Impact on Industrial Automation with the advent of IoT

Connected Industrial Devices are known as IoT which means it is about a lot of industrial devices networked together. This technology enables us to manage everything from anywhere, reducing complexity and hardware cost, flexibility and easy expansion. More wireless modules will be added. In other words, IoT is the network of physical objects or things embedded with hardware of electronics, softwares which are connected in network either in wired or wireless mode to collect and exchange data.

The devices used in industrial automation which includes PLC, SCADA, HMI, DCS, Industrial networking, AutoCAD, Panel Design, Motors and Drives will be networked together in a better way with high levels of security and reliability.

The first impact of IoT technology is in the automation industry as they have no option left but to use the latest features and technology available in the market which increase the operational efficiency manifolds in today’s scenario. 

 

 

Relevance of Profibus Communication for Industrial Automation Engineers

Every automation engineer whether from the background of electrical or electronics or instrumentation and control knows the importance of Profibus Communication. This technical note is primarily for freshers in the field of automation covering the whole spectrum of PLC, SCADA, HMI, DCS, Industrial networking, AutoCAD, Panel Design, Motors and Drives etc.

Profibus DP stands for “Process Field Bus Distributed Peripherals”. The main advantage of profibusdp connection is that we can connect master with slaves. Here master is our main controller and slave is our field device. This comes under the study of industrial networking.

In s7-300 (Rack type controller), one rack equal to 11 slots and at a time maximum of 4 slots are controlled by one controller. s7-200 and s7-300 works on half duplex protocols. Protocol is nothing but a set of rules for sending and receiving the data. Similarly, HMI also works on half duplex protocol which supports 32 nodes ( or devices). Maximum distance between master and slave can be 32 kms. The transmission rate of profibus connection is 9.6 KBps to 12 Mbps. Repeaters are used to boost the signal. We prefer serial transmission instead of parallel transmission in long distance connection because of lesser transmission loss and reduced cost. 

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SCADA Software and its Utilities in Plants

SCADA system is a centralized system which monitor and controls entire sites of a plant spread out over large areas. SCADA Supervisory Control and Data Acquisition system is basically software which is used to centrally monitor and control the process parameters of various sections of a plant in real time. The software contains a library, SCADA developer develops virtual image of various field devices, motors, hopers, solenoid valves, control valves, alarms, MEP section and attaches these graphics to the real world devices. Any changes in process parameters, position of devices is available to the operator on real time basis. Thus it’s a simulation through which all activities of the plant can be monitored and controlled. SCADA system is generally complex in configure but it is at the same time very easy to operate. Most controls are automatically performed either by Remote Terminal Units ("RTUs") or by PLC (Programmable Logic Controllers). For performing control action SCADA System needs PLC System, thus PLC SCADA systems are typically used together.

SCADA software is installed in a PC and is connected to various PLCs and other peripheral field devices. It generates applications for the demanding requirements of plant engineers, operators, supervisors and managers. These requirements are customized as per the needs of each plant. SCADA continuously received data from the plant in real-time, stores and processes it in the database, evaluates and generates displays parameters in digital or graphical form, generates alarms and events. It can also issue instructions to PLCs and generate reports from this data for use of plant operators, engineers, managers. 

SCADA system and its Sub-systems

• A Human-Machine Interface or HMI is the device which is used with standalone machines
• Remote Terminal Units (RTUs) which connect various sensors to the process system, condition the signal generated from sensors to usable signal and send this date to SCADA System.
• Programmable Logic Controller (PLCs) are the devices which actually control the process system.
• Industrial networks connecting SCADA the Remote Terminal Units.

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SCADA and its uses in a plant

·      Production department gets real time production parameter, manufacturing status is updated in real time basis and communicated to operator and control device

·      Production schedules can be viewed and updated automatically

·      Production specific information is managed and distributed when it matters the most

·      Data integrity and quality control is improved by using a common interface

·      Great platform for quality and statistical analysis

·      SCADA System helps in consolidation of manufacturing & lab data

·      SCADA software helps in troubleshooting and troubleshooting. SCADA system is directly connected to wide variety of field devices, so the defect rectification time is greatly reduced.

·      SCADA Systems facilitates plants to be viewed /monitored remotely. Alarms/Notifications can be automatically generated and e-mailed, messaged to the concerned.

·      Reduced downtime. Co-ordination among various departments is greatly enhanced.

·      SCADA Software with its real time functionality makes process operations easier.

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Industrial automation HMI/PLC SCADA software and Pharmaceutical companies

There has always been serious emphasis in reliable data in pharmaceutical manufacturing. In simple terms, pharmaceutical manufacturers should follow instructions and document actions correctly, so that if any deviation occurs in the product, the company can investigate it and put measures in place so that the same error does not happen again. This guarantees the repeatability and safety of the product being manufactured and protects the brand.

Data integrity refers to the completeness, consistency and accuracy of data, which needs to be attributable and legible. More importantly, drugs approved on basis of inaccurate data could pose a threat to patients’ lives. For all these reasons data integrity is at the heart of the pharmaceutical ecosystem.

Use of reliable HMI/PLC SCADA software

The pharmaceutical industry has been slowly transitioning from manual paper records to industrial automation PLC SCADA HMI based electronic records. Batch records are in electronic form today, but other systems, including production processes, documentation and sampling, are yet to be digitalised. Although paper records can work well for some companies but they leave scope for human error and data manipulation than electronic records.

The true benefits of digital records is realised when companies use reliable industrial automation HMI/PLC SCADA software that automatically records the actions at each stage. The PLC SCADA software also makes data manipulation impossible. Another advantage of using SCADA HMI software for electronic records is that there are no more gaps in the records, which in turn improves data accuracy/Integrity. HMI/PLC SCADA software can automatically log any critical event and allows users to set alarms or notifications whenever pre-defined values exceed set parameters. This ensures that any deviation in the industrial automation process is identified in real-time.

The individual login ensures data integrity

To ensure precise data integrity individual logins are assigned. The general practice used is to assign username and password to each operator/individual. With individual user login enabled, the system can record any action or change made by an operator, thus offering a clear picture of the overall industrial automation process.

Data safety Data safety is of critical importance for pharmaceutical companies. How does a manufacturer ensure that its production data is safe and cannot be manipulated? By using reliable HMI PLC SCADA Software, companies can help eliminate this issue. When exporting archives to an external database, the software uses its internal mechanisms to check whether the data has been correctly and completely transferred. The data is never lost or corrupted. To ensure data safety, the PLC SCADA software stores critical data such as audit reports, alarm and event. By integrating Industrial automation HMI/PLC SCADA software with ERP system, pharmaceutical manufacturers can achieve savings; reduce energy consumption and raw material wastage, eliminate unplanned downtime by applying predictive maintenance. Manufacturers can have optimum utilization of manpower by freeing the staff used for recording data manually and employing their skills elsewhere in the business.

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Industrial automation technologies in coming days

Industrial automation demands continuous innovation. Right from invention of PLC SCADA in late sixties to the introduction of the robots in industry today, technological developments are continuously shaping the industrial automation ecosystem.

 
Internet of Things

A new buzzword, the Internet of Things is a core component of the connected factory. The sensors used to link Industrial automation technologies together are not new, but the decreasing size and cost of sensors has increased technology penetration across a growing range of devices. The sensors gather information on level, flow, position, sound, vibration, temperature and much more and this data is fed to PLC SCADA and used to control processes, alert the plant manager of problems and correct issues – even before a plant manager is aware of the problem.

 
Computing power of Industrial automation

Industrial computers are the heart of industrial automation PLC SCADA systems. Introduction of small, powerful microprocessors, which can precisely control machines by interpreting signals from other equipment. Smaller, faster sensors linked to increasingly powerful computers are the key to the smart factory. Industrial automation systems with high computing power can capture, process and analyse the big data from the factory floor and use it to improve productivity, avoid downtime through predictive maintenance, improve equipment use, optimise energy use, enable remote access and manage cyber security. 

 
Software Power

The global industrial automation PLC SCADA software market is growing very fast, part of which has been attributed to the integration of software with design and enterprise features, improving functionality. One factor limiting the market and expected to continue to do so is system security. This is done using a set of standardised requests – APIs. These specify how components should interact and make it easier to develop programs. APIs are becoming a more common service or product. Manufacturing involves a range of tasks with multiple types of requirements. Businesses can now build APIs to accelerate new service developments, improve efficiency and cut costs. 

 
Wearable technology

Wearable tech in consumer markets is rapidly growing popularity; from fitness trackers to smart watches, wearable gadgets are everywhere. These devices can integrate real time data and information without hassle. Coming day could see an increasing number of wearable technologies in industrial environments. It will have multiple benefits. Operators can have access to greater real time data for better control.

In an increasingly automated environment, wearable tech could be a way to improve the collaboration between humans and robots. There will be improvements in health and safety also through this technology; Helmets and watches containing sensors in an Industrial automation environment linked to supervisors will generate alerts and alarms about the hazards and dangerous situation of the job in hand.

2017 is already set to be an exciting year in which developments in industrial automation will drive us closer and closer to the smart factory and smart Industry. 

 

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Industrial Automation Engineering as career for Fresh Engineers

Today, qualified professionals have wider range of options to choose a particular career path. What is needed is only creative and detail oriented, approach , interest in  working with machinery, A well-paying job with plenty of opportunities is waiting for you, you may be a good candidate for a career in industrial automation Engineering.

What is an industrial automation engineer?

For an industrial automation Engineer, sky is the limit as far as prospects are concerned, whether in process, manufacturing, industrial and many other spheres.. There are automation opportunities in both product- and service-oriented industries. At international level, many professional associations, are promoting and supporting industrial automation sector. Industrial automation engineer is responsible right from designing lay out of instrumentation, Bill of material, Programming of PLC SCADA Systems as per project requirement, simulation and testing inhouse before commissioning. They are also responsible for keeping documentation, design layouts, component specifications, warranties, post commissioning support, AMC s in case there is any.

Educational requirements for automation engineers

In our county most automation engineers start out with a bachelor’s degree/Diploma in either Electrical / Electronics / Instrumentation , and other identical disciplines, which may include courses in relevant subjects such as robotics, fluid dynamics, and databases. Those who acquire PLC SCADA Automation training from Sofcon India Pvt Ltd has a cutting edge as compared to others , as they need little on the job training and Industries prefer to employ such candidates.

Licensing and certification for industrial automation engineers

A certificate on Industrial automation from Sofcon training can enhance your prospects for landing a career in industrial automation engineering. This is most popular certification, approved by NSDC which demonstrates an understanding of instrumentation and automated controls. Sofcon India is training partner of NSDC and the said certificates are approved by NSDC, after  successful completion of training from Sofcon training institutes.

Important skills for industrial automation engineers

Industry expects the following skills for automation engineers:

·                     A firm understanding of software application  and computer programming

·                     Equipment troubleshooting skills

·                     The ability to perform complex system tests

·                     Creative thinking and detail oriented approach

·                     Excellent manual dexterity

·                     Strong communication skills to support interactions with other members of the team.

Employment outlook for industrial automation engineering

Manufacturing is moving increasingly toward machine based systems. Semi automatic Machines need to be fully automated, some processes need to be retrofitted, upgraded, new plants are being installed with fully automated lines/systems. PLC SCADA qualified Industrial automation Engineers are in high demand. Industrial automation Engineers can work in all sections; design, project execution, automation commissioning, testing, after commissioning support, defect rectification, maintenance etc. 

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Building Automation System & HVAC

Building Automation System, BAS is experiencing a boom globally. It is also known as Energy Monitoring Control System (EMCS), Facility Management System (FMS), Energy Management System (EMS). India’s current GDP is 7+. We are expecting a robust economy with nearly 10% GDP, which means there will be additional requirement of millions of millions of square feet area. Our infrastructure sector will boom, better airports, better metro systems, more industries, better transportation, hotels, commercial buildings, buildings for offices, ware houses etc. This will translate into more requirement of Building automation systems, Building management systems, Fire detection and alarm systems, Auxiliary power systems, HVAC control system, parking management systems, access control system, CCTV Surveillance system,

These topics are briefly touched under college education system. This development is going to create a vacuum, where there will be a huge gap between demand and supply.

We at Sofcon India Pvt ltd are committed to fill this gap. Our practical training on BMS, HVAC control system, HVAC Design & Drafting, Building automation system equips budding engineers with knowledge required to work in this area. Engineers who undergo training are well versed with practical aspects of job roles and get ready in a week’s time to be job ready independently.  Post training jobs are available in projects design, project commissioning, maintenance, operations, applications etc.

In the building automation domain are HVAC systems, as well as automatic control systems for lighting, security systems, elevators, escalators, automatic doors and all communications infrastructure. If all these systems are able to communicate with each other with help of wired or wireless communication systems like LonWork, BACNet and Profibusthen that building can be referred to as an Intelligent Buildings.

For Example: A multiplex can adjust the effort done by the compressor of the air conditioning unit on the data taken by the computer system from where the tickets are booked.

Example 2: In a mall, the engineer can choose between the electrical energy supplied from the electricity board or DG set on the basis of lowest cost in any period of time of that day.

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