Control system Integration challenges

Five Industrial Automation Challenge

Tips to manage and execute them with success

Control System integration technologies are changing rapidly, and manufacturing automation projects are becoming a challenge due to the complexity, scope, and human intervention.

Manufacturers need to cope and carry on with the constant changes in the way manufacturing process technologies is moving forward. Therefore, as an integrator, we can identify five manufacturing automation challenge:

Tips No. 1

<color=”red”>Control System Components:</color=”red”>

When building a control system need to consider several components from different suppliers. Furthermore, the project manager must ensure that all these components can communicate with each other without any setbacks. Industrial engineering knowledge is crucial to deliver a top-performing integrated system.

The operator interface (OI) is one main component of the automation system. For instance, it is essential for the operator to understand the interface between all automated equipment in a plant to achieve the operation successfully. In addition, a system integrator can help the operator to get an accurate understanding of the whole operating system. Hence, it is important to update the interference need according to the latest technology, it is crucial to get the operator to embrace the changes by incorporating the latest technology.

Tips No. 2

<color=”red”>Technology Interfaces:</color=”red”>

New technology represents a challenge for any automation project. However, updating the equipment with the constant changing of the software is a challenge, electronic technology or others automation equipment can make the difference in implementing a functional and high-performance control system integration or a poor performance system. Likewise, it is important to train the staff with the latest automation technology to keep the system running smoothly.

Tips No. 3

<color=”red”>Control and Field Instrumentation Documentation:</color=”red”>

Engineering expertise must follow documentation standards. In Fact, to successfully work with and well-structured design control systems, it is essential to understand the documents that are typically used to illustrate process control.

The system integrator provides very detailed documentation that includes all requirements from the automation control system. In short, the documentation of the control system does not follow standards for process control and instrumentation, then it may be necessary to manually create this documentation. For example, tag numbers may easily identify the field device when ordering and shipping, as well as installing in the plant.

Tips No. 4

<color=”red”>Process Flow Diagrams:</color=”red”>

The project manager is responsible for the selection of the devices that best match the process design requirements. This includes the selection of the transmitters that fit the operating conditions, the type and sizing of valves, and other implementation detail specified in the process flow diagram. Some of these diagrams are:

panel electrical wiring

  • Piping and Instrumentation Diagram – On the diagram describes all decisions or changes concerning field instrumentation, the assignment of device tags, and piping details. (P&ID)
  • Loop Diagram – Drawing that shows field device installation details including wiring and the junction box (if one is used) that connects the field device to the control system.

Tips No. 5

<color=”red”>Future Expansion:</color=”red”>

Companies need to plan when developing complex or even simple automation control system projects before jumping into execution. Searching for the right system integrator team early in the process and designing appropriate engineering design is key.

Performing an appropriate scope is critical to getting the project started and for future expansion. Consider company growing when implementing a control system including control panel expansion, industrial electrical wiring, and software upgrading capabilities.

Maximise the ROI

Industrial automation projects have so many challenges, find the right partner with enough knowledge and extensive technical expertise to integrate the automation system and its components. For instance, searching for the right control system integrator can help guide the project to success and maximise the ROI from an automation project.

Phoenix installs and integrates industrial control panels. We can customise single or multiples control panels as well as provide the electrical wiring design and documentation. In addition, we offer our project management and commissioning solutions.

Industrial Automation New Technology

Mobile Technology is moving into Industrial Automation

In recent years industrial automation new technology such as mobile devices are playing an important role in every aspect of our lives and they are increasingly demanding with automation systems changing how data is analysed, stored, and acquired.

Hence, some larger industrial control companies already have integrated mobile with data acquisition applications to their automation products. In addition, they are integrating mobile communications systems for better performance.

Mobile capabilities for Automation Systems

Hardware and software are part of the operations technologies in manufacturing plants, while information technology is for mobile communication systems. For instance, by integrating these two technologies, the end-users engage their mobile devices with no restrictions. It requires installing specific software and more advanced programming or configuration. Therefore, using a familiar web browser gives users the capability to do some setup in mobiles or tablet devices. Even though, PC access nor internet is required to do the work. Why invest in robot technology? See the main advantages of this new technology.

10 Top Advantages of Mobile Technology for Industrial Automation

Traditional Industrial Automation includes more complex architectures or steps while mobile technology provides simplified solutions. Also, see some of the advantages of the newer technology:

1. Improves data flow
2. Control who can have access to the data
3. Data provides additional services to customers and improves machine design.
4. Operators can monitor equipment located remotely or in hazardous areas
5. Progressive original equipment manufacturers (OEMs) will build the right data points into their equipment and gather results from a machine, a site, or even multiple sites
6. Management team and OEMs can access information from industrial automation systems from their Mobile
7. Remotely assess operating conditions
8. Reduce energy consumption and maintenance costs, and improve efficiency
9. Access to more detailed data; when and where owners of staffs need it
10. Preventive or predictive maintenance via details analysis

Mobile Security Concern

Even though the addition of mobile devices has advantages, it can also raise concerns about who can see or change industrial controller data. For instance, in a traditional system a serial cable connects the hardwired interface terminal to a PLC, the HMI user experience is local and separated from the rest of the world.

Security is also of great concern because it demands more attention for a mobile device on a Wi-Fi network, or connecting over the internet. In other words, it means all efforts should focus on security over external jackers.

Robot Automation Systems

The mobile devices and applications are now advancing into industrial robot automation systems because robot system is integrated to the plant operation process. Industrial robots – new robots or used industrial robots – are part of the whole process and they can also be monitored on how data is acquired, viewed, stored, analysed, and acted upon.

Therefore, factories can include any application such as robot milling, robot palletising, robot cutting, trimming, Robot robotic welding, or painting robots as part of their industrial automation.
Whereas factories want to include control systems, robot automation, or mobile technology into their automation systems, it is crucial to consult with a Control System Integrator, Robot Integrator or both depends on the complexity of the project.

Nevertheless, Industrial integrators will advise and guide you throughout the whole process saving time and cost.

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