直至最近,控制制造系统演化可描述为缓慢稳定进度。 控制器变强、网络变快和强健、操作器接口反应能力提高、驱动器增加特征并提高效率,传感器提高精度,但变化是增量累积化的,而不是大规模干扰性在这种气候中,选择升级遗留控制系统主要是避免故障函数。 如果替换组件和支持仍然随时可用,则故障延长故障风险最小化部件支持减少,延长停机率上升的风险。归根结底,每个控制系统都达到临界点,单故障或停机率事件会对生产产生不相称的影响,从而主动升级或替换系统是有道理的。然而,技术升级、特征增量或架构变换很少得到考虑,因为新选项大都功能相似于正在替换的东西。
相形之下,近年来制造自动化世界正与新技术、新思想和新软件交织在一起。创新环境为制造商提供新的可能性,特别是当他们采纳4.0原理时。 提升和/或更新控制系统的决定曾以降低风险为基础计算现在它也包括评价和权衡新特征和选项
运行良好15年或15年以上的机器可能从PLC、HMI和驱动器升级获益,但可能通过更多年。然而,万一设施正在引进新边缘连通技术并创建所有资产商业智能仪表板呢?新控制系统配有升级网络,包括VLAN从机器网络分离商业智能网络,可以解决这两个问题。同样的控件现代化项目现在可以单投资解决两个问题
现有的CIP滑动可能完全可用,但控件可能不再满足数据完整性和记录保存的要求。 更新对SCADA或MES系统整合以添加审计轨迹和电子签名可与新的AI工具合并开发更高效高效进程参数
A tank farm and transfer system may be performing adequately, but maintenance has noticed that drives and motors are being replaced more frequently. Upgrading to modern VFDs with advanced diagnostic capabilities and condition monitoring may not have the ROI to justify a project based on drive failures alone. But could that same project be combined with an energy usage monitoring and reduction initiative or added to a plan to add new a IO Link sensor network to monitor levels, temperatures, and flow? The additional diagnostic data could allow maintenance to predict failures rather than react to them and the automatic device configuration capabilities of the new hardware could reduce mean time to repair. New controls may also allow secure remote access, enabling all departments to more effectively operate and maintain the equipment.
The goal when looking at control systems modernizations is maximizing return on investment, and that hasn't changed. What has changed in today's environment is the number of new variables that can be added into the equation. Advances in traditional controls hardware along with new technologies that bring additional data and insight from the manufacturing floor can be incorporated simultaneously. Additional performance data can be gathered at the same time legacy hardware is life cycled out. New tools to monitor and improve processes can be implemented alongside updates required to meet new regulations. New user authentication and security can be implemented at the same time as an operating system is updated on a server. Downtime risk can be reduced and system performance can be improved.
不必害怕外想对控件系统实现现代化。你甚至可能没有意识到所有工具来增加设备进程的价值
