The efficiency of modern production facilities to a large extent depends on the quality of organization of automated systems. It is not only a matter of minimizing the labor of workers, but also of optimizing logistical functional processes. A well-coordinated and correct setting of automation allows you to spend less resources, maintaining the optimal pace of production and the proper level of product quality. You can count on such an effect only if properly selected industrial controllers for automatic systems participate in the management of the work. This is an obligatory component in any programmable complex through which the interaction of individual elements of production takes place.
Controller overview
In the industry, controllers are devices that act as a command center in relation to the equipment being serviced with an automatic control principle. The function of such devices is not complete without means of feedback, which is based on sensors that collect this or that information about the work process. Based on the information received, industrial controllers develop reverse commands,managing, thus, the entrusted systems. The coverage of one processor can be different. As a rule, modern models allow simultaneously processing signals from 200-250 pieces of equipment, also sending them signals with operating parameters settings. An important difference in the current understanding of the controller is the ability to function with data processing in program mode, that is, it provides for a serious departure from the principles of one-step rigid logic, on which automated production lines of previous generations worked.
Device
The basis is formed by a modular programmable type processor, which is complemented by a huge list of auxiliary systems and components. The basic elements of the main subsystem include input / output modules, communication tools, sensor sets, data storage devices, and operator control panels. The secondary modules, which, however, are rarely inferior in importance to the above-mentioned components, include protection systems, thermostats, displays and keyboards, as well as the latest complexes for organizing network data transmission. At the same time, the device of an industrial controller is not complete without the inclusion of engineering systems that can provide cooling of the equipment and, if necessary, its heating. As for the sets of sensors, their composition depends entirely on the facility on which the system is operated. These can be water or gas flow detectors, energy consumption meters and even motion sensors.
Working principle
When the modular structure is established and the production process is started, the recording of operational parameters begins. As already noted, the system can take into account hundreds of indicators, comparing them with the values of the program laid down by the user. Based on the results of this mapping, the controller makes a decision for the team. For example, if according to the technology a waterjet cutter can operate at a temperature not lower than 0 degrees, then the equipment will give a command to stop the process if the thermometer shows a value below the permissible value. Other industrial controllers work on the same system. The principle of operation also involves more complex decision-making algorithms. For example, dozens of indicators that affect the operation of one site or a specific piece of equipment can be taken into account. Also, during operation, the system monitors its own performance indicators, including power supply parameters.
Industrial controller applications
Such equipment is used in various fields, and not only in production. But the main areas are still metallurgy, the chemical industry, oil production, manufacturing industries, etc. For example, metallurgical plants, with the help of automation, control presses, lathes, the same cutters and grinding machines, which are subject to high demands in terms of accuracy of the result. In the chemical industry, industrial controllers control the technological processes of mixing substances, dosing and cleaning. In addition, logic programming tools effectively show themselves as part of security systems. In particular, the controllers control the functions of alarms, security posts, protective partitions and gates with an automated drive. Now it's worth taking a closer look at the manufacturers of modern controllers and the features they offer.
Controllers "ARIES"
Since 2005, OWEN has been developing automatic controls for the industrial segment, adhering to the principles of functionality, ergonomics and reliability. An important characteristic of these devices is the initial basing on a powerful hardware resource, which is complemented by wide software capabilities. As for the second aspect, Russian-made OWEN industrial controllers work in the CoDeSys software environment from German developers. From the point of view of operation, this equipment is advantageous for the possibility of component expansion, which makes it universal, as well as the inclusion of the latest means of communication interaction.
Segnetics controllers
Another domestic company engaged in the development of the industrial controller segment. At the moment, Segnetics specialists offer several solutions for different categories of users. The SMH2010 base series includes panel-mounted universal automation controls,which are optimally suited for use in the housing and communal sector. On the other hand, the production of industrial controllers at the facilities of this company is also focused on highly specialized tasks. For example, Pixel devices are specifically designed to control the ventilation system. There are also more complex models of controllers in the family, which can be successfully used in the areas of automation of technological processes on large production lines.
Advantech controllers
A promising manufacturer that focuses on the development of internal logical processes between controller components. At the moment, the company's lineup offers two complexes - APAX and ADAM. The first uses an open architecture, on the platform of which the functions of processing and managing information are combined. Communication tools involve building up components, which makes the system flexible in use. The ADAM family also offers industrial controllers with a developed filling for the control function and some additions. In particular, the system is provided with deterministic I/O, redundant power supplies and optimized memory.
Conclusion
The simplest automated production support systems gradually developed into complex multifunctional devices. Today, manufacturers of industrial controllers are setting themselves new order challenges that will have toimprove the efficiency of process management in different areas. Among the most important areas are the improvement of communication links, the optimization of power supply and the transition to more reliable element platforms. At the same time, domestic developers practically do not lag behind foreign specialists, offering quite competitive state-of-the-art solutions.
