Structural development of automation systems

The automation industry has been developing for many years, focusing on a five-tiered hierarchical structure. But new technology simplifies this model, eliminates tiers, improves performance, and reduces software maintenance costs. A commonly used architectural model to define manufacturing operations management is the five Purdue Reference Model (PRM), which later formed the basis of the ISA-95 standard. This model is usually expressed as:

Level 5 - Business System

Level 4 - Enterprise Resource Planning at Plant Level (ERP, MRP, MES)

Level 3 - Level of Business Unit

Level 2 - Machine/Process Automation Level

Level 1 - Controller Level

Level 0 - Sensor / Actuator

Existing automation systems generally reflect this architecture, with software running on general-purpose computers at levels 2, 3, 4, and 5.2, level 3 and level 4 databases and communication interfaces, buffers, and between each level Information is synchronized to the relevant human-machine interface and user interface. The limitations of computing costs and network bandwidth determine that this configuration is based on past technologies. However, the multi-level calculation model is complex and creates a large amount of costs, continuous configuration of control and life cycle investment. Fortunately, this model is changing to make a more efficient and smooth automated system architecture. In the new model, the controller can communicate information and appropriate methods and protocols can be used directly at all levels.

Ethernet communication has become a high-speed and commonly used technology for industrial automation protocols and business systems. More controllers support multiple Ethernet ports directly with industrial and commercial networks that exist throughout the industrial plant. Historians, analytics, real-time maintenance and monitoring are now included in the controller. This simplifies the application of these features and eliminates the cost, complexity, performance drag, and ongoing software maintenance of Level 2 and 3 software. More powerful controllers and communications enable coordination between controllers without the need for a separate computer as well as coordinating theirs. A good example is the controller, which contains the full ISA88 batch function, which only accepts bulk orders and executes them, thereby increasing production throughput and response.

Internet of Things

The "Internet of Things" becomes a reality where sensors and actuators are embedded in physical objects - from highways to heart pacemakers - and connected through wired and wireless networks that utilize Internet Protocol (IP). Industrial controllers have also begun to adapt to this trend by providing data refinement, local historians, analysis, and advanced control at source devices. Modern systems for communicating with controllers using "IP pipes" are very common manufacturing plants that include the ability to send e-mails, FTP files, all levels, and provide WEB pages. Open communication supports the use of XML, SOAP, SNMP, and OPC UA.

New varieties

Significant technological innovations and improvements have taken place in the past decade and will begin to be deployed at Level 0 and Level 1 devices. These devices integrate a powerful new CPU chip to simplify the automation architecture. The mass production of smartphones and tablets is rapidly increasing, and power, memory and communications are integrated in the CPU chip to reduce costs. In 2008 more than one billion US dollars, of which about 98% of CPUs were built in embedded devices. In 2010 took over 139 million mobile phone shipments. The mobile phone reflected this change began in 1983, the first handheld cell phone. The Motorola DynaTAC8000X is 13 x 1.75 x 3.5 inches in size and weighs 13⁄4 pounds, offers 30 minutes of talk time and 8 hours of standby power, and is sold at a retail price of $3,995 at $2012 ($9,281.84). Now a fraction of the cost of smart phones and provide significantly more power. Industrial controllers and new varieties of embedded industrial terminal equipment put this power and added new features including embedded Web servers, email clients and Web services. These functions allow these Level 0 and Level 4 and 5 system devices to communicate directly. This is common and now sees dual-core CPU controllers and some companies have announced quad-core controllers. For example, the new Intel multi-core Atom processor has begun to be incorporated into industrial controllers. These more powerful industrial controllers become automated computing engines and also begin to crash. The typical 5-level model and automation systems are more flexible and responsive.

Automation software

The establishment of a higher-level, powerful industrial controller directly into the beginning of these new varieties, without the need for intermediate-level software. Intermediate-level software and computers have achieved their purpose of buffering, synchronizing, translating, and improving sensor and controller information. However, they also created a large number of medium-level computers, databases, and software that are expensive and difficult to maintain. The temporary solution is to migrate to more powerful computers and existing mid-level virtualization software. This migration and virtualization improves performance and centralized software maintenance and configuration control. Over time, this middle-tier software function is adopting new and more powerful controllers.

Overall and adaptive

The possibility of new highly open communication in the terminal equipment and computing, for comprehensive and adaptive automation, in order to increase efficiency. In the step of the "Internet of Things" trend, this is a logical evolution and will lead to more responsive and efficient production.