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Later on, business is good and we decide that our factory could use two additional ovens. So we get the
mechanical parts built - and now we need to decide how we're going to control these new ovens. Now the
original PLC that we used for oven number one is quite capable of controlling the two additional ovens.
We just might need to add a few additional I/O modules to the chassis - and we'll certainly need to run
some more wires - but basically the same old PLC "brain" has plenty of extra horsepower to handle the
new ovens. But - here's an idea: Suppose that we buy two new PLC's - one for each new oven. Now that's
certainly going to cost us more money, but at least this way each oven could operate - or be shut down completely separately from the other two systems. That's going to make scheduling maintenance a lot
simpler - and generally give us a lot more flexibility in all of our operations. Plus - by having three
controllers - we're not putting "all of our eggs in one basket" as the old saying goes.
We talk the boss into it - and we buy the new PLC's and install them - and download copies of the
original program into them - and we're just about ready to go. But how about that operator control piece
of the puzzle? Since we're already using an HMI for our operator's control panel, all we have to do is
make two copies of the screens from our original oven - and set these new copies up on the operator's
HMI computer. Finally, we extend the communication cable from the HMI station over to the two new
PLC's - and now we're up and running.
Next the boss hires a bean-counter - someone whose job involves maximizing our factory's profits. Now
this person requires data - he needs to know how much it costs to operate the ovens - and how much
product we run through them - and how much of that product is "off-spec" and wasted. The best way to
get all of this production data is to ask the PLC's - after all, they're the "brains" that are controlling the
system. So let's upgrade the old HMI that the operator has been using - to something with more features.
This will be called a SCADA system - for "Supervisory Control And Data Acquisition". It will still have
control screens with all of the virtual buttons and meters and other whatnots that the operator needs to
control the ovens - but it will also have some additional features beyond the HMI - features which will
allow the SCADA system to suck the production data right out of the PLC's - and to store that data in
some type of computer database. Later, the bean-counter can retrieve that production data and analyze it
to his little heart's content. All is well.
Quick review so far: The machinery in our factory is being controlled by PLC's. For a little while we used
an HMI (Human/Machine Interface) software package - so that the Human operator could Interface (that
is, monitor and operate) the Machine. Later we moved from the HMI up to a more powerful software
package - a SCADA (Supervisory Control And Data Acquisition) system. This new software still allowed
our human operator to Supervise and Control the system - and it also added some features for Data
Acquisition for the bean-counter's benefit.
Now let's start over with a new factory - and this time we'll use a DCS (Distributed Control System).
Suppose that this time we know in advance that the factory we're about to build is going to involve a
rather sophisticated process - one which is going to require many interrelated steps - all of which must be
carefully coordinated in order to produce a sellable final product. We're talking about chemicals - or
pharmaceuticals - or something along those lines. (The term "continuous process" is a familiar buzzword