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Areas of application
Modern manufacturing technology sets high standards for industrial process automation. Manufacturing and supply of integrated industrial process automation systems, automated control systems and process optimization systems are among our company’s key areas of activity.
Automated control and monitoring systems are designed to control industrial processes; support the optimal industrial equipment operating mode, taking into account intermediate data; generate and issue reporting and archival documentation; troubleshoot measuring equipment in such industrial sectors as construction, food processing, chemical, oil refining and other industries.
Due to high quality and reliability of components supplied by the world’s leading manufacturers, such as Schneider Electric and Siemens, automated control systems offer their end user the most economically sound “price-quality” ratio. One of the economical advantages of integrated automation systems is the reduced cost of hardware components due to use of standardized components and modular structure, lower equipment lifecycle expenses and lower cost of spare parts.
Automated process control system must have:
— high information content allowing to assess technological processes, choose criteria and determine their relative importance;
— ability to diagnose technological conditions and industrial process malfunctions in order to make technological adjustments to manufacturing process, if necessary;
— ability to search for optimal operating mode;
— highly precise measurement of technological parameters and their regulation;
— availability of push-button automatic proportioning;
— ability to keep production cycle in accordance with previously specified algorithm;
— ability to expand control systems;
— ability to create automated work stations of operators based on automated process control systems.
Our automated process control systems accomplish all these tasks. Our service package includes: training, preventive measures, servicing, etc.
The hardware-software complex is meant to implement automated monitoring and control of industrial equipment and dispatching control of industrial process parameters.
Automation system's primary functions
Automated process control system’s primary functions are:
— automated supervisory control of industrial equipment parameters (levels, pressures, interface levels, temperatures and flow rates of processing units);
— correlation between measured values and rated values of technological parameters, generation of control signals, as well as warning and alarm signals;
— schematic representation of technological process development in the form of mnemonic diagrams, trends (temporally parametric variation lines), indicators;
— timing of fundamental technological parameters, generation of event logs and archival files;
— automated and manual operating control of electric bolts and control valves from automated workstation panels of operators;
— simulation of control objects, breakdowns and failures for the purposes of auto adjustment and operating personnel training.
Structure and functions
The development of multi-pillar automated data acquisition and processing systems and manufacturing process control systems requires special solutions in telecommunication network's architecture. Automated process control system is based on a hierarchical approach and multilayer structure.
There are four levels of hierarchy in automated process control systems:
lower level — transducers and actuating mechanisms;
middle level — industrial controllers;
upper level — industrial server and network equipment;
operating level — operator's and supervisory stations.
The lower level consists of sensors and actuating mechanisms installed in production facilities. Their design and performance ensure continuous and safe functioning in inclement weather conditions and explosion hazard zones. Communication between middle level sensors and actuating mechanisms is carried out via corresponding cables.
The middle level consists of industrial controllers, power automatics, indicators and secondary devices. They should be allocated over the territory so as to minimize expenses on cable installation and reduce the electromagnetic interference effect. Industrial controllers make up the core of software engineering tools.
Industrial controllers implement the following tasks:
— collection and processing of data, received from sensors;
— control of industrial objects according to previously specified algorithms.
Their identifying features are:
— wide range of modules making it possible to develop multifunctional monitoring and control systems;
— intelligent input/output modules, including independent operations controllers;
— duplication of central processing unit modules and power supply unit modules;
— module hot-swap option availability;
— output circuits availability in the form of explosion isolation “Intrinsically-safe electric circuit”.
Data transmission from controllers to the next level and control signals reception is carried out via the RS 485 standard interface. Communication between any industrial controller and server is carried out via two independent communication channels.
Duplication of “Server — industrial controller” communication channels is necessary in order to increase general reliability of the system.
The upper level is the level of industrial server and network equipment.
Network equipment consists of hubs, switches and adapters.
Industrial server is a highly reliable, fault-tolerant computer system. It ensures large amounts of real time technological data accumulation and safe long-term storage, as well as its accessibility to a large number of operating level automated work stations. Network and telecommunication equipment, network channels, telephone and fiber lines form a high-speed multi-pillar industrial computer network.
Fault-tolerance of the` network is secured by backing-up the network channels, communication lines and communication equipment.
The operating level consists of automated work stations of operators and supervisors and a network printer, which are all installed in various facilities and buildings.
Automated work stations connected to a local-area network form an integrated computer system. It graphically displays technological data, ensures alarm activation and communication between operators and automated workstations, provides communication with other control systems. Duplicating each other workstations (with equal data receiving and control functions), as well as technologically oriented workstations are created on this level. They adequately accommodate personnel and meet manufacturing technology specifics.
All supplied software is easily integrated into automated process control systems and other factory automation systems due to use of standardized solutions:
— communication protocols (Ethernet 802.3, TCP/IP, etc.);
— operating system (MS Windows 2000); — file formats (TXT, DOC, XLS);
— interfaces with DBMS (database management system) (ODBC, SQL);
— dynamic data exchange interfaces DDE, NetDDE.
This software fulfills all the necessary functions of human-machine interface .
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