The Next Generation of Process Automation: Going Beyond PLCs and DCSs

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From Analog to Digital: Evolution of the Automation Systems

What happens is any analog signal takes a longer time to get captured, and therefore when it came to the next level over the control switches, in today’s world it is called HMI (Human Machine Interface), earlier known as Operator Workstation (OWS), it used to take a longer time for refreshing – which meant that you needed more number of controllers, if you wanted a particular response at the level of HMI.

This is how both these technologies evolved. Now, over a period of time, there were developments on both sides. About 10 years ago, a time came when it was felt that these two technologies are more or less converged at a point. Thus, emerged a platform called PAC (Process Automation Control).

Back in Control with Process Automation

A process automation controller caters to both analog heavy and digital heavy functions. Secondly, over a period of time, the DCS environment called for a program, which was not like Ladder in the digital heavy section, but was more of functional blocks or sequential logic, which ensured that analog data are captured and processed at certain determined values through macros.

Now, Rockwell has come from digital intensive functionalities, so today what you see as ControlLogix, it is a process automation controller. Now the challenge comes as to how we will position it. It is all about understanding what a Control-Logix is. It is far ahead of PLC. It is not a DCS controller as well. It is far ahead of both the platforms. Because, today a ControlLogix can work in DCS environment, it can also work in a sequential logic digital environment. So, the Process Automation Controller is the key – on which our entire solution platform for the process space is revolving around.

The Challenge: Avoiding HMI Overflows

Added to that, there is the next level HMI, where it is characterised. Because if you have more analog heavy operations, then you need a certain number of controllers, which do not get overloaded. Typically, we say about 40 to 45 per cent loading of the controller, beyond which if you load analog heavy operations, you will have problems when it comes to HMI freezing, HMI cascades, alarm management and so on...

Discover, why hardware solutions are sometimes not enough to provide protection against HMI hanging on page 3!

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