The document describes a PC-based industrial automation control system for a test facility. It discusses the objectives of automating plant operations for optimal production efficiency. It then provides an overview of different automation system types including PLC, DCS, and PC-based systems. The document outlines the architecture and advantages of traditional PLC, DCS, and industrial PC-based control systems. It also describes Teclever's PC-based control system framework and its features.

1. Industrial Automation
PC Based Control System
Overview

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

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

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

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

6. 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

7. 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

8. 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

9. 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

10. 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

11. Case Study

12. Test Facility Control System

13. 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