Lecture 4: SMART Industry Flashcards
What is a Programmable Logic Controller?
- Ruggedised computer that can read sensor inputs, carry out logic operations and timing functions, and control power outputs to system components
- Can be programmed by connection to a PC
- used for both continuous control in process industries, and discrete manufacturing
What is a Supervisory Control and Data Acquisition?
- Provides higher level of visibility and control than PLC’s
- Collects data from lower level controllers and provides this to human supervisors via Human Machine Interfaces (HMIs)
- Consists of a central supervisory computer, HMIs that allow humans to intervene in automated operations, PLC’s and other controller elements, and a communication network
What is a Distributed Control System?
- Model for describing integration of enterprise software with factory automation software
- Hierarchial so each layer only talks to adjacent layer
Layer:
0) Physical elements being controlled - machines, sensors, actuators
1) Local controllers - PLC’s etc.
2) Supervisory computers and HMI’s
3) Whole site supervision eg. Manufacturing Execution Systems
4/5) Strategic and business planning software such as Enterprise Resource Planning
What are the advantages and disadvantages of a hierarchial structure in a control system?
Advantages:
- Clear what happens at each level
- Mission critical data flows can’t be interfered by non-mission critical data
- Security (levels 0 to 3 can be protected by a firewall)
Disadvantages:
- Inflexible for smart industry
- No direct access to raw data at level 0
Why is a network with direct peer to peer communication between nodes ideal for smart industry?
- Nodes are physical objects such as sensors and actuators or software services such as HMIs
- Such a network is agile and flexible rather than traditional automation architectures
- Easy to add new devices and services to system
However, data and access security can be harder to manage
What are some technologies that support smart industry?
- Sensors and actuators (capable of being addressed by network protocols and transmitting data over a network)
- Cloud computing (remote servers accessed over the internet, providing sophisticated data analysis, archiving and visibility services)
- Embedded intelligence (microprocessors integrated into machines providing local decisions to be made without reference to a central controller, and for peer to peer communication - machines talking to each other)
- Wireless connectivity (reduced the need to lay data cables for sensors and actuators, however still needs power)
- Human Machine Interfaces
What can a sensor measure?
Temp, proximity, water quality, pressure, chemical concentration, imaging, light, humidity, etc.
What are the advantages of cloud computing?
- User companies don’t need to own and maintain complex IT systems
- Services can be scaled largely
- Users can have access to the latest IT capabilities
- Services provide benefit from economies of scale through serving many clients
- Enables large amounts of data to be analysed into information (eg. Cement manufacturer analysed data to find efficiency improvements and reduced CO2 emissions by 200,000 tonnes per year)
What is embedded intelligence and what are the advantages?
- Putting intelligence (ability to recognise current state and make decisions about actions) directly into industry machines
- In some ways its the opposite of cloud computing as it is local instead of remote
Advantages:
- Fast response to changing conditions
- Immunity to network outages
- Can provide data streams to cloud services
Example: machine detecting overheating so reschedules work to avoid a shutdown
What is a Human Machine Interface?
- They show key indicators of state of process in an easy to understand form
- Operating staff use them to make minute to minute decisions on facility operation
- Management use them to make longer term, strategic decisions
Wireless networks and mobile devices make HMIs available wherever the information is needed
What is the Internet of Things?
General systems that can send and receive data over the internet eg. Smart lights, smart doorbells, surveillance cameras, smart speakers, heating controls
What is the Industrial Internet of Things?
- Industrial systems that can send and receive data over the internet
- Must be robust and secure as they are mission critical and safety critical
- Objective is to reduce human intervention so highest efficiency can be achieved
What are CyberPhysical Systems?
- Industrial systems that can operate autonomously (make decisions and changes) - not always with the Internet
- Consists of sensors and actuators which act in a self-organised and decentralised manner
- Each production element knows its own skill, capability and position
- Sensors determine current operating status and position, actuators carry out pre-planned operations or corrective actions, AI makes decisions based on local information and that shared from wider system.
What is Industry 4.0?
Overarching vision for future industry enabled by smart systems
1.0 was industrial revolution
2.0 was production lines
3.0 was computational and logic control
4.0 is intelligent, modular and flexible
What are the six core principles of Industry 4.0?
1) Interoperability - using internet to communicate between human processes and factories, uses IoT and IoS (cloud computing), everything has some level of control over everything else
2) Virtualisation - simulation of real scenarios to aid decision making, parameters can be tested before implementation
3) Decentralised decision making - CPS are empowered to make decisions of their own based on supplied info.
4) Real-Time Capability - data collected and analysed in real time, so status of plant is permanently tracked and issues can be addressed quickly
5) Service Orientation - factories can provide services both internally and externally to multiple companies
6) Modularity - modular manufacturing systems are easy to upgrade or replace with little interruption to production so its more flexible
