The effectiveness of modern production facilities to a large extent depends on the quality of organization of work of automated systems. The point is not only to minimize the labor of workers, but also to optimize the logistic functional processes. A well-coordinated and correct adjustment of automation allows you to spend less resources, maintaining an optimal production rate and the proper level of quality of products. You can count on such an effect only if correctly selected industrial controllers for automatic systems participate in the work management. This is a mandatory component in any programmable complex through which the interaction of individual production elements occurs.
Controller Overview
In industry, controllers are called devices that act as a command center in relation to serviced equipment with an automatic control principle. The function of such devices can not do without feedback, which is based on sensors that collect this or that information about the work process. Based on the information received, industrial controllers develop reverse commands, thus managing entrusted systems. The coverage of one processor may be different. As a rule, modern models allow you to simultaneously process signals from 200-250 pieces of equipment, also sending them signals with settings for operating parameters. An important difference of the controller in the current sense is the ability to operate with data processing in program mode, that is, it provides for a serious departure from the principles of one-step hard logic, on which automated production lines of previous generations worked.
Device
The basis is formed by a modular processor of programmable type, which is complemented by a huge list of auxiliary systems and components. The basic elements of the main subsystem include input / output modules, communication tools, sets of sensors, data storage devices, as well as operator control panels. The secondary modules, which, however, are rarely inferior in importance to the aforementioned components, include safety systems, temperature controllers, a display and keyboards, as well as the latest systems for organizing network data transfer. At the same time, the device of the industrial controller does not do without the inclusion of engineering systems that can provide cooling of the equipment and, if necessary, its heating. As for the sets of sensors, their composition completely depends on the object on which the system is operated. It can be water or gas flow detectors, energy meters and even motion sensors.
Principle of operation
When the modular structure is established and the production process is started, the registration of operational parameters begins. As already noted, the system can take into account hundreds of indicators, comparing them with the values entered by the user of the program. Based on the results of this comparison, the controller makes a decision for the team. For example, if according to the technology a waterjet cutting machine can operate at a temperature not lower than 0 degrees, then the equipment will give a command to stop the process, if the thermometer shows a value below the permissible value. Other industrial controllers work on the same system. The principle of operation also involves more complex decision-making algorithms. For example, dozens of indicators affecting the operation of one section or a specific piece of equipment can be taken into account. Also during operation, the system also controls its own performance indicators, including power supply parameters.
Application of industrial controllers
Such equipment is used in various fields, and not only production. But the main areas are still metallurgy, the chemical industry, oil production, manufacturing industries, etc. For example, metallurgical plants use automation to control presses, lathes, the same carvers and grinders, which have high demands in terms of accuracy of the result. In the chemical industry, industrial controllers control the processes of mixing, dosing and cleaning. In addition, logical programming tools effectively show themselves as part of security systems. In particular, the controllers control the functions of alarms, security posts, protective partitions and gates with an automated drive. Now it’s worth getting acquainted with the manufacturers of modern controllers and the capabilities that are offered in them.
Controllers "ARIES"
Since 2005, OVEN enterprise has been developing automatic controls for the industrial segment, adhering to the principles of functionality, ergonomics and reliability. An important characteristic of these devices is the initial basing on a powerful hardware resource, which is complemented by extensive software capabilities. As for the second aspect, the industrial controllers of Russian production "Aries" work in the CoDeSys software environment from German developers. From the point of view of operation, this equipment is advantageous by the possibility of component expansion, which makes it universal, as well as the inclusion of the latest means of communication interaction in the complex.
Segnetics Controllers
Another domestic company engaged in the development of a segment of industrial controllers. Currently, Segnetics experts offer several solutions for different categories of users. The basic SMH2010 series includes universal panel automation tools that are optimally suited for use in the housing and communal sector. On the other hand, the production of industrial controllers at the facilities of this company is also focused on highly specialized tasks. For example, Pixel devices are specifically designed to control the ventilation system. There are more complex controller models in the family that can be successfully applied in the areas of automation of technological processes on large production lines.
Advantech Controllers
A promising manufacturer that focuses on the development of internal logical processes between the components of the controllers. Currently, the company offers two complexes in its lineup - APAX and ADAM. The first uses an open architecture, on the platform of which the functions of processing and managing information are combined. Communication tools involve the build-up of components, which makes the system flexible in use. The ADAM family also offers industrial controllers with advanced hardware for the control function and some add-ons. In particular, the system is provided with deterministic input / output, redundant power supplies and optimized memory.
Conclusion
The simplest systems for automated production support have gradually grown into complex multifunctional devices. Today, manufacturers of industrial controllers set themselves tasks of a new order, which should increase the efficiency of process control in various fields. Among the most important areas, one can single out the improvement of communication links, the optimization of energy supply, and the transition to more reliable elemental platforms. At the same time, domestic developers practically do not lag behind foreign experts, offering completely competitive solutions of a modern level.