Examples

Industrial Automation
Automation Examples
Examples of Automated Plants

1 Introduction 1.1 Automation and its importance
1.2
1.3
Applications of automation
Types of Plants and Control 1.3.1 1.3.2 1.3.2 1.3.3 Open Loop and Closed Loop Control Continuous processes Discrete processes Mixed processes
1.4
Automation hierarchy
1.5
Control System Architecture
Cars
today: 50..100 ECU (electronic control units)
critical new applications: brake-by-wire, steer-by-wire (X-by-wire) increased safety ? extreme price squeezing of the cost is electronics, tendency increasing http://spectrum.ieee.org/green-tech/advanced-cars/this-car-runs-on-code
Mercedes CL 600 drive-by-wire
there are more than 20 interconnected computers on a locomotive radio link vehicle control unit display unit
Rail vehicles
VCU DU TCU TCU
VCU DU
SBB 460 brakes Benefits: diagnostics traction control unit energy signaling
reduce operation costs, faster diagnostics, better energy management, automatic train control.
Airplanes
avionics: flight control (safe flight envelope, autopilot, engineer) flight management flight recording (black boxes, turbine supervision) diagnostics fly-by-wire
high reliability
Launch vehicles
GPC 1 CPU 1 IOP 1
GPC 2 CPU 2 IOP 2

Intercomputer (5) Mass memory (2) Display system (4)
GPC 3 CPU 3 IOP 3
GPC 4 CPU 4 IOP 4
GPC 5 CPU 5 IOP 5
Control Panels
Payload operation (2) Launch function (2) Flight instrument (5;1 dedicated per GPC) Flight - critical sensor and control (8)
serial data buses ( 23 shared, 5 dedicated )
Robots
extension limited to 2-3 m (portal robots 10-20m) frequent reprogramming for new tasks, tooling simple embedded computer, hierarchical control
Substations
protection (Lines, transformers, generators) very high speed response control (remote or local) to guarantee power flow, safe operation (interlocking) measurement (local and remote), electricity bill, power flow in grid
Pharmaceutical Industry
Inventory Recipe management Packaging Sampling Tracking & tracing Comply with government rules:
Typical of batch processes.
Manufacturing
Flexible Automation
numerous conveyors, robots, Download from production management,

CNC machines, paint shops, logistics. connection to administration
Warehouses dependency on the extreme

availability of the control system Connection to * supply chain management, * order fulfilment * customer relationship and * commercial accounting (SAP)
Printing machines
tasks of control system:

motor control (synchronisation of the printing cylinders) ink and water control paper web control (reelstands (Rollenwechsler, bobines), web tension, emergency knife) interface to operator (commands, alarms) production preparation and statistics - up to the press room
very high requirements on availability: two hours delay and the production is lost.
Oil & Gas, petrochemicals

"upstream": from the earth to the refinery down-sea control
special requirement: high pressure, saltwater, inaccessibility explosive environment with gas.
distribution
special requirement: environmental protection
"downstream": from the oil to derived products

special requirement: extreme explosive environment Switzerland: Colombey, Cressier Industrial Automation
Chemical industry
logistics, local control of reactors
e.g. LONZA
Characterized by batches of products, reuse of production reactors for different product types (after cleaning).
Process Industry
Process Industry = industries de transformation, Verfahrenstechnik (one of the many meanings of process)
Cement
Pulp & Paper

Metals and Minerals Glass production Chemical .
Continuous flow of materials, often 24 hours a day

Steel mills
particularity: synchronization of the motors in the rolling mill
Cement Works
The rotating oven is the heart of the cement process: the grinded kiln is burnt and comes out as chunks later reduced to powder. Control tasks: Oven rotation and temperature control fuel supply, silos, transport belts, grinding mills, pollution monitoring, quality supervision, filler stations,... Switzerland is leading nation in Europe (Holcim, Jura, )
Mining
Building Automation
basics: fire, intrusion, climate, energy management HVAC = Heat, Ventilation and Cooling = air conditioning
visitors, meeting rooms, catering,. low price tag

Automation of Building Groups
EPFL
Airports
large building automation system: fire, security access, energy, lighting, air conditioning, communications, traffic control
movie
luggage control in Zurich-Airport Industrial Automation
Traffic control
fire intrusion energy water ventilation pollution monitoring cameras light control traffic jams prevention,....
(Tunnel Letten near Zurich)
Harbours
from ship planning to crane manipulation and stock control
Water treatment
(fresh and waste water) manage pumps, tanks, chemical composition, filters, movers, quality... auxiliaries: methane electricity generation
Desalination plants
Power plants
Hydro - river - dams - storage dams Thermo - coal - gas - atom - solar - waste Alternative - wind - photo-voltaic
tasks: fuel supply primary process control (steam, wind) personal, plant and neighbourhood safety monitoring environmental impact electricity generation (voltage/frequency) energy distribution (substation) 24 / 365 availability
Waste treatment, incinerators (waste-to-energy)
raw material supply burning process smoke cleaning environmental control co-generation process (steam, heat) ash analysis ash disposal
Power transmission network

International Control Center
SS
Substation (Unterstation , sous-station)
National Control Center
SS
Regional Control Center
Regional Control Center
SS
switchyard, postes HT Schaltfeld
PP PP SS
Substation
SS
PP
SY
PP
Power Plant Centrale, Kraftwerk
SY
Huge number of "points" (power plants, transformers, breakers, substations) lying 2km to 2000 km apart. All time-critical operations executed locally in the substations and power generation units.
Swiss electricity interconnection network
Railways electricity network
Pipelines
particularities: long-range communication system, safety, explosive environment

Assessment
Name the applications you remember and indicate at least one task for the control system What could be the order behind the plant types that were presented ?

Examples

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Examples

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Industrial Automation

Examples of Automated Plants

Control System Architecture

today: 50..100 ECU (electronic control units)

Mercedes CL 600 drive-by-wire

VCU DU TCU TCU

GPC 1 CPU 1 IOP 1

GPC 2 CPU 2 IOP 2

GPC 3 CPU 3 IOP 3

GPC 4 CPU 4 IOP 4

GPC 5 CPU 5 IOP 5

serial data buses ( 23 shared, 5 dedicated )

Typical of batch processes.

numerous conveyors, robots, Download from production management,

CNC machines, paint shops, logistics. connection to administration

Warehouses dependency on the extreme

tasks of control system:

Oil & Gas, petrochemicals

"downstream": from the oil to derived products

Pulp & Paper

Continuous flow of materials, often 24 hours a day

particularity: synchronization of the motors in the rolling mill

visitors, meeting rooms, catering,. low price tag

Automation of Building Groups

(Tunnel Letten near Zurich)

Waste treatment, incinerators (waste-to-energy)

Power transmission network

Substation (Unterstation , sous-station)

National Control Center

Regional Control Center

Power Plant Centrale, Kraftwerk

Swiss electricity interconnection network

Railways electricity network

particularities: long-range communication system, safety, explosive environment

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