subject: Next Generation of Industrial Automation [print this page] Next Generation of Industrial Automation Next Generation of Industrial Automation
Introduction
Recent trends in automation are characterized by geographical distribution and functional integration. On the technical level, the goal is to easily connect devices and software components from different vendors. Functionally, there is a need for interoperability of control functions on different hierarchical levels ranging from field equipment to process control, operations management and various Internet-based service applications. This article discusses current technological trends and outlines a new, component-based control system platform that supports the reuse of both system and application software. Description
In the current highly competitive business environment, the industry is challenged by the demand for productivity, quality, safety and environmental protection. Tight profit margins and networked manufacturing emphasizes the need for integration and global optimization of production facilities. The role of information technology in achieving these goals has become critical. Large and complex production systems cannot be efficiently and safely managed without advanced information management and process control. End users expect to get improved functionality at reasonable cost. Management of knowledge and real-time information, integration with condition monitoring and plant maintenance, high availability, flexible upgrades and life-cycle support are examples of key requirements. System integrators need efficient tools for building applications. Manufacturers face the challenge of satisfying customers needs while still maintaining a sound and profitable product structure in a rapidly changing technical and business environment.
For many years, integrated, intelligent and dependable control systems have been the focus of standardization organizations, industrial consortia and research groups. The solutions have, however, been hard to reach, partly due to the complexity of the issue and partly because of conflicting commercial interests. Only few efforts have provided practical results about common architectures and application objects that could make systems really understand each other. Technically, open control systems still focus on ways of making bits and bytes flow between devices from different vendors. There is also a gap between research results and real-life applications. Instead of elegant control theories, practical automation projects often struggle with low-level technical problems. Important issues are, for instance, how to find out user requirements, how to interface different products, and how to reuse existing application software.
Earlier generations of digital control systems have been combinations of existing automation practices and advances in electronics and information technology. With the emergence of microprocessors in late 70s, faceplates of pneumatic controllers were transferred to computer screens of Distributed Control Systems (DCS). Since then, PC technology has, after a long debate, found its way to industrial applications. Current control systems are typically a mixture of many techniques.
We can expect that a similar situation will exist in the future also. Increasing processor power, consumer electronics, mobile communication networks and programming languages provide the tools to implement smart functions that have been unrealistic before. Meanwhile, recent advances in the control domain have grown upwards from low-level programming languages and communication standards in the direction of more comprehensive data models and reference architectures. The increasing degree of horizontal and vertical integration leads to complex applications, which, in turn, calls for more powerful communication and computation models in control systems.
Conclusion
The goal of this article was to outline the concepts and architecture of a new platform for various types of applications, e.g. in industrial automation, environmental monitoring and energy distribution. These systems are today characterized by the distribution of intelligence to devices close to the processes and equipment under control. At the same time, there is a strong tendency towards vertical and horizontal integration of all functions within a plant, an enterprise or a manufacturing network.
These trends have their implications also to automation business. Instead of building familiar DCS and PLC applications, the suppliers of manufacturing equipment and control systems must be able to provide more comprehensive solutions including, for example, information management, optimization, remote diagnostics, maintenance and continuous process improvement. In addition to a physical control system, the customer expects to get long-term services that have a clear added value to the business. Rapidly changing technologies and standards, and the requirements for low cost, short delivery times, safety and overall quality make the design, implementation and maintenance of control systems a demanding task.
