A Data-Driven Approach for Design and Development of Batch Process Automation System of a Plant

Abstract

Industrial automation processes make use of control systems to operate and observe machines as well as processes. Automation in industrial workplace gives advantages of enhancing quality and productivity whereas minimizing errors, improving safety, and adding flexibility to manufacturing process. The aim of this work is to implement the simulation-based data driven control automation in which I have to design, develop and automate the complete plant through Programmable Logic controllers (PLC). Keeping this in view, I have designed the redundant controller architecture by using Device Level Ring (DLR) topology; a cost-effective control solution in which the single point of failure on networking and SCADA/HMI layer will be minimized. V-Cycle process model will be followed during detail design and development phase of the project till complete simulation. Control Logix soft computing technique used for logic development. I have developed complete simulated data driven control project in which I have utilized different soft computing techniques and software’s for industrial automation including RS-Logix5000/Studio 5000 for logic development, RSLinx for communication between PLC controllers and SCADA/HMI layer are used. Factory talk View Studio will be used for graphics development. Also, I have used the soft computing techniques for reporting purpose. SQL Database management console utility have utilized for reporting DB. For simulation activity, I have used RS-Simulator. Simulated data driven automated SCADA/HMI system are ensure to meet the performance parameters i.e. increase productivity, increase efficiency, reduce variability and ensure safety. Major parameters are showed in form of Bar-Trends. Health Statuses of control hardware and communication diagnostics are very helpful for system health checks and monitoring in diagnostic HMI.