Trends in automation and control in the 2013 and beyond

This paper focuses on my views on the trends of automation and control in the 2013 and beyond. These comments are based on a wide range of users, suppliers and industry advisors, and are attended by numerous industry forums, conferences and trade exhibitions each year. Designers with years of practical experience in the field of automation and control are also reflected in these views.

Enterprise Automation System

Any reasonable scale is impossible industrial plant installation has a single control system architecture trend is to have a software platform that unifies operations and information flow to improve decision-making, improve flexibility, reduce risk, and improve productivity. This is going to be done more when a unified software architecture is chosen by a provider. These platforms are based on an open software architecture that includes a high-performance real-time database that supports a variety of industry standards, including OPC,OPCUA,B2MML, multiple native protocol drivers, ERP interfaces, and database interfaces. The key to success is the integration of Third-party applications using open standard software platforms that can be easily configured as applications without the need for custom software. Enterprise automation software has only just begun, there has been a lot of hype with many vendors claiming to have an integrated product. The reality is that most vendors are still loosely coupled with software applications that do not make a cohesive enterprise management system. Users need to carefully evaluate the product and choose a legitimate integrated enterprise software solution.

Collapse schema

New technologies may require the creation of streamlined 2-3-tier automation systems to improve performance and reduce software maintenance costs. The five-tier system model has been concentrated in the automation industry for many years and has been commonly expressed in the 5-level Purdue model, which is a significant simplification.

Level 5-Business system

Level 4-plant-level enterprise resource plan (erp,mrp,mes)

Grade 3-level of business unit

Level 2nd-machine/process automation level

Level 1-Controller level

Level 0-sensor/Actuator

Existing automation systems generally reflect this architecture, running software on general-purpose computers at levels 2,3,4, and 5. Level 2,3 and 4 devices typically include a database and communication interface, in addition to the associated HMI and other interface buffers and information synchronization between each level. Historically, this configuration has been determined by the limitations of computational costs and network bandwidth. However, this multi-level, multiple computing model is complex and creates a large amount of cost, continuous configuration of control and lifecycle investment. In the new mode, the controller information is communicated to all levels directly from level 0 and 1 to 4 and 5 use appropriate protocols, especially Web services.

Automated Computing Engine (ACE)

More powerful controllers, automated computing Engine (ACE), Level 2nd, 3rd and 4 features embedded in the future market, which will continue to accelerate and make the crash of the automation architecture. This breed has dual-core and four-core CPUs, and is an automated control and computing engine that enables them to function in factory workshops, including embedded historians, analytics, alarm management, equipment diagnostics, and advanced control to optimize extended enterprise system functions and rules engines. These powerful devices, perfect sources of information in the workshop carry out meaningful data. Adding a higher level of functionality directly to these new controllers eliminates the need for hierarchical 2,3 and 4 of computers, which improves system performance, eliminates bottlenecks, eliminates duplicate databases, simplifies configuration control, and lowers software maintenance costs.

Opcua

OPCUA brings industry standards for open computing, enabling engineers to realize the concept of digital factories and improve productivity. OPCUA technology provides an efficient, secure infrastructure for all automated systems, SCADA manufacturing, communications, and process control for computing from sensors to businesses. By using internationally recognized computing standards, OPCUA will be a fair competitive environment for the general computing industry of automation systems. OPCUA employs industry-standard Web services, which is the preferred method for communicating and interacting with all network devices on the system. The World Wide Web Consortium (WWW) defines a software system for Web services design that supports the interaction of machines through network interoperability. "This is the task of the automation system. OPCUA fabric is incorporated into the controller, for example, the Plcopen OPCUA function block is the IEC61131-3 standard, encapsulating the Iec61131-3 Information Model extension of a map-like software model. The OPCUA server provides a standard way for the controller to include the controller, HMI, MES,LIMS,ERP and other systems of the OPCUA client to expose the data.

Free Panel Installation

Our goal is to eliminate the control cabinet and simplify wiring. Automated product design concepts to eliminate industrial networking protocols that require equipment to be installed in cabinets to begin with, IP67 and ip20i/o equipment support. A complete iec61131-3 controller is embedded into the IP67 and IP20I/O modules, and the number of parts is reduced and the counter is another example. New trends further controllers, actuators, servo motors, valves, equipment and HMI devices do not need to be mounted on panels, thus reducing costs, simplifying installation and reducing maintenance labor.

Large data-Information lever

The amount of data in the automation system has exploded and monitored in real time data. Tools to analyze the emergence of these large large datasets will be used to improve productivity and innovation. The accelerator for this trend is more powerful low-cost computers, wireless sensors, software and analytics software. Lower-cost computing capabilities have been able to use advanced analytical software operations and improve productivity. This opens up a door for companies to find more ways to analyze to improve efficiency. Predictive maintenance is a good example of how to predict the analysis before a problem occurs, thereby avoiding production disruption. In addition to reducing downtime, this also maximizes the use of skilled maintenance personnel who are in short supply. More and more users and vendors have gone beyond the software's dashboard to use power calculations to create advanced control and automation. In addition, advanced analysis can greatly improve the decision-making and improve the manufacturing process.

Transformation and upgrading

The opportunities for transformation and upgrades are enormous and will last for years. ARC Consulting Group estimates that the $65 1 billion value of the process automation system is nearing the end of its service life. At least 2.2 billion dollars, these systems are installed in North America, most of which are over 20 years of age. Manufacturers in the United States and Europe are more likely to maintain existing systems and add new features and features to save money. Almost all of the automation providers have a cabling system that provides a software conversion program that moves customers from the old system to the new, retaining the existing sensor wiring. After leaving the system and bolting new features, many users see more value. At the top of these old systems add-on software is used to increase asset management, advanced control and other functions. The gateway has become a very popular bottom to the existing system to add new controllers, sensors and wireless sensors. Life's I/O hardware, controllers and sensors of the old system proved to be far more than life expectancy for 10, the original idea. In many cases, investing in new, more efficient machines replaces older production equipment with automated systems to replace more efficient investment ratios.

Remote monitoring

Remote monitoring continues to grow, improved and refined hardware and software tools. Remote monitoring features allow shrinking automation and control specialists to help solve factory problems without the need for travel and will continue to become more powerful. These tools allow the expert to serve them in the factory based on the on-site rules of the system, and their knowledge is institutionalized. There is a serious lack of knowledge, experience and skills for people who will be able to grow in experienced people, with a shrinking developed and developing countries. The continuous improvement of mobile phone technology is being increasingly implemented by remote monitoring because it is ready-made and easy to deploy. The handset and the SMS technology controller will grow to support this trend. This development will continue to utilize technologies including the Internet, cloud computing, basic software rules, IP video and audio communications.

Information security

More advanced methods, software and hardware will be developed to protect the network security attacks of automation, control and SCADA systems. Network security has been discussed for quite some time, but it seems to be a problem that does not come to the forefront until there are major disasters, such as the Saudi Aramco attack on the Stuxnet worm that wiped out 30,000 computer systems in August 2012. There is likely to be a more successful attack that will inspire the future of network security for industrial automation systems. "Big Game" in my opinion has not begun, opponents are just beginning to learn, stamp and collect data. Looking back on the history of classic military struggles the winners in the defense of a major attack before their opponents usually get good reconnaissance and detection. Further bearing the analogy of the war, is the typical movement, many fights. An enhanced industrial Ethernet network may need to migrate to IPV6, including a stronger security model, Internet Protocol Security (IPSEC), a communication session for each IP packet, and encryption on the hardware encryption method for each network connection.

Integrated machine Design

Vision has a complete systematic approach to designing products, machines and production lines as a whole process begins to appear and will accelerate. Optimize, debug, increase production, improve quality, reduce cost of manufacturing process is to build a production line or a single machine before the software design and modeling tools. Machine and related automation in one integrated software design environment, design, modeling and simulation, with great capacity. In this process, engineers can optimize the minimum energy consumption of complete machine automation generated by the controller code. Open standards Enable connection modeling software to automatically generate controller code for robots, machine tools, PLC and other industrial controllers. Conforms to the Plcopenxml exchange standards, such as the simulation and modeling software manufacturer that is being used to automatically generate controller programs. The adoption of these technologies enables enterprises to compete in the advantages of reducing costs and risks. In order to make full use of this method, the traditional silo company must work together.

Robot

In the wider industry is accelerating the use of robots with lower cost and more flexible robots. "Smart" robots can create integrated robotic vision systems that will identify software. In addition, robots have become simpler to plan, including the ability to teach robots to perform tasks. As early as last year, the International Robotics Federation reported that robot sales grew by 38% in 2011, the highest level ever recorded in a year. The most important country is the growth rate of 39% and 51% between China, the United States and Germany. The two largest markets are still Japan, followed by South Korea. Cars, food and beverages, metals, machinery and other industries have grown above average robot orders. Robots allow manufacturers to improve productivity, reliability and quality objectives. Improvements in security, flexibility, accuracy and ease of use accelerate through with lower cost.