This document provides an overview of industrial automation and process control systems, including basic control concepts, advanced control systems, and the objectives of automation. It describes common automation system types like PLCs, DCSs, and PC-based control systems. It also outlines the architectures of traditional PLCs, DCSs, and industrial PC-based control systems. Finally, it discusses Teclever's PC-based control system offerings, including features like a real-time Linux environment, standard driver support, and SCADA integration. It provides an example case study of a test facility control system project.

1. Overview
Industrial Automation
rtPAC Systems

2. Process Control
 Basic Process Control Concept
 A measurement of the state or condition of a process
 A controller calculating an action based on this measured value against
a pre-set value [set point]
 An output signal resulting from the controller calculation which is used
to manipulate the process action through some form of actuators.
 The process itself reacting to this signal, and changing its state or
condition.

3. Advanced Control Systems
 Objective: Process control
information system Automating
the Plant Operations
 In producing the required output
of the product with minimal
quality variation
 Optimal consumption of raw
material and energy
 Maximum efficiency
 Improved Productivity
 Efficient Monitoring and Control
 Scalable and Robust
 Types of Automation Systems
 Programmable Logic
Controller [PLC],
 Distributed Control System
[DCS] and
 PC Based Control System
Sensors &
SCU
Control
Valve
Control
Station
PLC [or]
DCS [or]
PC Based
ADC
DAC
AA
Process
Controlled VariableMeasured Variable

4. Architecture of Traditional PLC
 PLCs were designed to eliminate the
electro mechanical relays.
 Advantages
 Programming language is based on
relay wiring symbols familiar to most
plant electrical engineers.
 High reliability and minimal
maintenance
 Small physical size
 Ability to connect to the computer
systems in the plant.
 Moderate to low initial investment.
Input
Module
Output
Module
Man
Machine
Interface
Control
Station
Load
Devices
PLC
Input Sensing
Devices

5. Architecture of DCS
 DCS is a derived version of
multitasking and multi loop controller
used for process control.
 Advantages
 Compact to contain ON/OFF
controllers
 Control algorithm changes do not call
for hardware changes
 Reduced complexity and easy
expandability
 High speed of the control processing
 Continuous trend data available
 Sequential, batch and feed back
control are possible
Field
Transmitter
Analog
Devices
P
S
PCServers with
Propitiatory Software
Control
Valves
Isolators
Input Sensing
Devices
Link
Mod
C
P
u
A
I
A
O
D
I
D
O
Digital
Devices
Motor
LEDs

6. Architecture of IndustrialEmbedded PACs
Plug In
Cards
PAC
E/
A
E/
A
Ethernet to other PC’s
Profibus, Interbus etc
 PC Based Control System provides
homogeneous environment
 Advantages
 Software oriented environment
 Standard development tools based
control software and application
software
 Not device specific, so no issues in
handling the devices from different
vendors
 More reusability since software based
 Simulation environment for cross
checking
 Reduced Hardware cost
 Provide a Open Control System
 Options with Fieldbus
 CANopen. Modbus, PROFIBUS,
PROFINET, Interbus, Ethernet
Powerlink, EtherCAT, EthernetIP,
DeviceNet, ControlNet, Foundation
Fieldbu

7. TECLEVER’s offerings
 PC Based Control System Framework
 Features
 X86 Based system with Medium to High processing power based on
requirement
 Real time Linux based environment for Hard Real time application
 Developed mostly with FOSS components
 Easy integration with any OPC based SCADA packages
 Custom Web based control for non critical process monitoring
 Standardized driver modules for various Data acquisition cards. [Possible
to have different vendor cPCI/PXI cards]
 Possible to have both Data acquisition and control in a single controller.
 Possible to configure a High reliable redundant system
 Standard Software oriented environment for SCADA and User control
program
 Developed a User Control program framework where support for traditional
Ladder or FBD based development is enabled

8. User Control Program
 Development environment is based on Open Source Framework for
writing control program
 Compliance to IEC 61131, PLCOpen and CanOpen standards
 Any existing application compliance to this can be easily ported to our
development environment.
 Supports programming in LD/FBD/ST/IL/SFC
 Compiles ST/IL/SFC code into ANSI-C code.
 All POU parameters and variables are accessible through nested C structs
 Able to generate application code for different RTOS/Linux environments
 Enabled to work on a single Configuration file across controller/ Monitoring
software and Use Control program development. So seamless integration
of User control program into system control application

9. Controller/Data Acquisition Module Standard driver support for DAQ cards in Hard Real Time OS
 Any cPCI or PXI based card will be supported for the control
requirement
 So no vender specific looking is required
 Control System configuration thru configuration file, enables to use the
same application across different control requirement
 Diagnostic information for monitoring purpose
 Failure handling for any application problem thru a text based script
 Distributed engineering unit conversion to avoid load at monitoring
server
 Configurable mode to send RAW value to monitoring station for
calibration

10. Controller/Data Acquisition Module
 Optional redundancy management for any single point of failure
 Possible to have multiple thread User control program
 Standard ethernet based communication to and from DAQ system and
server.
 High speed operational cycle [Possible to have as small as 10msec]
 Able to handle very large number of channel systems

11. SCADA Server/ Operator Station
 Supports any standard OPC communication supported SCADA
packages
 Optional Web Based Monitoring system for monitoring
 SCADA System configuration thru configuration file
 SNMP based Network Diagnostic information for monitoring purpose
 Offline GUI for any specific reporting requirements
 Support for 10msec data logging
 Redundancy management at OPC communication and Application
server levels

12. Case Study

13. Test Facility Control System

14. Project Description
 The objective of this project is to design, develop and install a PC based
control system.
 A PXI/cPCI based control system with SCADA running in PC and Server in
distributed configuration is proposed for designing the control system.
 The control system acquires the data from field control elements then
processes the data in real time and generates output. The normal cycle
time of the system is 10msec.
 The acquired data and generated output are used for online monitoring
and controlling the test system. The data is logged at both the server and
controller for offline analysis.
 Data exchange between all the subsystems is through Dual redundant
Ethernet.
 Redundancy management at controller, server for fail-safe mode of
operation