Otomasi Industri

1.1

Gambaran umum Otomasi

Definisi

Automation (otomasi):
1)

Semua tata cara yang bertujuan untuk mengganti pekerjaan manusia dengan mesin
(contoh otomasi adalah ilmu pengetahuan terapan)

2)

Teknologi yang digunakan untuk maksud ini

(contoh perusahaan ini mempunyai departemen otomasi)

Automatisation (otomatisasi)
1)

penggantian pekerjaan manusia menggunakan mesin-mesin

(contoh otomatisasi dari pabrik tekstil menuai protes dari para buruh)

2)

penggantian kegiatan yang dilakukan dengan sadar menjadi spontan

(contoh pelatihan para pelaut membuat otomatisasi dari penanganan di perkapalan)

Otomasi dan otomatisasi seringkali membingungkan, dalam bahasa inggris adalah sama
(sama seperti electricity dan electrification)
Industrial Automation
2014

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Otomasi dan makhluk hidup

Otomasi =
sistem syaraf
Society

Enterprise
Trends & History = Brain

Display and react = Cortex

Communication networks = neural, spine

controller = ganglions

Sensors & Actors = Sense cells & muscles

physical plant = skeleton

Industrial Automation
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Otomasi sebagai hirarki pelayanan

5

Planning, Statistics, Finances

administrasi

Production planning, orders, purchase

perusahaan

Workflow, order tracking, resources

Supervisory

(manufacturing) eksekusi

SCADA =
Supervisory Control
And Data Acquisition

Group control
Unit control
1
Field
Sensors
& actors
0

A V

Primary technology

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2014

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Otomasi sebagai jaringan komputer

Internet

DB, Historians,
Operator Workplaces

Optimizers, MES

Plant Network
OPC Server

OPC Server

OPC Server

Control Network
IEC 61850 station bus

Controller

Fieldbus

Hart

Protection &
Control

Profinet

HART mux

Instruments

Process
Instrumentation

Industrial Automation
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LV Electrification

Power generation

Substation
Automation

Power Management

Overview 1.1 - 5

Masalah teknis dalam otomasi

Pemrosesan dari aliran informasi

Penerapan keamanan dan ketersediaannya
Pengurangan biaya pekerja

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2014

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Expectations
Optimalisasi Proses

Energy, material and time savings

Quality improvement and stabilisation

Reduction of waste, pollution control

Compliance with regulations and laws, product tracking

Increase availability, safety

Fast response to market

Connection to management and accounting (SAP)

-> Acquisition of large number of process variables, data mining
Pengurangan biaya-piaya pegawai

Simplify interface

Assist decision

Require data processing, displays, data base, expert systems

-> Human-Machine-Interface (HMI)
Optimalisasi Asset

Otomasi dari rancang-bangun, komisioning dan perawatan

Konfigurasi perangkat lunak, back-up dan versioning

Life-cycle control

Maintenance support
-> Engineering Tools
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2014

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Kuantitas Data dalam pabrik-pabrik (Plants)

Power Plant 30 tahun yang lalu
100 measurement and action variables (called "points")
analog controllers, analog instruments
one central "process controller" for data monitoring and protocol.
Coal-fired power plant sekarang
10'000 points, comprising
8'000 binary and analog measurement points and
2'000 actuation point
1'000 micro-controllers and logic controllers
Nuclear Power Plant
three times more points than in conventional power plants
Electricity distribution network
100000 - 10000000 points
information flow to the operators: ~ 5 kbit/s.
human processing capacity: about 25 bit/s
without computers, 200 engineers (today: 3)
Pengurangan dan pemrosesan data sangat diperlukan dalam mengoperasikan pabrik

Industrial Automation
2014

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Daftar Isi

1 Pendahuluan

Industrial Automation
2014

1.1

Otomasi dan kegunaannya

1.2

Contoh dari proses otomasi

1.3

Jenis-jenis plants dan controls

1.3.1

Open loop and closed loop control

1.3.2

Continuous processes

1.3.3

Discrete processes

1.3.3

Mixed processes

1.4

Hirarki otomasi

1.5

Arsitektur sistem kendali

Overview 1.1 - 9

Otomasi Plant

Semua sistem otomasi mempunyai struktur yang sama

Yang berbeda adalah jenis dari plant yang dikontrol, kuantitas informasi, penyebaran
secara geografi

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2014

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Automation Systems - World Players

Largest Company

Based

Major mergers

ABB
Alstom-Schneider-Areva
Emerson
General Electric
Hitachi - Yokogawa
Honeywell
Rockwell Automation
Invensys
Siemens

CH-SE
FR-GB
US
US
JP
US
US
UK
DE

Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-Bailey

Alsthom, GEC, CEGELEC, Telemcanique,..
Fisher, Rosemount

Allen Bradley, Rockwell,..

Foxboro, Siebe, BTR, Triconex, Wonderware
Plessey, Landis & Gyr, Stfa Controls, Cerberus,..

80 Mia / year business

(depends on viewpoint),
growing 5 % annually
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2014

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Terms

plant:

objek dari otomasi

general contractor: organisasi pemasok berbagai komponen

turnkey factory: klien hanya menyewa konsultan untuk mengsupervisi kontraktor

mulai banyak, kontraktor umum membayar dirinya dengan mengoperasikan plant.
mulai banyak, pemasok dibayar berdasarkan hasil.

Industrial Automation
2014

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Four distinct businesses

primary technology
(mechanical, electrical)

automation equipment
(control & command)

engineering &
commissioning

maintenance
& disposal

offered by different companies

Industrial Automation
2014

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Life-phases of a Plant (Example: Rail Vehicle)

Manufacturers

Equipment Design

control

air conditioning

brakes

(dveloppement, Entwicklung)

Equipment Production
(production, Herstellung)

car body design by assembler

Assembler (ensemblier)

Engineering

Sleeping Wagon XL5000

(bureau dtude, Projektierung)

Commissioning
(mise en service, Inbetriebnahme)
Client, Service

Maintenance
(entretien, Unterhalt)

Recycling
(Recyclage, Wiederverwertung)
Industrial Automation
2014

Start on
service
brakes

replacement
brakes

Out of service

Overview 1.1 - 14

Research and Development

The components and tools are developped

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Design

From the customers requirement specs to the system design

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Programming and engineering

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2014

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Factory Acceptance Test

The client verifies that the system is ready

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Commissioning on site
hard work

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2014

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Maintenance

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Automation network view

6
Operator

23
2
4
33

horizontal

communication
Control Bus

Fieldbus

2.3

direct I/O

Fieldbus
microPLCs

4.1

Sensor-Actuator Bus

Industrial Automation
2014

4.3

controllers

2.1

Engineering

4.2 programmable

Control level

Field level

12
2

vertical Comm.

SCADA level

File
Edit

transducers / actors
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