Industrial Automation Automation Industrielle Industrielle Automation

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Industrial AutomationAutomation
IndustrielleIndustrielle Automation

• Control System Architecture
• 1.5 Architecture de Contrôle - Commande
• Leittechnik-Architektur

Prof. Dr. H. Kirrmann
ABB Research Center, Baden, Switzerland
2008 June, HK
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1.5 Control System Architecture
1 Introduction 1.1 Automation and its
importance 1.2 Applications of automation
1.3 Plants and controls 1.3.1 Open loop and
closed loop control 1.3.2 Continuous
process 1.3.3 Discrete process 1.3.3 Dual
plants 1.4 Automation hierarchy 1.5 Control
System Architecture
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Principle
The control system has to suit the plant, not the
reverse
The structure of the control system should
reflects that of the plant
Ideally, each unit of the plant should have its
own controller, interacting with the controllers
of the other, related units, mirroring their
physical interaction. Example Airbus a wing is
delivered with its own computers.
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Busses and processors in industrial plants
instrument bus (mimic board)
open network, WAN
Operator panel
Mimic board
Process pictures
Process Data Base
workstation bus
station
Logging
station
plant bus (500m .. 3 km)
processor pool
P
P
P
C
P
P
C
P
PLC nodes
node bus
(multi-processors)
I/O
MEM
I/O
MEM
BC
fieldbus (30m..2 km)
directly coupled
control
backplane bus
input/
stations
output
sensor bus (0,5.. 30 m)
sensor bus
transducers
plant (Werk, usine)
M
valve
thermo-couple
motor
position
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Example Printing Architecture
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Example Production management system
productionplanning
enterprise network
scheduling
maintenance
quality control
plant network
cell
transportationcell control
manufacturingcell control
floor network
robotcontroller
millingmachine
rail-guided vehicle
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Example Power plant control - 1980 (!)
Control systems look similar
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Example Honeywell TotalPlant (2003 same
structure)
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Example Rockwell (Allen-Bradley) NetLinx
Programmable Device Support PC
EtherNet / IP
Controller and Bridge
Servo
ControlNet
HMI
Linking Device
Bridge or Linking Device
Drive
HMI
DeviceNet
Modular I/O
Micro PLC
Sensor
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Example Emerson's PlantWeb (Delta V)
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Example ABB Industrial IT (redundant system)
Plant Network / Intranet
Enterprise Optimization (clients)
Workplaces (clients)

3rd party application server

Firewall


Client/server Network
engineering workplace
application server
aspect server


Control Network
Programmable Logic Controller AC 800C
Serial, OPC or fieldbus

touch-screen
Redundant
AC 800M
Field Bus
Field Bus
3rd party controllers, servers etc
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The internet dimension (example Alstom)
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The wireless dimension (example Schneider)
No more wires, but the structure remains
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A real substation project
Global Position
Disturbance Recorder
to
Operator's Workstation 1
Engineering Workstation
Printer Server 1
Operator's Workstation 2
System
Evalution Station
Central Station
PTUSK Scope

132kV FOX


Equipment
Alarm and



Event Printer 1
132kV analog
11kV analog
Ether
LA36W
Input
Input
net
Printer Server 2
Verbindung zu E4
Alarm and
o/e
Event Printer 2
11kV Modem
LAN-Interface
LA36W
to LV SCMS
NSK
GPS
Master
Redundant Station LAN TCP-IP
Front-End Station
Front-End Station
Computer 1
Computer 2
RS232
Manual
Switch
4 x Star Coupler
RER111 including
redundant
power supply
FO
Fibre optic station bus (LON) in star
configuration
Main 2
Main 1
ystem
S
o/e
Siemens 7SD610 für
Advanced
E19 Verbindung
SACO64D4
Auxiliary alarm unit
Automation
SAS570
B69
SACO64D4
Auxiliary alarm unit
ubstation
Überstrom
Pilot wire diff. prot.

SOLKOR R/Rf.
S

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Centralized Control Architecture (classical)
Central Computer
(Mainframe)
Group
Group
Group
PLCs
Control
Control
Control
Sensors, Actors
plant
Classical, hierarchical, centralized architecture.
The central computer only monitors and forwards
commands to the PLCs
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Decentralized Control System (DCS)
peer-to-peer (horizontal communication)
hierarchical (vertical communication)
engineering workstation
operator workstation
data logger
plant bus
controller
controller
controller
controller
field bus
plant
all controllers can communicate as peers
(without going through a central master),
restricted only by throughput and modularity
considerations.
Note Honeywell's "DCS" stands for "Distributed
Control System", it is not a decentralized
control system, but a control system for the
process industry.
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Hierarchies are simple and traditional
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but Distributed Control Systems reflects a more
complex world....
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Assessment
1. Draw a typical hierarchical control system
showing busses and controllers 2. How does the
network hierarchy relate to the plant control
hierarchy ? 3. What is the difference between a
centralized and a decentralized control system
? (can this difference be seen from the outside
?)
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