BRPI0912486A2 - instrumentation, control and automation module - Google Patents

Abstract

INSTRUMENTATION, CONTROL AND AUTOMATION MODULE. This patent application describes an Instrumentation, Control and Automation Module (MICA) developed for laboratory teaching and technical training activities in the areas of industrial and building control and automation. More particularly, the technology now proposed (MICA) presents a flexible and versatile structure of software and hardware that allows to develop, test and validate automation system projects with different sensors, actuators, industrial pilot plants, and tests and experiments can be done in laboratories or close to industrial plants.

Description

INSTRUMENTATION, CONTROL AND AUTOMATION MODULE - MICA

APPLICATION FIELD

This patent application refers to a device used for teaching instrumentation, process control and automation at various levels of training: technical, higher and postgraduate (specialization, master and doctorate). It can also be used for technical training in teaching lab or shop floor, demonstration in classrooms, labs and science and technology fairs. Other uses include the development of instrumentation systems, process control and automation, supervisory system testing and human-machine interfaces, development and testing of discrete event automation systems, and testing and validation of industrial instrumentation, process control and automation.

TECHNICAL STATE

It was published in the Annals of the 58th Annual Meeting of SBPC - Florianópolis, SC - July / 2006, the summary entitled "TEACHING MODULE FOR INSTRUMENTATION, CONTROL AND AUTOMATION TEACHING", written by Anísio Rogério Braga, Carmela Maria Polito Braga, Daniel Almeida Godinho , Karluce Santos Rezende. This is a brief presentation of the concept of the didactic module, at that time in development phase, with experimental construction of the parts.

Lab-Volt has a line of mobile training systems in Instrumentation and process control. These are modules on crazy wheels, which allow easy movement of the same in the laboratory. They consist of workstations designed for training in instrumentation and process control. Each station can operate separately or be interconnected with another line station, simulating more complex systems. Each station is designed and built with a focus on the simulating process, ie flow, level, pressure, temperature, analytical process or multiprocess station. All stations have a microprocessor controller and plotter, as well as traffic lights and banana pins for access to the signals of the measuring instruments and actuators installed at each station.

TECHNICAL STATE PROBLEMS

Teaching modules for teaching and technical training purposes are predominantly built as solutions:

• Restrictive, closed and limited hardware modification;

• Didactics in the presentation, but distanced from the reality paradigms of factory floor. It is common to use low cost sensors without industry standardization;

• Focused on demonstrative solutions for specific training;

• Limited in terms of operational condition testing and instrument and equipment failure. Faults are pre-programmed for general training evaluation;

• Encapsulated and restricted, i.e. without expansion flexibility, and when they exist they are usually proprietary;

• Encapsulated with built-in power and drive electrical connections (shrouded by opaque protective obstructions), normally fixed, without ample modification or reconfiguration possibilities;

• Proprietary and restrictive software applications limiting use to demonstration and training tasks.

TECHNOLOGY ADVANTAGES

The Instrumentation, Control and Automation Module has the following advantages:

• Compact and didactical integration of industrial process automation and control aspects that establish and connect user archetypes to the shop floor reality paradigms, creating technologically equivalent and representative associations with Control Room, Equipment and Instrument Cabling Trays, Process Factory Floor with discrete manufacturing cell mechanical simulation, operator panel simulation (with Remote and Local mode option), Manual and Automatic operating modes, semaphore visual beacons, siren simulating buzzer;

Using color coding to relate and group equipment and instruments in the field with Programmable Logic Controller - PLC input and output cards, eg sensor connections are made with blue banana pins and PLC digital and analog input connections. , where the sensors must be connected, are also highlighted with blue pins highlighted by a graphic area also in blue color. Simulation of an instrumented integrated manufacturing cell consisting of: rotating aluminum disk-shaped table, inductive, capacitive and photoelectric presence detection sensors arranged 120 ° equidistant along the disc's surroundings. The disc is driven by a bidirectional, programmable speed PWM (pulse width modulation) type servomotor. This set of discs, sensors and servomotor drive represents a typical process usually formed by conveyor belts in the automobile and beverage industry, among others. The belt is simulated by an aluminum disk and the parts or pieces to be transported or manufactured along the belt extension and its manufacturing cell are represented by removable fins arranged along the entire circumference of the disk with the following characteristics: metallic opaque (detected by inductive and capacitive sensors), metallic mirror (detected by inductive, capacitive and photoelectric sensors), opaque plastic (detectable by capacitive sensor), reflective plastic (detectable by capacitive and photoelectric sensors).

Simulation of diverse and typical automation system failures such as: changed operating conditions due to process failure (eg removal of fins on manufacturing cell simulator disk; remote to site switch on factory floor panel), switched electrical connections causing addressing errors of variables whether measurement or actuation, obstruction of the sensing area (eg inductive, capacitive or photoelectric detector permanently triggered due to the presence of elements external to the simulated process). Change in sensor installation distances that may be unsuitable for desired part detection, operational flashing of equipment and instruments (e.g. electrical connections can be easily switched manually); Encoder-type speed sensor simulation using aluminum disc, which also simulates a conveyor belt, fins and inductive, capacitive and photoelectric sensors / detectors; Expected expansion on both front panel and temporary or permanent external connections. Using DIN rails for mechanical fixation of Instruments, parts and small equipment typically installed in CCM - Motor Control Center as contactors and pushbuttons. Extended PLC card connections using banana minipins according to color coded interconnect input, output and power of cards, instruments and industrial equipment;

Encapsulation of power and drive electrical connections embedded within the module body, but with module closure with translucent material, allowing not only extensive visual inspection of the internal connections, but also modifications and installation of new equipment or instruments using the base. DIN rail for mechanical fixing of parts;

Integration of electrical parts, equipment, sensors and actuators used in real industrial installations, whose electrical connections are reconfigurable using an organized structure with side-drilled channels to facilitate cable routing and electrical connections. The channel simulates a cable tray used on the factory floor and the internal area enclosed by the channel represents the factory floor. Connections on the outside of the channel surrounds are extensions of the PLC card connections arranged in female connections for banana minipins.

The MICA module is formed by an angled wedge structure that facilitates the viewing and operation of commands locally by more than one operator simultaneously. The front panel is colored with bounded areas and connections coded in the following colors: Blue for digital and analog input, Yellow for digital or analog output, Gray for relay isolated connections (24VDC, 127VAC and 220VAC), Red for power supply voltages. + 24VDC, Black for connections to the 24VDC or GND (Ground) source reference potential.

The module structure is metallic, mobile and robust, making it possible to install both in laboratories and commissioning and validation testing in industrial environments on the shop floor for commissioning, validation, demonstration or training.

Installation of emergency pushbutton to simulate danger or interruption of operation. LIST OF FIGURES

Figure 1: MICA1 front view schematic diagram

Figure 2: Side View of MICA

DETAILED DESCRIPTION OF THE INVENTION

The Instrumentation, Control and Automation Module (MICA) was conceived, designed and implemented in the LVAS - System Validation Laboratory of UFMG and in the Applied Electronics and Industrial Process Control Laboratory of CEFETMG. MICA's portable structure, with fully reconfigurable software and hardware, enables testing, experimentation and validation of instrumentation, process control and automation system designs with various sensors and actuators with standardized connections for industrial systems. Tests and experiments can be done in laboratories or near industrial plants.

MICA's design has been detailed in CAD and enhanced with the aid of scale models for space and functionality adequacy. The front of the panel has drawings illustrating its circuits, respecting a predefined color coding for electrical connections, and ease of device handling along with a safe and organized way of working (see Fig. 1).

The module color code is set according to its signal type, which is 24VDC positive power supply (red), power supply reference, negative pole, (black), digital or analog input (blue), digital output or analog (yellow), relay output (gray). Electrical connections are easily constructed and have to be made color-coded so that sensors highlighted in blue are connected to digital or analog inputs also marked in blue. The physical structure with standardized, color-coded channels, terminals, and flexible cables makes it easier and safer to teach or lecture the circuits run by students or training personnel before allowing them to energize during experiments with the system. MICA and its respective subsystems. A Programmable Logic Controller - PLC used may contain digital inputs, relay and transistor digital outputs, analog voltage and current inputs and outputs; communication via RS232 serial port and Ethernet network; 24Vdc power supply and other application-specific modules to be installed in the module expansion area. The PLC is fitted to the panel structure by means of a DIN rail. This rail is extended to the right side of the PLC, allowing the docking of auxiliary modules or other sensors and actuators, allowing the expansion of the inherent features of MICA. The programmable controller gives the panel the configuration and programming features of the software input and output features. The PLC input and output connections are extended to pins arranged in groups to allow for the mounting of various electrical connections using colored mini-banana pins and cables. Connection pin groups are highlighted in color to differentiate analog and digital input and output functions, and non-electrically isolated interfaces. Analog connections can be made both in voltage and current according to industry standards. The cable organization of the connections between the PLC, the sensors, actuators and switches is made in channels that guide the cabling, thus avoiding loops and entanglements in the assemblies. The wedge-shaped metal structure of the panel allows a broad view of the assembly, as well as providing space internally to house electronic circuits and contactors that serve to drive higher power loads such as motors and heaters outside the panel. A three-phase electrical connection is provided on the right side of the module for external power drives for safety and isolation for module front panel operation. External loads are actuated by means of a contactor remotely actuated by the PLC or manually by a pushbutton on the front of the panel.

Three LED beacons simulate a traffic light or generic light actuators.

To simulate a conveyor belt system, an aluminum disc, controlled by a servo motor, is used in which fins of different materials are detected, distinctly detected by inductive, capacitive and photoelectric sensors, arranged around the disc. The fins are numbered and the disk placement referenced for simulating different manufacturing processes or process automation and control.

A siren is used as an output device for sound signaling.

As can be seen in figure 1 and figure 2, the parts and functionality of MICA are:

1. Programmable logic controller - PLC (located at the top of the module representing the Control Room paradigm;

2. Pins for extended PLC digital input and output connections;

3. Cable routing channel for electrical connections. Outlines the area representing the shop floor paradigm;

4. Spinning disk that simulates an integrated manufacturing cell; Removable fins are installed on the periphery of this disk.

5. Discrete sensor and its connections for disc part detection

6. Discrete sensor and its connections for disc part detection

7. Discrete sensor and its connections for disc part detection

8. Pushbutton for manual activation of external loads to the module.

9. Lights

10. Pins for connecting sensor and actuator power supply.

11. Pins for connecting power supply to sensors and actuators.

12. Pins for extended PLC digital input and output connections.

13. Switches for remote and local mode switching 14. Buzzer

15. Insulated pins for extended PLC digital input and output connections.

16. DIN rail for mechanical connection of extra modules.

17.Area for mounting external modules and with additional functionality to MICA.

18. Connections for rotary disc drive.

19. Programmable Logic Controller and external modules mounted on the front panel (side view).

20. Cable routing channel (side view).

21. Non-slip rubber feet for module support.

22. Emergency signal.

23. Emergency Key.

24. Channel holder for storing cables of various sizes.

25. Socket for connection to mains.

26. Side opening for connecting external single and three phase loads to the module.

27. DIN rail for internal mechanical installation of modules and support for future expansions.

28. Contactors1 fuses, protective relays, and power supplies internal to MICA.

29. DIN rail for mechanical module installation and support for future front panel expansions.

30. Translucent protection for viewing internal connections, but protecting direct contact with internal energized circuitry when operating.

Control and Automation System:

The Control and Automation Architecture provided by the module is the traditional PLC plus Supervisory Control and Data Acquisition (SCADA) system in which the PLC performs the direct interface functions of the control system with the process. It is up to the PLC to determine the state of the field switches (open or closed) and the sensor measurements of the process variables by means of discrete and analog input cards. The PLC also acts on the process drive devices, logically opening and closing valves, starting and stopping engines or continuously manipulating valve positioning or engine speed.

The physical connection between PLC and PC microcomputer, where the module operation and supervision software (SCADA) is installed, is made through an ethernet network cable. An operation and supervision application remotely triggers MICA with a basic module user interface screen. The use of a supervisory application allows, besides the friendly operation and supervision of the functionality of the module in remote operation, the storage of measured variables in a database.

All features of the module can be monitored by the operation and supervision application via industrial ethernet or RS232 connection, enabling the user in a didactic, flexible, safe and reliable way to study dynamic process control systems, reconciling aspects of theoretical abstractions with the practice in a typical industrial control and automation architecture.

Sensing and Triggering:

The MICA module has three digital proximity sensors installed on its front, one capacitive ("C" - sensitive to metallic and non-metallic objects), which detects variation in the electrostatic field, an inductive ("I" - sensitive to metallic), which detects changes in the magnetic field, and a photoelectric ("F" - sensitive to reflective objects), which detects reflective surfaces. The sensors have NO- Normally Open and NF- Normally Closed contacts for testing various automation strategies.

Sensors can be actuated manually or by means of test fins installed on the spinning disk on the front of the panel. These fins are of four types as listed in table 1.

Table 1: MICA Spinning Disk Test Fins <table> table see original document page 12 </column> </row> <table>

C: Capacitive; I: Inductive; F: Photoelectric

Safety:

The MICA module has an easily accessible mushroom-mounted emergency button on top of the module that allows quick shutdown of module power manually in case of imminent risk to the operator or module. The safety switch cuts out power to the outputs and inputs, but keeps the PLC energized so that it can detect and track any potential faults.

Usage examples

With a little imagination MICA recreates a number of real-world automation applications such as the advantage of being able to test not only control logic but also interaction with hardware i.e. instruments, equipment and process.

Example 1 - Speed measurement of a rotor: The disk represents the rotor and the plate fins welded to the rotor. The average velocity can be measured by the time elapsed between two successive fin detections. A common application of this strategy is found in belt conveyors where, in the belt tensioning rotor, it is necessary to detect speed drops that indicate possible belt overload or breakage.

Example 2 - Tank Level Control: In this abstraction, the position of a disk fin represents the level of a tank (see Fig. 2). Two proximity sensors, one before and one after the vane, represent level switches (high and low) and the rotating speed of the disc represents the difference between the inlet and outlet flow rates (or the tank fill rate). Level control can be performed, for example, by setting the output flow and making a logical control of the pump status, turning it on when the low level indication and turning it off after high level indication.

Claims (13)

1. INSTRUMENTATION, CONTROL AND AUTOMATION MODULE characterized by comprising: a) Programmable logic controller - PLC (1); b) Pins for extended PLC digital input and output connections (2); c) Channel for routing electrical connection cables (3); (d) rotating disc (4); e) removable fins (4); f) Discrete sensor and its connections for disc part detection (5, 6 and 7); g) Pushbutton for manual activation of loads external to the module (8); (h) traffic lights (9); (i) pins for connection of sensor and actuator power supply (10 and 11); j) Pins for extended PLC digital input and output connections (12); (k) keys for remote and local mode switching (13); I) Audible signal (14); m) Insulated pins for extended PLC digital input and output connections (15); n) DIN rail for mechanical connection of extra modules (16); o) Area for mounting external modules and with additional functionality to MICA (17); p) Connections for drive of the rotating disc (18); q) Programmable Logic Controller and external modules mounted on the front panel (19); r) Channel for the organization of electrical connection cables (20); (s) non-slip rubber feet to support the module (21); (t) emergency signal (22); (u) emergency key (23); v) Channel type support for storing cables of various sizes (24); w) Power outlet socket (25); x) Side opening to connect external single and three phase loads to the module (26); (y) DIN rail for internal mechanical installation of modules and support for future expansions (27); z) Contactors, fuses, protective relays, and power supplies internal to MICA (28) aa) DIN rail for mechanical module installation and support for future front panel expansions (29). bb) Translucent protection for viewing internal connections, but protecting direct contact with the energized circuits inside the panel when in operation (30).