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Industrial Automation examples
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Automation Examples1.2Exemples de sites automatissBeispiele AutomatisierungssystemeProf. Dr. H. KirrmannEPFL / ABB Research Center, Baden, SwitzerlandIndustrial AutomationAutomation Industrielle Industrielle Automation2008 March HK
*1.2 Automation ExamplesIndustrial Automation
Examples of Automated Plants1 Introduction1.1Automation and its importance1.2Applications of automation 1.3Types of Plants and Control1.3.1Open Loop and Closed Loop Control1.3.2Continuous processes1.3.2Discrete processes1.3.3Mixed processes1.4Automation hierarchy1.5Control System Architecture
*1.2 Automation ExamplesIndustrial Automation
Carstraditional: appliances control (windows, seats, radio,..)motor control (exhaust regulations)critical new applications: ABS (anti-skip) and EPS (stability), brake-by-wire, steer-by-wire (X-by-wire) increased safety ?extreme price squeezing2001 US model: 19% of the price is electronics, tendency: +10% per year.
*1.2 Automation ExamplesIndustrial Automation
Rail vehiclesdisplay unitvehicle control unitDU TCU DU TCU VCUradio linkthere are more than 20 interconnected computers on a locomotivebrakessignalingtraction control unitdiagnosticsenergyBenefits: reduce operation costs, faster diagnostics, better energy management, automatic train control. VCUSBB 460
*1.2 Automation ExamplesIndustrial Automation
Airplanesavionics:flight control (safe flight envelope, autopilot, engineer)flight managementflight recording (black boxes, turbine supervision)diagnosticsfly-by-wirehigh reliability
*1.2 Automation ExamplesIndustrial Automation
Launch vehiclesserial data buses ( 23 shared, 5 dedicated )GPC 5IOP 5GPC 4IOP 4GPC 3IOP 3GPC 2IOP 2GPC 1IOP 1Intercomputer (5)Mass memory (2)Display system (4)Payload operation (2)Launch function (2)Flight instrument (5;1 dedicated per GPC)Flight - critical sensor and control (8)Control PanelsCPU 1CPU 2CPU 3CPU 4CPU 5
*1.2 Automation ExamplesIndustrial Automation
Robotsextension limited to 2-3 m (portal robots 10-20m)frequent reprogramming for new tasks, toolingsimple embedded computer, hierarchical control
*1.2 Automation ExamplesIndustrial Automation
Substationsprotection (Lines, transformers, generators) very high speed responsecontrol (remote or local) to guarantee power flow, safe operation (interlocking)measurement (local and remote), electricity bill, power flow in grid
*1.2 Automation ExamplesIndustrial Automation
Pharmaceutical IndustryInventoryRecipe managementPackagingSamplingTracking & tracingComply with government rules:Typical of batch processes.
*1.2 Automation ExamplesIndustrial Automation
Manufacturing
*1.2 Automation ExamplesIndustrial Automation
Flexible Automationnumerous conveyors, robots, CNC machines, paint shops, logistics.Download from production management, connection to administration
*1.2 Automation ExamplesIndustrial Automation
Warehousesextreme dependency on theavailability of the controlsystem
Connection to * supply chain management, * order fulfilment* customer relationship and * commercial accounting (SAP)
*1.2 Automation ExamplesIndustrial Automation
Printing machinestasks of control system:motor control (synchronisation of the printing cylinders)ink and water controlpaper web control (reelstands (Rollenwechsler, bobines), web tension, emergency knife)interface to operator (commands, alarms)production preparation and statistics - up to the press roomvery high requirements on availability: two hours delay and the production is lost.
*1.2 Automation ExamplesIndustrial Automation
Oil & Gas, petrochemicals"upstream": from the earth to the refinerydown-sea control
"downstream": from the oil to derived productsspecial requirement: extreme explosive environmentdistributionspecial requirement: high pressure, saltwater, inaccessibilityexplosive environment with gas. special requirement: environmental protectionSwitzerland: Colombey, Cressier
*1.2 Automation ExamplesIndustrial Automation
Chemical industrye.g. LONZAlogistics,local control of reactorsCharacterized by batches of products, reuse of production reactors for differentproduct types (after cleaning).
*1.2 Automation ExamplesIndustrial Automation
Process IndustryMetals and MineralsGlass productionChemical .Process Industry = industries de transformation, Verfahrenstechnik(one of the many meanings of process)CementContinuous flow of materials, often 24 hours a day
*1.2 Automation ExamplesIndustrial Automation
Steel millsparticularity: synchronization of the motors in the rolling mill
*1.2 Automation ExamplesIndustrial Automation
Cement WorksControl tasks: Oven rotation and temperature controlfuel supply, silos,transport belts,grinding mills,pollution monitoring,quality supervision,filler stations,...
Switzerland is leading nation in Europe(Holcim, Jura, )The rotating oven is the heart of the cementprocess: the grinded kilnis burnt and comesout as chunks later reduced to powder.
*1.2 Automation ExamplesIndustrial Automation
Mining
*1.2 Automation ExamplesIndustrial Automation
Building Automationbasics: fire, intrusion, climate, energy managementHVAC = Heat, Ventilation and Cooling = air conditioningvisitors, meeting rooms, catering,.low price tag
*1.2 Automation ExamplesIndustrial Automation
Automation of Building GroupsEPFL
*1.2 Automation ExamplesIndustrial Automation
Airportslarge building automation system: fire, security access, energy, lighting, air conditioning, communications, traffic control luggage control inZurich-Airport
*1.2 Automation ExamplesIndustrial Automation
Traffic controlfireintrusionenergywaterventilationpollution monitoringcameraslight controltraffic jams prevention,....(Tunnel Letten near Zurich)
*1.2 Automation ExamplesIndustrial Automation
Harboursfrom ship planningto crane manipulationand stock control
*1.2 Automation ExamplesIndustrial Automation
Water treatment(fresh and waste water)
manage pumps, tanks, chemical composition, filters, movers, quality... auxiliaries: methane electricity generation
*1.2 Automation ExamplesIndustrial Automation
Power plantstasks: fuel supplyprimary process control (steam, wind)personal, plant and neighbourhood safetymonitoring environmental impactelectricity generation (voltage/frequency)energy distribution (substation) 24 / 365 availabilityHydro - river- dams- storage damsThermo- coal- gas- atom - solar - wasteAlternative- wind- photo-voltaic
*1.2 Automation ExamplesIndustrial Automation
Waste treatment, incineratorsraw material supplyburning processsmoke cleaningenvironmental controlco-generation process (steam, heat)ash analysisash disposal
*1.2 Automation ExamplesIndustrial Automation
Power transmission networkPower Plant Centrale,Kraftwerkswitchyard, postes HTSchaltfeldSSRegional
Control CenterRegional Control CenterPPSubstation
(Unterstation, sous-station)SSSSPPSSPPSYSYPPHuge number of "points" (power plants, transformers, breakers, substations)lying 2km to 2000km apart.All time-critical operations executed locally in the substations and power generation units.
International Control CenterNational
Control CenterSSSubstation
*1.2 Automation ExamplesIndustrial Automation
Swiss electricity interconnection network
*1.2 Automation ExamplesIndustrial Automation
Pipelinesparticularities: long-range communication system, safety, explosive environment
*1.2 Automation ExamplesIndustrial Automation
AssessmentName the applications you remember and indicate at least one task for thecontrol system
What could be the order behind the plant types that were presented ?
*1.2 Automation ExamplesIndustrial Automation
2001 US Cars: 19% is electronics