The evolution of control architectures

© 2004, HOÀNG MINH SƠN Chương 1 The Evolution of Control Architectures Hoang Minh Son Dr Ing. December 24, 2004 2 © 2004, HOÀNG MINH SƠN Contents  Review of industrial control systems  Evolution of control system architectures  Advantages of true distributed control  Challenges and research topics  Summary and conclusion 3 © 2004, HOÀNG MINH SƠN PROCESS AUTOMATION Mechanical Devices (James Watt’s Flying-Ball Governer, 1870) Direct Digital Control (1965-1975) Programmable Logic Controllers (Bedford, Allen-Bradley, 1969) Electronic PIDs (1940-1950) Compact Digital Controllers (80s) Mechanical Devices Electromagnetical Relays (1920) Distributed Control Systems (TDC2000, Honeywell, 1975) Pneumatic PIDs (1920-1930) Hybrid Control System (90s) Fieldbus Control Systems - Networked Control Systems FACTORY AUTOMATION A brief history of industrial control systems 4 © 2004, HOÀNG MINH SƠN Levels of distribution Centralized Control Distributed I/O Distributed Control Distributed Intelligence Higher performance Increased reliability DDC PLC, DCS PLC, DCS NCS, FCS 5 © 2004, HOÀNG MINH SƠN NCS/FCS Architecture True distributed control using fieldbus technology Direct communication between field devices Integrated Control and Fieldbus Engineering Coordinating Controller High-level Controller Most of basic control functions implemented in field devices 6 © 2004, HOÀNG MINH SƠN Wiring and installation Traditional PLC/DCS architecture NCS/FCS architecture 7 © 2004, HOÀNG MINH SƠN Distribution of control function AO AO AI AI PID PID AI AI PID PID AO AO PID PID AO AO AI AI AI AI AI AI AI AI PID PID AO AO Traditional PLC/DCS architecture NCS/FCS architecture 8 © 2004, HOÀNG MINH SƠN Engineering: traditional way Controller control programming field device configuring Fieldbus 9 © 2004, HOÀNG MINH SƠN Engineering: FCS/NCS Controller Fieldbus Integrated Engineering 10 © 2004, HOÀNG MINH SƠN Information integration TAG = LIC-012 VALUE = 70.34 UNIT = m 3 STATUS= GOOD ALARM = Y/N NCS/FCS TRANSMITTER 15.3 mA DCS/PLC TRANSMITTER [...]... Interdisciplinary research Real-time systems Control © 2004, HOÀNG MINH SƠN Engineering Computer Science Distributed control Networked control Communication Technology Industrial communication Distributed computing 17 © 2004, HOÀNG MINH SƠN Summary and conclusion The evolution of control architecture is very similar to the history of human society forms The trend of industrial control system is toward distributed... Existing Digital Control Theory based on: – Centralized architecture, centralized (multivariable) controllers – Synchronized I/Os – In general: monorate sampling, deterministic delays © 2004, HOÀNG MINH SƠN Clock D/A Process A/D Digital Controller 12 Research topic: Control structure design © 2004, HOÀNG MINH SƠN Also known as “Plant-wide control , one of the the most actual topics in process control Problem:... how to: – Select appropriate input and output variables for control purpose – Automatic pairing of manipulated input to controlled output for single-loop, decentralized control design – Design appropriate control strategy – Assign single-loop control algorithms to specific field devices and controllers 13 Research topic: Real-time issues in NCS Controller Tc1 © 2004, HOÀNG MINH SƠN Tbus Tio Tin I/O Sensor... advantages of distribution Reduced material and installation cost (cables, I/O modules, I/O terminations, transmitters, control box, ) Higher performance and increased reliability Integrated engineering, simplified configuration and parameterization of field devices Control configuring instead of programming Powerfull diagnosis and maintenance ability 11 Challenges: Distributed control theory Existing... history of human society forms The trend of industrial control system is toward distributed intelligence (true distributed control) Advatages of distributed control: cost savings, more functionality, higher performance and increased reliability Research topics needed: distributed control structure design, real-time issues, hybrid systems Future direction: 3C interdisciplinary research 18 © 2004, HOÀNG... Tin I/O Sensor Tout Bus trường Sensor Tsd Tc2 Ts Ta Actuator I/O Tio Tad Actuator 14 Research topic: Real-time issues in NCS © 2004, HOÀNG MINH SƠN Time periods (sampling time, scan time, bus cycles, control cycles) not synchronized between interconnected devices Different characteristics among bus systems Uncertain time delays Event-based sampling, multi-rate sampling 15 Research topic: Hybrid Systems . SƠN Chương 1 The Evolution of Control Architectures Hoang Minh Son Dr Ing. December 24, 2004 2 © 2004, HOÀNG MINH SƠN Contents  Review of industrial control systems  Evolution of control system architectures . conclusion  The evolution of control architecture is very similar to the history of human society forms  The trend of industrial control system is toward distributed intelligence (true distributed control) . delays 13 © 2004, HOÀNG MINH SƠN Research topic: Control structure design  Also known as “Plant-wide control , one of the the most actual topics in process control  Problem: Given an interconnected,