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Automation Examples 1.2 Exemples de sites automatisés Beispiele Automatisierungssysteme

Industrial Automation Automation Industrielle Industrielle Automation. Automation Examples 1.2 Exemples de sites automatisés Beispiele Automatisierungssysteme. Prof. Dr. H. Kirrmann. EPFL / ABB Research Center, Baden, Switzerland. 2008 March HK. Examples of Automated Plants.

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Automation Examples 1.2 Exemples de sites automatisés Beispiele Automatisierungssysteme

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  1. Industrial Automation Automation IndustrielleIndustrielle Automation Automation Examples1.2 Exemples de sites automatisésBeispiele Automatisierungssysteme Prof. Dr. H. Kirrmann EPFL / ABB Research Center, Baden, Switzerland 2008 March HK

  2. Examples of Automated Plants • 1 Introduction • 1.1 Automation and its importance • 1.2 Applications of automation • 1.3 Types of Plants and Control • 1.3.1 Open Loop and Closed Loop Control • 1.3.2 Continuous processes • 1.3.2 Discrete processes • 1.3.3 Mixed processes • 1.4 Automation hierarchy • 1.5 Control System Architecture

  3. Cars traditional: appliances control (windows, seats, radio,..) motor control (exhaust regulations) critical new applications: ABS (anti-skip) and EPS (stability), brake-by-wire, steer-by-wire (“X-by-wire”) increased safety ? extreme price squeezing 2001 US model: 19% of the price is electronics, tendency: +10% per year.

  4. Rail vehicles there are more than 20 interconnected computers on a locomotive vehicle control unit radio link display unit VCU VCU DU DU TCU TCU SBB 460 brakes diagnostics energy signaling traction control unit Benefits: reduce operation costs, faster diagnostics, better energy management, automatic train control.

  5. Airplanes “avionics”: flight control (safe flight envelope, autopilot, “engineer”) flight management flight recording (black boxes, turbine supervision) diagnostics “fly-by-wire” high reliability

  6. Launch vehicles Control Panels GPC 1 GPC 2 GPC 3 GPC 4 GPC 5 CPU 1 CPU 2 CPU 3 CPU 4 CPU 5 IOP 3 IOP 1 IOP 2 IOP 4 IOP 5 Intercomputer (5) Mass memory (2) serial data Display system (4) buses Payload operation (2) ( 23 shared, Launch function (2) 5 dedicated ) Flight instrument (5;1 dedicated per GPC) Flight - critical sensor and control (8)

  7. Robots extension limited to 2-3 m (portal robots 10-20m) frequent reprogramming for new tasks, tooling simple embedded computer, hierarchical control

  8. Substations protection (Lines, transformers, generators) very high speed response control (remote or local) to guarantee power flow, safe operation (interlocking) measurement (local and remote), electricity bill, power flow in grid

  9. Pharmaceutical Industry Inventory Recipe management Packaging Sampling Tracking & tracing Comply with government rules: Typical of batch processes.

  10. Manufacturing

  11. Flexible Automation numerous conveyors, robots, CNC machines, paint shops, logistics. Download from production management, connection to administration

  12. Warehouses extreme dependency on the availability of the control system Connection to * supply chain management, * order fulfilment * customer relationship and * commercial accounting (SAP)

  13. Printing machines • tasks of control system: • motor control (synchronisation of the printing cylinders) • ink and water control • paper web control (reelstands (Rollenwechsler, bobines), web tension, emergency knife) • interface to operator (commands, alarms) • production preparation and statistics - up to the press room • very high requirements on availability: two hours delay and the production is lost.

  14. Oil & Gas, petrochemicals "upstream": from the earth to the refinery down-sea control special requirement: high pressure, saltwater, inaccessibility explosive environment with gas. distribution special requirement: environmental protection "downstream": from the oil to derived products special requirement: extreme explosive environment Switzerland: Colombey, Cressier

  15. Chemical industry logistics, local control of reactors e.g. LONZA Characterized by batches of products, reuse of production reactors for different product types (after cleaning).

  16. Pulp & Paper Process Industry Process Industry = industries de transformation, Verfahrenstechnik (one of the many meanings of “process”) Cement Metals and Minerals Glass production Chemical …. Continuous flow of materials, often 24 hours a day

  17. Steel mills particularity: synchronization of the motors in the rolling mill

  18. Cement Works The rotating oven is the heart of the cement process: the grinded kiln is burnt and comes out as chunks later reduced to powder. Control tasks: Oven rotation and temperature control fuel supply, silos, transport belts, grinding mills, pollution monitoring, quality supervision, filler stations,... Switzerland is leading nation in Europe (Holcim, Jura, …)

  19. Mining

  20. Building Automation basics: fire, intrusion, climate, energy management HVAC = Heat, Ventilation and Cooling = air conditioning visitors, meeting rooms, catering,…. low price tag

  21. Automation of Building Groups EPFL

  22. Airports large building automation system: fire, security access, energy, lighting, air conditioning, communications, traffic control luggage control in Zurich-Airport

  23. Traffic control fire intrusion energy water ventilation pollution monitoring cameras light control traffic jams prevention,.... (Tunnel Letten near Zurich)

  24. Harbours from ship planning to crane manipulation and stock control

  25. Water treatment (fresh and waste water) manage pumps, tanks, chemical composition, filters, movers, quality... auxiliaries: methane electricity generation

  26. Power plants Hydro - river - dams - storage dams Thermo - coal - gas - atom - solar - waste Alternative - wind - photo-voltaic tasks: fuel supply primary process control (steam, wind) personal, plant and neighbourhood safety monitoring environmental impact electricity generation (voltage/frequency) energy distribution (substation)24 / 365 availability

  27. Waste treatment, incinerators raw material supply burning process smoke cleaning environmental control co-generation process (steam, heat) ash analysis ash disposal

  28. Power transmission network InternationalControl Center Substation SS ( Unterstation , sous-station) National Control Center SS Regional Control Center Regional Control Center SS PP SS Power PlantCentrale, Kraftwerk PP switchyard,postes HT Schaltfeld PP SY SS PP SY Substation Huge number of "points" (power plants, transformers, breakers, substations) lying 2km to 2000 km apart. All time-critical operations executed locally in the substations and power generation units.

  29. Swiss electricity interconnection network

  30. Pipelines particularities: long-range communication system, safety, explosive environment

  31. Assessment Name the applications you remember and indicate at least one task for the control system What could be the order behind the plant types that were presented ?

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