automation and control applications, NI products make sense for industrial automation and control.

 

I have been intrigued by NI FPGA based products since they were introduced, but they have been pricey. The newest FPGA controller offering is approximately $500 list price.

 

National Instruments is not a mainstream industrial control and automation product supplier. However, NI products are being applied in very high performance niche applications.

Read more »

Energy harvesting: a practical reality for wireless sensing

There are some very exciting high growth projections for wireless sensing for the Automation industry. More sensors mean more process efficiency, lower operating costs, lower maintenance costs, higher reliability, and greater safety. Wireless sensing provides the opportunity to install masses of sensors with virtually no cost of installation by reducing the need for cables carrying the signals from the field to the control room. Wiring costs can easily be 80%, or more in a hazardous area, of the total cost of installing a new sensor. Who wouldn’t like to get the same job for one-fifth of the cost or five times as many sensors for the budget? And it is not just the cost of the installation; there are many cases where plant has to be shutdown to facilitate installation adding another massive sum to the cost of new sensors.

Most of us routinely use wireless (cell phones, Wi-Fi) for communication, and the potential for machine-to-machine wireless communication is considered to be even larger. Wireless transmission of sensor data is now well established as a reliable method of monitoring industrial plants. It is even being perceived by some users as more reliable and maintenance free than hard wiring.

This whole new approach to Automation has been made possible by the convergence of new technologies:

• Low power electronics including microprocessors with sleep modes
• RF transmission systems that use digitally encoded signals (e.g. digital television and Wi-Fi) with an order of magnitude less power required than older analogue systems
• New energy harvesting techniques

So why is there so much interest in energy harvesting? Simply, you cannot get the full benefit of wireless unless the power source is also wireless. This means either a battery or some form of energy harvester. Until recently, the usual power source available to power a wireless sensor node or network (WSN) has been batteries. With their limited and non-deterministic life span, hazardous content, shipping and disposal requirements, batteries alone are not likely to provide a power source that will last the life cycle of the WSN application without maintenance intervention. The ideal solution is an energy harvester that is “fit and “forget” and will have a lifespan in excess of the WSN that it is powering.

What is energy harvesting? Energy harvesting is the extraction of usable energy (usually converted into electrical energy) from otherwise wasted energy available in the environment. On the macro scale (MegaWatts - MW) this includes hydro-electricity, wave power, solar panels, and wind turbines. However for wireless sensing, we are talking about harvesting immediately available energy such as vibration, heat, light, and RF energy to produce milliWatts - mW.

 
Power requirements for WSNs
Whether the power source is an energy harvester or a battery, it is important to minimize power consumption. Much can be done to minimize average power requirement; for example reducing reporting frequency. If a wireless system is being used for machinery condition monitoring, then it is unnecessary to specify the transmission of full vibration spectra every minute, when it is replacing a man on bicycle with a hand-held device who goes around once a month (provided it is not raining and he has nothing more urgent to do). Also parameters can be monitored and analyzed in the WSN, and it can be programmed to transmit alarm signals only when there is a problem.

To illustrate the issues, this article takes the example of a WSN that requires an average power of 3mW to compare various options. This is not untypical of either a frequent reporting requirement (such as several times per minute) or a high data requirement (such as complete vibration spectra).
The following table shows the theoretical life of standard sized cells from a leading Lithium battery manufacturer. In practice, the theoretical capacity is reduced by such factors as the need for intermittent high currents for RF transmission, self discharge, and low temperatures. Some newer designs perform closer to theoretical capacity and may include energy storage to help with the peak power requirements of WSNs.


Energy harvester power
So what are the options for energy harvesters to deliver 3mW? The following are systems available today, and they represent each of the main types of energy source that can be used in practice in many types of plant and other machine applications to provide the required power. Each of these uses a source of energy readily available in many but not all applications. However, with this choice, it should be possible to select a suitable device for the vast majority of applications.



More info here.

Read more »

CP1E smaller Omron PLC

New design. For small PLC Omron. To achieve the desired result with a shorter time and cheaper cost. Of experience and learning to truly Omron developed a new concept to develop products that focus on simplicity and economy but also its readiness to continue for the future.

Input and output prices were down. This is achieved using a high-performance chips that can handle high-speed signals at 100 kHz for the control of machines with speed and precision. Also equipped with high speed-output 100 kHz (in transistors) for the type of servo motor. Completely redesigned. The input / output of CP1E are cheaper compared to similar products.

An analog of the modern machinery to control the variable parameters in analog format. To activate other devices.

With a continuous output CP1E-NA20 (under the CP1E) packed into this capability without having to buy more. The analog resolution up to 1 / 6000 or 0.016% full scale resolution detail to cover most of it.

It has USB and RS232C with it has come to a USB port for connecting a computer to upload or download downloading program. USB cable is available in the market for the RS232C standard has a touch screen and whether the presence of an external load cell. Or used in SCADA.

To further expand in the future. Whether it be on a channel by using the expansion units 3 units or more channels of communication option board is required to choose a RS485/422A, Ethernet or RS232C.

Read more »

OMRON PLC - How to Use OMRON PLC Function Block

Function Block potential of our Omron CS / CJ PLCs for future projects. Our typical projects include the control of a few hundred devices (doors, intercoms, cameras, card readers, etc.). It is generally of PLC logic, just the same, except that they shall refer to various IO addresses.

Desrcibe The logic that is suitable for your project, you are perfect for Function Block processing.

If you and add a Function Block instance, copy the same instance will be labeled as you describe.
You can create a new copy by right-clicking on the Function Block and the change of the name.

However, it is quite possible the same instance in multiple copies Function Block Function Block reuse. But be careful that you do so only if the Function Block-code can be worked in, a single scan, so there are no timers, counters and data control statements, such as PID, which require multiple scans complete.
So if you Function Block contains only simple functions the same conductor Function Block instance can use and saves space. If your case requires separate Function Block user, you can still edit and update all at once through the internals of Function Block Function Block invocations.
You can find Function Block to authorities under the symbol table data type “Function Block”.
For more information about Function Block, see the “CX-Programmer Operation Manual Function Blocks Structured Text” that are found in the CX-Programmer-folder in the Start menu.

I have a love-hate relationship with building blocks. In my experience:

Function blocks are good for:
1. Mathematics (transformations, scaling, floating-point calculations, etc.)
2. Loops (I find it much easier to code loops in structured text)
3. repetitive tasks such as door logic, logic cylinder, stop logic, etc.

Function blocks are bad because:
1. too much memory
2. adds scan time
3. difficult problems if you do not know how Function Block does
4. to test more work ahead and to document
5. can be dangerous if you try to get online editing and “accidentally” change all instances of the block

The newest and latest CX Programmer Version 4 CPUs possible Function Block can not be created / edited by online processing.
CPU version 4 function blocks can be processed online, but it can not be created (from scratch) online.
CX Programmer 7.0 or higher is required for this function.

The indirect nature of the programming can be very powerful when you get your head around ..
Just a little something about Function Blocks with Omron PLC:

Look in the PLC memory usage on the “View / See Memory (UM). Sorry, but I’m in the Cx-P Spanish!
Sometimes, when large Function BlockS (ie, floating-point calculations), or simply to build only Function Blocks Omron (as Mechatrolink or DeviceNet), the PLC CJ1M become small and it must be greater than PLC (CPU43 or higher).

Function Block is a good tool to typical problems of copy and paste causes the programming to avoid if you need more time in the same routine, order, or steps, but conscious memory (EMS) are!

Read more »

Technology in the PLC

PLC has been developing the capabilities of simple form and transform the same price level ever. And the development of which will go on. What’s left to do and tons more or no less interesting question.

As a related technology. We conclude the development of PLC from the past to current and upcoming follows.

1) patterns of language use. Still can not say that it will not use the ladder diagram (Ladder Diagram), but the role of the function block (Function Block) is more or even a programming language (Instruction List), which will combine both possible. IEC61131 requirements or not.

2) The development of the ability of PLC to manage mobile devices that generate a lot more like a servo motor. Linear motors. Inverter. By either increasing the speed of mobile functionality to support fast and accurate. Development of special cards for specific actions. Software development or software package for ease of use. These things will become easier and more common in PLC new generations.

3) the support for a network which has become a standard already. Optimization with a reduced number of cables used in plant and machinery is a current push for network-level devices (Component network), such as DeviceNet, Componet, EtherCat the needs for communication of control and order. and management of production networks driven in control and command (Control network), such as Ethernet / IP Controller Link and so on.

4) speed development. Still significant. Response to changes in a timely manner of machinery, more and more intense. The high-speed machinery. Especially in response to a device Encoder, Interrupt input, High speed pulse, even high-speed analog channels.

May be more Development plc. If you are considering the purchase or invest any new PLC. PLC that you are interested or have developed?

Read more »

Solve CP1H R88D Servo Motor Controller

I work around a CP1H R88D servo with a pulse output 0 problem. All power settings are standard, except for the electronic gear ratio. The example is the Handbook of 2000 pulses per revolution motor set.
Fine adjustment of the drive car (one horizontal spindle).

I have the move to Omron (power) function block in the CP1H.
The distance between the CP1H and the servo is about 6 m (2 m). The drive is a Panasonic with brake and encoder (not absolute).


Two cases:
1. 2000 pulses is not a revolution engine, only about 3 / 4 2000 pulses also not equal to 2000 forward pulse times (by a significant amount).
2. The highest speed I can use and still move the actuator 100, although I keep hearing that the CP1H is capable of more. The CP1H seems not the problem. When ordered with a speed of more than 100, the power simply ignore the incoming pulse.

I’ve been through all CP1H/R88D manual and found no answers. Has anyone successfully ran a similar sytem? Anyone have a hint of things to look for?
The manuals never a PNP output to the PLC station in pulse mode. It seems that the manuals are to be desired. I found three departments, which called into question. Well, I’m looking forward to implement the same system with an absolute encoder - should be a breeze - right!

Read more »

Monitoring memory space in the PLC.

Often used in the PLC to consider that choosing which version to use the CPU will have enough space to run the program. The count is difficult enough to evaluate. Because the function of machines, each machine has a different way of thinking is difficult and complex simplicity. And do not depend on the number of I / O.
So if you find ways to estimate a cursory I can do it without writing a program in advance because the CX-Programmer. Can be simulated. (Must be a joint program with the CX-Simulator).

Steps to use.

1. When writing a program so close to actually work. Is enough to see the capacity of content from programs like the CX-Programmer Tools by going to the Cross-Reference Report or press Alt + x.

2. Press the button Generate.

Total UM status means that all memory of this PLC model.
Free UM status means that the available memory remaining space to tell the normal PLC programming in units of step.

3. Commands each command of the PLC. To use the same memory. Depending on the complexity of the computation of new CPU can see that each step of the orders at the end of Part Programming Manual.

4. Students. Cross-Reference Report in addition to more memory space, the rest of the PLC can also be sure that nothing of the PLC variable that is already taken some Used many times. This would be ideal to modify or add applications. Which can be selected Report type: Usage overview (which is pretty. It shows only the active variables) Memory area: Choose the type of variables to display.

5. And then press the Generate button, the program displays a report describing the use of memory out.

Read more »

History of PLCs

Today i have article that story in PLCs,Twenty-five years I was in my last year with Allen-Bradley PLC and a specialist and educator. I grew up with the PLC in 1774, the PMC. What a trip through the PLC-2, PLC 3, PLC 5, computer-based programming instead of a luggable terminal and a 10 MB hard disk for the PLC-3 GA module for remote data collection and programming remotely through the RM modules.

A laptop for programming (Data General) was more than $ 8,000. Hard drive space is outrageous expensive, and Windows will not be used. PCs were ahead, and programmers learned useful DOS software.
From 1977 to 1985 there was an enormous growth pattern that most had not imagined. Remote I / O, HMI, SCADA, and similarly, the PLC to the DCS world compromise. Servo Control was also available. Special keyboards set them up.
Bit-flipping was an art.

We had to do in ASCII module interfaces, and network modules with interfaces for mini-computers like the DEC VAX and PDP-11.

Some applications were too fast for the PLC, but not much. Everything was a good deal for the PLC and the companies and individuals.

In 1986 I founded my own company and am involved with the newfangled software arena. Life changes decision proved quite good.

ICOM, Tele-thinking, tender gray, Taylor et al. made DOS-based PC programming software. Moved to PC-based HMI and ARCnet came to town.

But what really changed since 1985? It depends on who you ask. Marketing vs Engineering is the battlefield, as hardware costs have fallen to the point of goods.

Let me table for the next month to develop a perspective on where we are and where we come from.

Applications that make use of automation changed, but some are not. The reasons for the use of automation, more enterprise-centric. This wish it was in 1985-it just was not easy to implement.

“Real time” a new meaning, so that access to data is crucial. It was, but the preservation of the data was primitive. OEMs developing and producing their own interfaces for the collection of data for customers. We just have easy access to such data today.


Electrician to resolve successfully the systems of fixed terminals. The documentation was found on the printed scale. Difficult to navigate, but they were successful.

Encoders, converters, control circuits and more linked (then and today) with special I / O. Today, however, there are I / O buses, remote I / O of something. Instead of treating a PLC data table for hiking or quantitative information, you get the data from the device. But the data is similar, yes?

At the risk has changed, old, I do not think much. ControlLogix is ​​no different than the PLC-3 from 1980. You can scan multiple cards to support redundancy, the use of special communication card, data collection and other languages. It is a remote I / O and remote programming possible in both.

Applications are available for client / server environments. Mainly based on UNIX, but they worked.

Then something really monumental happened changed the rules changed, the development cycle, and changed the operative work. This cycle / career change made changes, what we have today. We had the goods but few were in force.

The shift was monumental software. Windows 3.0, NT and IBM OS / 2 Presentation Manager creates a free-for-all. A small company called Wonderware HMI took over the company. Because it was so easy, PLC were targeted. Ethernet landed in the workplace, and ensure that each Ethernet PLC had to speak.

New and improved technology may not necessarily be a different function. get from 1985 to 2010 Oldsmobile Porsche both what you want. We want to buy different things with the data. This requires a number of different “things” and it’s slow, painful and not to the order indicated that to change much advertising.

Read more »

Automation Standard for PLC programming

The IEC 61131-3 standard for PLC programming is a non-standard, since many of the rules are so general, and because there are so many exceptions and extensions of the original proprietary software definitions and original promise of portability of software between devices are open.

Capitalism is a great positive force that could improve trade and increase economic benefit and mutual well-being of all: that is, until a few million bad apples begin to cut. Unfortunately too short-sighted and selfish business interests and their puppets legislative promise honest promises its customers and fellow citizens, but then they break for a one-sided personal gain and coat their crimes in another round of conservative financial policy. These are tumors, the invisible hand of Adam Smith should be able to clean themselves.

But combining the flypaper of false promises, advertising, spin and other trick-of-hand with a semi-conscious consumers, voters and other shellfish to purge these lesions to become resistant. Therefore, the old invisible hand can not seem to shake off the parasites, the patriotic singing her praises, and then do everything to undermine it. No wonder that vampires are so popular these days.

Of course, process control and automation sector is far from immune to this disease. Technical misinformation, dishonest marketing and products that do more to suppliers market shares, as a service to protect the customer “has his years of characteristics of the production. More than 10 years old, I thought it would be good to compare an article PLCs (SPS) and other devices to write head-to-head, if only to get a better idea of how this may have a particular application better than the other brand. What a rookie. Not only do I not have the technical means to do it, but I found it almost impossible to direct comparisons between the control and regulation technology components as a consequence of the small but significant and seemingly inexplicable differences in their specifications and operating parameters of research. Resources told the time to me that many of these differences redundant and seemed to exist only in order to avoid comparison with competing products. How beautiful.

And do not even get me started on the long struggle fieldbus and the subsequent eight-member non-standard IEC 61158 standard. It was as one would a bunch of clowns came through on a railway line argument for the Ethernet Express and mowed them down all. Of course some of the more nimble acrobats survived by jumping on a moving train with their versions of its Ethernet, they used to dilute, I mean, make Ethernet robust enough for the manufacturing sector since.

“I weep for you,” said the Walrus. “I am deeply sorry.” With sobs and tears he from which the biggest, sorted with his handkerchief to his eyes streaming. -Lewis Carroll, Through the Looking-Glass and what Alice found there, 1872. ”
One of the most unfortunate examples of this misleading and useless arguments that further development of the IEC 61131-3 standard for programming PLCs. Introduced in 1993 and revised in 2003, including the five sections of software rules for ladder logic diagrams, block diagram, structured text, sequential lessons and lists.

But for many programmers, developers and users believe it is another non-standard, since many of the rules are so general, and because it can be so many exceptions and proprietary software enhancements, that their original definitions and original promise of portability of software between the devices is open.

“I have already maintained by that I do not believe that a standard as much as a guide for the vendor product,” says Jeremy Pollard. Our many years of “Embedded Intelligence columnist in Control Design and staff, has detailed offer about the problems with 61131-3 and the benefits they can still use. You can read all about it on www.controldesign.com/articles/2008/107.html.
Unfortunately, reminds a lot about the development of standards 61131-3 and other efforts to undermine me about Captain Barbossa in Pirates of the Caribbean. When talking about the pirates’ code of brotherhood, “he rolled his eyes and says,” Well, they tend guidelines. ”
Refer from By Jim Montague

Read more »

What can you expect from Mitsubishi Modular PLCs?

Global use
A wide range power supply means your Modular System Q will work all over the world and with the huge range of shipping approvals, CE compliance, as well as manufacturing to Automotive industry quality levels, SystemQ is a product to trust.

Totally scalable
System Q is designed to grow with your application, from the Q00J standalone solution to the networked and redundant process CPU Q25PRH. System Q's platform concept allows you to add and customize the special functions you need.

Multi CPU
The SystemQ Automation Platform allows you to use multiple CPU’s on a single backplane. You can combine up to four CPU types, such as PLC, Motion, PC, Q-C and Process CPU’s, as a single seamless solution.

Multi network connectivity
From basic AS-Interface to Ethernet based networks, System Q can communicate easily with Mitsubishi or third party products. To increase the productivity in your plant, System Q can also provide a direct connection to any database based on SQL via an Ethernet connection.

Flexibility
The wide range of power supplies, CPU’s, I/O Modules, Special Modules and Communication Modules makes System Q one of the most flexible modular automation systems in the world.

Dual redundancy
The redundant Process CPUs Q12/25PRH can, with standard PLC technology, provide a hot standby system with the automatic synchronization of data. The modular concept also allows different degrees of redundancy from power supply and control systems to redundant network modules.

Read more »

Mitsubishi Electric Modular PLC – MELSEC L Series

The Melsec L series is a powerful but compact modular controller with many features built-in to the CPU itself. With its excellent cost performance and usability it is ideal for use in mid-size control applications.

High system flexibility
The rack-free design promotes high system flexibility with minimum form factor. The single-CPU architecture includes built-in Ethernet and Mini-USB interfaces, a SD/SDHC memory card slot for program storage and data logging, and 24 digital I/O for simple high-speed counting and positioning functions. The high-performance CPU also includes a CC-Link V2 Master/Local station for connection to the powerful open field network CC-Link.

Besides the functions already built-in, the CPU can be supplemented with up to 10 extension and special function modules for additional digital and analog I/Os, highspeed counters, communications interfaces, Simple Motion, positioning etc.

The compact size, easy expandability, networking capabilities, and multitude of built-in high-powered functions makes the L series ideal for both stand-alone machines as well as networked stations in larger applications.

Data logging
The built-in data logging function provides an easy way to collect information for troubleshooting, performance evaluation, and other uses. The included configuration tool makes setting up the data logging function a breeze with a step-by-step wizard like interface. Using GX LogViewer, the captured data is easy to interpret and understand.

USB and Ethernet as standard
The built-in USB 2.0 port or Ethernet interface can be used to connect directly at the installation site. The Ethernet interface supports direct connection and does not require any configuration of the PLC or PC to operate.

Advanced programming software
GX Works2 represents the next generation in PLC maintenance and programming software and is perfectly suitable for the L series.

Read more »

Mitsubishi Electric Modular PLC – PLC control

The modular concept
Building on its predecessor, the AnSH, System Q is a control concept that allows users to mix and select the best combination of CPUs, communication devices, specialist control modules and discreet I/O on a back- plane. This allows users to configure systems into what they need, when they need it, where they need it.

Multiple capabilities
Basic and advanced PLC CPUs, specialist motion and process controllers and even PCs can be combined into a single System Q solution with up to four different CPUs. This gives users a choice of control philosophies, programming concepts and programming languages – all from a single platform.

An automation platform for the future
Flexibility and scalability are key design features that enable System Q to truly be a single Automation Platform. Users can apply simple control to an individual machine or integrated plant wide management all from the same hardware base.

Supporting the System Q platform is a suite of software tools enabling easy and comprehensive integration through EZSocket, Mitsubishi’s own middleware. In addition, Mitsubishi also offer software tools that comply with international standards such as IEC1131.3, OPC and Active X. This tremendous flexibility permits users to reduce development time, simplify commissioning, and provide ongoing system maintenance.

Basic PLCs
Not every control application requires the full power of System Q. For example, many machine builders embed control technology into their machines and require small compact designs featuring flexible high-speed operation. System Q’s Basic PLC CPUs offer just this kind of solution, balancing power and performance against cost. A good example of this is the Q00J CPU.

This all-in-one unit provides power supply, CPU and backplane as a single, ready-to-use unit ideal for small systems that still require powerful performance. Other Basic PLC CPU options include the classic modular designs Q00 and Q01, the first steps on the path to the full System Q automation platform.

Advanced PLCs
For advanced machine designs and controlling manufacturing cells, including infrastructure and site-wide management, System Q’s advanced PLC CPUs offer incredible performance and versatility.

Processors are available with a wide range of memory capacities, all of which can be expanded as required. This means that System Q PLCs can support complex programs as well as store large volumes of operation data.

Universal PLC CPUs
These universal PLC CPUs are the latest generation of modular CPUs for the MELSEC System Q controller platform and they are the foundation of the iQ Platform system. They can be combined with the motion, robot and NC CPUs to configure scalable and highly flexible modular automation systems.

Scalable
With the exception of the embedded Q00J CPU, all System Q PLC processors are interchangeable, which means processing power can be increased as applications grow, protecting your investment in infrastructure and hardware.

Multi Processor support
Up to four separate System Q PLC CPUs can be placed in a single system. These can be used to control their own set of dedicated tasks or for sharing the processing and control load, making the total system highly responsive. This provides users with faster, more dynamic control, leading to better production quality and improved production rates.

Read more »

GX IEC Developer - MELSOFT-Mitsubishi PLC Software

GX IEC Developer is more than a powerful IEC 1131.3 programming and documenation package. It supports your entire MELSEC PLC impleentation from the initial project planning to everyday operation, with a wealth of advanced functions that will help you to cut costs and increase your productivity.

The sophisticated program architecture comes with a range of new, user-friendly functions, including structured programming and support for function libraries.

Top-down application architecture
During the planning phase GX IEC Developer's structuring tools help you to organise your project efficiently: Use the intuitive graphical tools to identify and display tasks, functional units, dependencies, procedures and application structures. In addition to making your work easier, this also significantly reduces error frequency in later project stages.

Flexible implementation
In the engineering phase you then choose the programming language that best matches the structure of your project.

Program frequently-used functions in function blocks and organise them in libraries. This gives you the confidence that comes with knowing you are using tested, reliable code. Password support helps you to protect your valuable expertise.

Simple configuration of control components
Configuration of controller components is performed quickly and efficiently in tables with interactive dialogs and graphical support. And this powerful support is available for standard and special function modules as well as for the controller CPUs. You no longer have to create application programs to configure your system.

Setting up the hardware and network configuration
Powerful testing and debugging tools provide information on the current status of the controllers and the network you are connected to. Network functions like status and error displays, remote SET/RST functions for controllers and peripherals, Live List, Cycle Time, Connection State and more enable you to locate and correct errors quickly and get your hardware and networks up and running in record time.

Setting up the application program
GX IEC Developer comes with everything you need to get your applications installed, set up and running as quickly as possible, including comprehensive online programming functions, fast and informative monitoring displays, the ability to manipulate device values with the graphical editors, manual and automatic step mode execution in IL, the display of manipulated device values in the EDM (Entry Data Monitor) and much more.

Normal operation
During normal daily operation you can also use GX IEC Developer to display important system status information, either in stand-alone mode or called by another program in the control room.
Installation and maintenance

Top-down architecture, structured programming, comprehensive printed documentation and support for user-defined help for your function blocks all help to reduce the learning curve. You can make the information needed for installing and maintaining the system available to the operators quickly and efficiently, with minimum training overheads.

Key features include:

• Powerful "Top-down" development environment
• Total overview of PLC project and resources
• Suited to large and complex projects
• One programming software for modular and compact PLCs (Q/A and FX Series)
• Flexible program development
• Superior program documentation for easy understanding
• State-of-the-art PC software technology acc. to IEC 1131.3
• Programming languages FBD, AWL, KOP, AS and STC
• Powerful offline simulation
• Online program modification
• Function blocks (FB, FC)
• Libraries Minimum downtimes

Read more »

GX Developer - MELSOFT-Mitsubishi PLC Software

GX Developer supports all MELSEC controllers from the compact PLCs of the MELSEC FX series to the modular PLCs including MELSEC System Q. This software shines with a simple, intuitive interface and a short learning curve.

GX Developer supports the MELSEC instruction list (IL), MELSEC ladder diagram (LD) and MELSEC sequential function chart (SFC) languages. You can switch back and forth between IL and LD at will while you are working. You can program your own function blocks (MELSEC QnA/QnAS/System Q series), and a wide range of utilities are available for configuring special function modules for the MELSEC System Q. And "configure" is the operative word here - you no longer need to program special function modules, you just configure them.

The package includes powerful editors and diagnostics functions for configuring your MELSEC networks and hardware, and extensive testing and monitoring functions to help you get your applications up and running quickly and efficiently.

You can also test all of your program's key functions before they are implemented with the GX Simulator offline simulation mode.

GX Simulator also enables you to simulate all your devices and application responses for realistic testing.

• Standard programming software for all MELSEC PLCs
• Comfortable prompting under Microsoft Windows
• Ladder Diagram, Instruction List or Sequential Function Chart
• Changeable during operation
• Powerful monitoring and test functions
• Offline simulation for all PLC types
• No hardware needed

Read more »

PX Developer - MELSOFT-Mitsubishi PLC Software

Using the PX Developer, process applications can be designed, debugged, monitored and maintained.

Read more »

GX Configurator - MELSOFT-Mitsubishi PLC Software

GX Configurator DP can be used to configure all Profibus/DP modules of Mitsubishi's modular PLCs. In addition to MELSEC PLCs it also supports connection of Mitsubishi frequency inverters, the E series of graphical control units and remote I/O modules.

Integrating slave modules from third-party manufacturers is as easy as importing the GSD data. GX Configurator DP makes Profibus/DP very easy to handle. To configure your network with this software system you just drag ready-to-use graphical images of your devices onto the Profibus/DP network representation on the screen. Then you enter the device station numbers and specify which PLC addresses you want to allocate to the remote Profibus/DP slaves. A wide range of user parameters are supported for the Profibus/DP-Slaves; configuration is handled transparently with the GSD files.

Key features include:

• Easy set-up for Europe's most popular network
• Supports Mitsubishi Profibus products and 3rd party products
• No PLC programming skills neededGraphical interface for easy set-up
• Easy to understand network layout
• User-friendly configuration software for PROFIBUS/DP
• 32-Bit version for MS Windows 95/98 and NT4/2000
• Supports the configuration for all PROFIBUS/DP modules
• Wide range of user parameters by using GSD files for configuration
• Easy configuration of 3rd party slave units
• Download of the tabular configuration data via network

Read more »