SCADA system and features of SCADA Software

In early years of industrial automation, PLC system used to function like black boxes. Once you develop a program in PLC programming software, download the program in PLC System, it used to run for years. Problem with this arrangement was that we never knew what is going on inside the PLC system. Today industrial automation systems come with PLC SCADA software. By using PLC SCADA software combination we can have better monitoring and control of the plant, at the same time we can have access to process information. SCADA system enables plant operators, handlers, engineers, managers to view and interact with the working of entire plant operations through mimics/graphical representation.

PLC SCADA software is loaded on a PC and is connected to various PLC systems and other field devices. SCADA system regularly collects data from the plant in real-time, stores and processes the date, analyses and generates alarms and events and displays information to plant handlers, supervisors and managers and also issues instructions to PLCs on the plant floor.

WHAT is TAG in SCADA System?

A tag database consisting of records are called tags. In the tag database you define the data you want SCADA software to monitor. If you have several machines with similar function and they all require the same tags, you can create a folder called M1 and define its tags. To create the tags for M2 you will have to use duplicate Folder command and specify M2 as the folder name. This creates a folder called M2 containing all the tags that are in the folder M1. Tags can be 3 types: digital, analog and string.

Features of SCADA software

Dynamic Process Graphic: Graphics/mimics developed in SCADA software should resemble the actual process equipment. SCADA software generally have good library of symbols for developing the mimics as per requirement. Once the operator sees the SCADA screen he should understand what is going on in the plant.

Real time and Historical Trend the trends play very important role in SCADA Software. Whenever any production batch fails or the plant trips, historical trend data helps production managers/handlers of the plant in analyzing the causes.

Alarms warn the operator when something goes wrong. An alarm indicates that process has stopped operating within acceptable, pre-defined limits or it has broken down. Alarms have important role in PLC SCADA industrial automation. Generally SCADA System has alarm like temperature should not cross 70 deg or lever should be less than 50%, So if the parameter goes beyond Alarm State the operator should be informed with the visual or audio alarm. Alarms are most important part of plant control operations, the operator must know instantly when something goes wrong.

Recipe Management Most of the SCADA software come with this feature. This feature is useful in plants manufacturing multi products. You just have to load the recipe of that particular product, production will be as per the recipe. There are many plants in India today, who receive recipe from their parent plant overseas, days production is based on the recipe.

Security is very critical feature in PLC SCADA Software. You can allow certain access levels to the operator, process handlers, engineering & maintenance dept. for example operators should be able to only operate the system, he should not be allowed to change the application. The design engineers should authority to editing/changing the application.

Device connectivity Today there are scores of manufactures of PLC SCADA Software. SCADA software should be such that it is easily connected to all types of hardware/software. Since a plant/manufacturing unit may have PLC SCADA from multi brand. The best SCADA software is the one which is easily connected to all PLC SCADA brand of multiple manufactures.

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Forces driving innovation in Industrial Automation

We are compelled to thinking about where the automation industry used to be and the forces that will be shaping it in the future.

Past Innovations

In the last few years there has been Industrial automation and control system technological shifts that significantly impacted manufacturing productivity and efficiency:

• Numerical Control
• PID Control
• Distributed Control System (DCS)
• PLC Control systems
• SCADA systems
• Industrial Networks (i.e. Ethernet, controlnet, DeviceNet, Modbus, Profibus;)

During each innovation, there has always been resistance by suppliers to embrace new technology. Wide adoption of Microsoft Windows to replace proprietary operating systems had a significant impact on the industry. Traditional industrial automation vendors resisted the use of Microsoft Windows for a wide range of reasons. It was the early adopter Wonderware that used Windows to create the modern HMI. Wonderware was founded in 1987 for Windows-based Human Machine Interfaces (HMI). Idea was that operators monitoring factory operations would be more productive if they use a machine that was fun and easy to use. Automation users found Wonderware to be significantly more effective than any other offering on the market. Over a period of time almost all principal automation product manufacturers switch to Microsoft platform.

Internet of Things (IoT)

The impact of Internet of Things (IoT) technology on industrial automation control system is going to be significant in the days to come. Technology is driving for high-performance low-cost processors, low-cost sensors, analytic software, vision camera systems, cloud platform and high performing distributed architecture. This development is going to lead to lower cost and higher performance industrial automation systems.

Based on the past technology adoption pattern it will take time for traditional industrial automation suppliers to incorporate these technologies into their products. IoT technology is going to enable innovation in industrial automation control products, to be developed and commercialized by innovative companies.

The growth of more powerful IoT technology at lower costs is explained by Moore’s Law. The law predicted the number of transistors in a given integrated circuit size doubles approximately every two years thereby increasing processing power and speed.

Forcing Factor - Operational Technology (OT) & Information Technology (IT) Integration

Tighter integration of OT & IT is recognized for improving manufacturing efficiency, enhanced quality, and better flexibility. It is refreshing to see innovative industrial automation suppliers are already providing building blocks to accomplish the vision of the connected enterprise. Industrial Automation is becoming part of the business information loop.

OPC UA technology provides an efficient and secure infrastructure for communications from sensor to business enterprise computing for all industrial automation systems in manufacturing, SCADA, and process control. 

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The future of Industrial automation PLC SCADA technologies

Every industrial automation PLC SCADA project starts with the familiar process of counting I/O, selecting vendors, laying out PLC chassis, and distributing requests for quotes. And finally you are commissioning a system built on general standards, repeating the same mistakes as previous systems.

The conversations also repeat during bid review or negotiation meetings when someone points out inconsistent or outdated standards. Technology is changing so fast, and the past few years have brought technical advances that have breathed new life into Industrial automation groups and started great discussions around what the future holds. There is still a lot of work to be done.

Virtualization is a great example. Early adopters saw the benefits, and news spread like wildfire. As SCADA (supervisory control and data acquisition), manufacturing execution systems, and historian capabilities increased, so did the need for processing power, and virtualization was the perfect answer. Companies now manage sites globally from central locations and deploy engineering resources via remote connections without travel. Replacing broken or failed operator and engineering workstations is as simple as connecting power, video, and network cables. Virtualization is now commonplace in Industrial automation domain. And many are asking what is next. Things like faster scan rates, increased memory, tougher security, and unified communication protocols are great.

The next big thing is waiting to happen. The Industrial Automation technology exists, and it is our job as automation professionals to help push, innovate and stay ahead on these advancements, while pushing industrial automation PLC SCADA vendors to reinvent their product portfolios. Industry has become more demanding asking for virtualized controllers and solution with mobility. but they are easily feasible with existing technology. The success of our industry depends on it.

HMI/PLC SCADA industrial automation applications have already secured their place as key components for any smart factory, collecting and analysing data from machinery on the production floor, right up to traditionally IT-focused applications. Humans by nature are reluctant to give up control; however, fully automated facility does not mean a complete end of human interference on the factory. Considering the huge focus in industrial automation / automated equipment and intelligent HMI/PLC SCADA software, it is important that manufacturers invest in employee training, enabling talented engineers from industrial automation domain to focus on important tasks. 

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Smart Home a future reality

Like smart phones, smart homes is going to creep into your life. A few years down the line, when you buy appliances you will be faced with surveillance systems. To paint your house you will find electronics dissolved in the paint, to maintain the temperature. To renovate your house you will find that doors and windows are no longer simple wooden structures but electronically reinforced super smart security systems. In short you will no longer find devices that you have to operate but will end up with house full of devices that talk to each other, manage themselves and ultimately keep you safe and comfortable, too. 

Smart thermostats, smart power sockets, energy management systems, connected home monitors, automatic garden sprinklers, HVAC Systems, electronics surveillance systems, connected slow cookers, drones that check who is at the door and more. 

Surveillance and Security systems which mainly deal with communication and collaboration between sensors embedded in a smart home is going to be reality. As of now you use alarm clocks, in future a smart alternative could automatically judge how long it takes you to get ready for work and wake you up accordingly considering the traffic on your route. Another  interesting scenario is that of multiple homes connected together to form a smart neighbourhood that will have improved security systems, surveillance systems, energy efficient systems, building automation systems, HVAC control systems, fire detection & alarm systems, electronics physical security systems, access control systems CCTV surveillance system.

Some wonderful futuristic technologies, right from the door handle. When you arrive at the house today, you find is a snazzy metallic sheet with small peephole in it. There is no handle or lock visible on the door. But as soon as the biometric camera (What you thought was a peephole) has scanned you and recognised you as authorised person, a door handle pops out of the sheet, as soon as you touch the handle to pull, it quickly checks your temperature and heart rate to ensure you are okay. If there are any updates it will be communicated to you; such as your child is yet to return from school, you have received a courier and so on. You can also check the whereabouts of other family members as door syncs to their schedules too.

Let us step into the kitchen. Based on the stock inside the fridge and depending on the health parameters collected by the door handle and other connected devices being used by the rest of your family, this smart device gives you the suggestions what to cook. Once menu is decided, step by step cooking instructions are displayed on kitchen counter.

Drones will be used as surveillance system to protect your home. They can hover about and can be controlled by smart phones.

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A huge opportunity waiting ahead for Embedded system engineers

Recent market survey findings clarify that mostly used micro controller is ARM. This is 32 bit Micro controller comes in different package. ARM Micro controller Processor is used in almost all of the smart phones, ARM controllers are becoming a rage in the market . ARM system-on-a-chip technology with multiple cores is working more efficiently in next gen mobile processors. Low in cost and high in features made them the first choice for the developers. ARM Micro controller with Core Future and is going to be for a joyful ride to the world of 32 bit processors.

There are many industries which work on the ARM Micro controllers, there are job vacancies in both the software and hardware domain but industries prefer fresher with hands-on skill or engineers having undergone embedded system training, AVR /ARM micro controller training.

Future Scope:

Samsung has expanded its facility in Noida that produces Mobile Phones, Refrigerators and LED Televisions. Lava international invested Rs 2,615 Cr in two units to generate capacity of 18 million electronics devices per month. These facilities will also have inhouse hardware research and development laboratories. There is going to be a huge scope for Embedded systems design engineers. Freshers who are trained on AVR & ARM Micro controllers will have preference.

The company plans to hire 64,000 direct and employees for the two plants. Karbonn & WWT Co which are into mobile design, manufacturing & supply are joining hands with an aim to boost local manufacturing. This will give boost to local manufacturing & help in local employment. Make in India vision will also get boost.

Carrier scope:

Lava,Karbonn,Samsung,Intex,Panasonic,LG,Sony,Philpes,Micromax,Intex,Dell,Lenovo etc.

This is going to create huge demand for Embedded Engineers, Electrical Engineers, Electronics Engineers with knowledge of micro controllers, embedded system 

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