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Industrial Automation Systems
Industrial control systems (ICS) is a term used to describe the whole of control and measurement systems and instruments used to automate industrial processes. ICSs are used in critical sectors such as manufacturing, transportation, energy, treatment by being specialized on a sector basis and they ensure efficient, high quality, consistent and safe execution of industrial processes.
ICSs monitor and control production processes and activities. In case of any anomaly, they automatically intervene and take action to correct the error and return the process to normal. In this way, they ensure consistency in production quality and prevent a waste of energy.
A well designed ICS can increase the energy efficiency of businesses by 20%.
Energy efficiency increases with efficient operation of machines and systems.
Accident risks are minimized by automatically alerting and taking action in case of any security gap with integrated security systems.
Customer satisfaction is ensured by maintaining consistency in product quality.
Service and maintenance costs are saved up by early detection and intervention of faults.
Supervisory Control and Data Acquisition (SCADA), Distributed Control System (DCS), Industrial Automation and Control System (IACS), Programmable Logic Controller (PLC), Control Loops , Programmable Automation Controller (PAC), Remote Terminal Unit (RTU), Human-Machine Interface (HMI), Control Servers, Intelligent Electronic Devices (IED), and sensors are the components of ICSs.The fact that the developing technology makes the integration of operational technology (OT) with information technology (IT) more cost-effective has made the use of smart sensor technologies and wireless communication widespread within ICSs.
Scada consists of PLCs that continue their functions in various locations. It is also integrated with the HMI to provide central monitoring and central control.
Scada allows for long distance monitoring and control of sites. It automatically fulfills the follow-up and action responsibilities of the operators. Widely used in industries such as pipeline monitoring, treatment plants, power generation and distribution facilities.
DCS is a control and decision making structure that monitors and manages multiple local controllers. It is generally used in facilities with more than one interconnected process. They have their own management panels and data storage structures, and they are generally run back-up. It is widely used in facilities and industries such as manufacturing, chemical processes, petroleum refineries.
PLC is the control mechanism of both Scada and DCS in the field. They are responsible for monitoring and controlling processes locally. Although RTUs play the same role as PLC in Scada systems, their main task is to provide communication between central control units and field equipment.
HMIs are graphical user interfaces that provide communication between human operator and controller equipment. ICSs, on the other hand, allow the operator to monitor the whole system through the graphical interface, to be warned in abnormal situations and to allow operators to intervene in the system.
Sector: Manufacturing
Job: Process Control & Monitoring
Goal: Sustainability
We worked on the production line of our customer, who is serving in the automotive production sector. We carried out work to ensure that the filling processes on the assembly line are not interrupted in the auxiliary plants of the filling equipments in the 550 m long assembly line.
Since there are many independent stations in such production lines, a problem to be experienced in one of the stations means that the production line stops or the product is not completed. This means a decrease in product quality or a prolongation of production cycle times, that is, a decrease in productivity.
In the study carried out for this purpose, stock tracking and facility status monitoring systems were integrated, while system operation and pump controls were locally automated for filling equipment. A web-based system tracking platform, which serves on customer servers over a closed network, was put into service.
Thanks to hourly and daily stock reporting, our customer started to regulate raw material supply frequencies more accurately. In critical production processes, incorrect planning in logistics processes was prevented by notifying the suppliers directly of the stock status by the system.
Thanks to the consumption data that was not available before, correlations can be made between the production periods, the type of product coming off the assembly line and the changes in production speed and raw material consumption. In this way, issues such as periodic planning, updates in the production strategy or investments to be made on the line were evaluated more accurately. With the activation of the alarm management system, it was observed that repair times were reduced by 15% with automatic notifications to the relevant units in case of anomalies encountered throughout the facility.
The work, which initially started at 2 auxiliary plants, has been expanded upon request and transformed into a structure with a total of 6 auxiliary plants.
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Registered Company Number: 12983685
Registered Office:408, Screenworks, 22, Highbury Grove, London, N5 2EF
Contact Office: 86-90 Paul Street, London, EC2A 4NE
Email: info@ravtechautomation.com
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www.rav-tech.co.uk
Certificate No: 9497479