Integration
Integration is typically managed through one of three mechanisms:
Direct Integration – Business systems include connectivity (communications to plant floor equipment) as part of their product offering. This requires the business system developers to offer specific support for the variety of plant floor equipment that they want to interface with. Business system vendors must be expert in their own products, and connectivity to other vendor products, often those offered by competitors.
Relational Database (RDB) Integration – Business systems connect to plant floor data sources through a Relational Database Staging Table. Plant floor systems will deposit the necessary information into a Relational Data Base. The business system will remove and use the information from the RDB Table. The benefit of RDB Staging is that business system vendors do not need to get involved in the complexities of plant floor equipment integration. Connectivity becomes the responsibility of the system integrator.
EATM (Enterprise Transaction Modules) – These devices have the ability to communicate directly with plant floor equipment and will transact data with the business system in methods best supported by the business system. Again, this can be through a staging table, Web Services, or through system specific business system APIs. The benefit of an EATM is that it offers a complete, off the shelf solution, minimizing long term costs and customization.
Custom Integrated Solutions – Many system integrators designs offer custom crafted solutions, created on a per instance basis to meet site and system requirements. There are a wide variety of communications drivers available for plant floor equipment and there are separate products that have the ability to log data to relational database tables. Standards exist within the industry to support interoperability between software products, the most widely known being OPC, managed by the OPC Foundation. Custom Integrated Solutions typically run on workstation or server class computers. These systems tend to have the highest level of initial integration cost, and can have a higher long term cost in terms on maintenance and reliability. Long term costs can be minimized through careful system testing and thorough documentation.
A programmable logic controller (PLC) or programmable controller is an industrial computer that has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, machines, robotic devices, or any activity that requires high reliability, ease of programming, and process fault diagnosis. Dick Morley is considered as the father of PLC as he had invented the first PLC, the Modicon 084, for General Motors in 1968.
Supervisory control and data acquisition (SCADA) is a control system architecture comprising computers, networked data communications and graphical user interfaces for high-level supervision of machines and processes. It also covers sensors and other devices, such as programmable logic controllers, which interface with process plant or machinery.
A distributed control system (DCS) is a computerised control system for a process or plant usually with many control loops, in which autonomous controllers are distributed throughout the system, but there is no central operator supervisory control. This is in contrast to systems that use centralized controllers; either discrete controllers located at a central control room or within a central computer. The DCS concept increases reliability and reduces installation costs by localising control functions near the process plant, with remote monitoring and supervision.
Open Platform Communications (OPC) is a series of standards and specifications for industrial telecommunication. They are based on Object Linking and Embedding (OLE) for process control. An industrial automation task force developed the original standard in 1996 under the name OLE for Process Control. OPC specifies the communication of real-time plant data between control devices from different manufacturers.
The OPC Foundation is an industry consortium that creates and maintains standards for open connectivity of industrial automation devices and systems, such as industrial control systems and process control generally. The OPC standards specify the communication of industrial process data, alarms and events, historical data and batch process data between sensors, instruments, controllers, software systems, and notification devices.
Automatic test equipment or automated test equipment (ATE) is any apparatus that performs tests on a device, known as the device under test (DUT), equipment under test (EUT) or unit under test (UUT), using automation to quickly perform measurements and evaluate the test results. An ATE can be a simple computer-controlled digital multimeter, or a complicated system containing dozens of complex test instruments capable of automatically testing and diagnosing faults in sophisticated electronic packaged parts or on wafer testing, including system on chips and integrated circuits.
Computer-integrated manufacturing (CIM) is the manufacturing approach of using computers to control entire production process. This integration allows individual processes to exchange information with each part. Manufacturing can be faster and less error-prone by the integration of computers. Typically CIM relies on closed-loop control processes based on real-time input from sensors. It is also known as flexible design and manufacturing.
A systems integrator is a person or company that specializes in bringing together component subsystems into a whole and ensuring that those subsystems function together, a practice known as system integration. They also solve problems of automation. Systems integrators may work in many fields but the term is generally used in the information technology (IT) field such as computer networking, the defense industry, the mass media, enterprise application integration, business process management or manual computer programming. Data quality issues are an important part of the work of systems integrators.
Profinet is an industry technical standard for data communication over Industrial Ethernet, designed for collecting data from, and controlling equipment in industrial systems, with a particular strength in delivering data under tight time constraints. The standard is maintained and supported by Profibus and Profinet International, an umbrella organization headquartered in Karlsruhe, Germany.
Direct digital control is the automated control of a condition or process by a digital device (computer). Direct digital control takes a centralized network-oriented approach. All instrumentation is gathered by various analog and digital converters which use the network to transport these signals to the central controller. The centralized computer then follows all of its production rules and causes actions to be sent via the same network to valves, actuators, and other heating, ventilating, and air conditioning components that can be adjusted.
An industrial control system (ICS) is an electronic control system and associated instrumentation used for industrial process control. Control systems can range in size from a few modular panel-mounted controllers to large interconnected and interactive distributed control systems (DCSs) with many thousands of field connections. Control systems receive data from remote sensors measuring process variables (PVs), compare the collected data with desired setpoints (SPs), and derive command functions that are used to control a process through the final control elements (FCEs), such as control valves.
A computer appliance is a home appliance with software or firmware that is specifically designed to provide a specific computing resource. Such devices became known as appliances because of the similarity in role or management to a home appliance, which are generally closed and sealed, and are not serviceable by the user or owner. The hardware and software are delivered as an integrated product and may even be pre-configured before delivery to a customer, to provide a turn-key solution for a particular application. Unlike general purpose computers, appliances are generally not designed to allow the customers to change the software and the underlying operating system, or to flexibly reconfigure the hardware.
Inductive Automation is a supplier of web-based industrial automation software based in Folsom, California, US. The Ignition SCADA platform is the company's main product line.
Manufacturing execution systems (MES) are computerized systems used in manufacturing to track and document the transformation of raw materials to finished goods. MES provides information that helps manufacturing decision-makers understand how current conditions on the plant floor can be optimized to improve production output. MES works as real-time monitoring system to enable the control of multiple elements of the production process.
On the top-side facilities of offshore oil and gas platforms, the Master Control Station (MCS) is a dedicated system that controls and retrieves data from subsea equipment on the ocean floor. The MCS is supplied by the manufacturers of the subsea control modules (SCM), an MCS is required for each vendor. This can be a challenge in some scenarios.
An enterprise appliance transaction module (EATM) is a device, typically used in the manufacturing automation marketplace, for the transfer of plant floor equipment and product status to manufacturing execution systems (MES), enterprise resource planning (ERP) systems and the like.
A universal gateway is a device that transacts data between two or more data sources using communication protocols specific to each. Sometimes called a universal protocol gateway, this class of product is designed as a computer appliance, and is used to connect data from one automation system to another.
An RF module is a (usually) small electronic device used to transmit and/or receive radio signals between two devices. In an embedded system it is often desirable to communicate with another device wirelessly. This wireless communication may be accomplished through optical communication or through radio-frequency (RF) communication. For many applications, the medium of choice is RF since it does not require line of sight. RF communications incorporate a transmitter and a receiver. They are of various types and ranges. Some can transmit up to 500 feet. RF modules are typically fabricated using RF CMOS technology.
Ignition is an Integrated Software Platform for SCADA systems released by Inductive Automation in January 2010. It is based on a SQL Database-centric architecture. Ignition features cross platform web based deployment through Java Web Start technology. The Ignition platform has three main components: the Ignition Gateway, the Designer, and the runtime clients. Independent modules provide separate functionality in any or all of the platform components. Ignition SCADA modules provide features such as: Real-Time Status Control, Alarming, Reporting, Data Acquisition, Scripting, Scheduling, MES, and Mobile support.
Operational technology (OT) is hardware and software that detects or causes a change, through the direct monitoring and/or control of industrial equipment, assets, processes and events. The term has become established to demonstrate the technological and functional differences between traditional information technology (IT) systems and industrial control systems environment, the so-called "IT in the non-carpeted areas".
