Controllers for the automation of production: classification and architecture

In the process of designing systems that provide production tasks, many operational nuances are taken into account. Each complex is individual, but the principles of its implementation are based on a basic set of requirements. The system should be efficient, reliable, functional and at the same time ergonomic. The link between the directly technical part of the production support and the control tasks is realized by the controllers for the automation of the processes. They concentrate information coming from different technological areas, which is the basis for making certain decisions.

Classification of controllers by field of application

Almost every modern enterprise uses systems that allow automating work processes to some extent. And the nature of the functions served can be completely different. In the chemical industry, for example, the programmable equipment controls the dosing, the volumes of the flow of bulk and liquid materials through the controllers, monitors the properties of various substances with sensors, etc. In the service sector of transport organizations, the emphasis is on the management of power equipment, as a rule, loading and unloading. Widespread and universal controllers for the automation of ventilation, heating and water supply. This is a group of systems that manage engineering and utilities in enterprises in various fields. Conversely, there are highly specialized areas in which individual development of systems for specific needs is needed. These areas include the oil industry and metallurgical plants.

The principle of operation of controllers

The industrial controller is a microprocessor, which provides hardware and software. The first part, in fact, serves the physical work of the system, based on the nested task execution program. An important aspect of any configuration of this type is the regulatory infrastructure. That is, the software base is responsible for making certain decisions, but in the future, the received signals are received at the command points given directly to the working equipment. Thus, controllers for automation control machines, conveyor lines, technical power tools, etc.

Another equally important component of the common control infrastructure are sensors and indicators, on the basis of which the controller develops solutions or strategic chains that determine the modes of operation of equipment. These may be sensors that assess the condition of apparatuses and aggregates, serviced materials, microclimate parameters in the production room, and other characteristics.

Automation Controller Architecture

Under the architecture of the controller is understood the totality of components, due to which the automation control function is realized. Typically, the architectural configuration involves the presence of a processor, network interfaces, memory and I / O systems. This is a basic equipment, but depending on the needs of a particular project, the composition and characteristics of individual parts can vary. Complex controllers for automation are called modular. If the traditional simple architecture is a unified block with a typical composition of functional elements that are not available for change by the operator, then in complex architectural models a multicomponent modular configuration is realized. It allows not only maintenance of a single closed unit, but also each module separately. Now it is worth considering some parts of the architecture in more detail.

Types of architecture modules

The basic modular device is represented by a microprocessor. From its power depends on how difficult tasks can be solved by a specific controller. Also important is the storage device. It can be integrated into the system without the possibility of further changes. But most often external flash memory modules are used, which can be changed depending on the current tasks. Responsibility for the actions taken by industrial automation controllers is largely borne by input-output devices. Through these channels, the processor receives information for processing and subsequently gives the appropriate commands. In modern systems, an increasing role is played by interface modules, on which the communication capabilities of the controller depend.

Main characteristics of the processor module

When developing a control system, it is especially important to take into account the basic characteristics and capabilities of the microprocessor. As for the basic operating parameters of this module, they include clock frequency, bit depth, task execution periods, memory, etc. But even these characteristics do not always become decisive, since the performance of modern even budget microprocessors is enough to maintain most of the production processes. It is much more important to determine the communication capabilities and functions that controllers perform to automate the operation of the enterprise. In particular, operators put the ability to work with a wide range of network channels, interfaces and programming languages. Separately, it is worth noting the possibility of connecting display devices, controls, modern displays and other components.

Operator panel

Regardless of the characteristics of the filling of the controller, an operator station with an appropriate relay must be provided to control its functions. Outwardly, such devices resemble a small computer provided with input and output devices, process sensors and a display. The simplest controllers for the automation of production include the possibility of programming through this panel. And under the programming can mean elementary installation commands of entry level. The most sophisticated operator panels also perform self-diagnosis and self-calibration.

Automation system power sources

The average range of voltages supplying industrial controllers is in the range of 12-48 V. The source is usually a local network at 220V. In this case, not always the power supply unit is in proximity to the serviced equipment. For example, if controllers are used to automate a boiler house in metallurgical multi-stage production, then the distributed power network can be equidistant from several energy consumers. That is, one circuit will serve the boiler for soft metals, and the other for solid ones. In this case, the voltage may vary in the lines.

Conclusion

Workflow automation systems are increasingly integrated into the infrastructure of modern enterprises. Accordingly, the controllers for automation systems in different modifications are widely distributed. In itself, the content of such a device does not require special expenses. The main difficulties in working with this equipment relate to the quality of programming and optimization of the configuration layout. But along with this, to simplify the operator's functions, modules that assume self-tuning according to the basic data entered by the user are becoming more popular.