SCADA – Supervisory Control and Data Acquisition

A Closed loop control system has a Sensor-Controller-Actuator. The Bimetal Thermostat has all the three in the Bimetal itself. The Sensor, the Relay Contact and the Intelligence. This is Process Control when implemented to control the temperature in a Bakery Oven.

This leads us to Sensors-Transmitter-Controller-Outputs-Actuators. Where each is an independent electronic/electrical component of an entire Process Control system. The Process could be Temperature, Pressure, Speed, or Level.

Industrial Automation encompasses many such Process Control Systems to form a Engineered System Solution for an Entire production line with different stages and process types.Visual SCADA

At the machine end, the control has to be real time and highly reliable, dedicated controllers both Analog and Microcontrollers based are used. Analog as a fallback/override/trip or backup controller in case Embedded system gets stuck/fails.

These controllers or transmitters also send the data of the process back to a center control panel room. The actuators and outputs also have an override from the control panel. Sometimes Intelligent controllers at machine end can be remotely tweaked/tuned by Control room. This is possible due to Embedded systems and Flash., It also can pose problems if misused. Using SCADA such networking of these process control systems and Monitoring, Tweaking, Data Collection and Analysis is possible.

Come Internet or Web and Wireless, the scenario changes entirely. The Control room stays where it is, the Tablets can Access and utilize the SCADA and entire plant at the machine end also. The Control room can be carried around with limited access. This evolves further to that extent that an expert engineer can check the status of the Product Line from any Web Browser and suggest remedial actions to the others at the factory. He can even see the status on mobile devices. Now study the Resources below.

Red Lion Controls – HMI and Process Control – HMI operator interface panels for PLCs, motor drives.

Sielco Sistemi – Winlog Pro is a SCADA/HMI software package – TCP/IP Client Server support, Intranet/Internet architecture.

See Some Industrial Grade SCADA Solutions here

Learn about SCADA by trying out these –

wSCADA – Internet SCADA – Office Factory Integration – Online Automation

Industrial Process parameters, production flow or work status, material offtake, processing of products, incoming inspection status and quality process monitoring. All these need to be interfaced with the ERP and access to Mobile devices like Smartphones and remote Computers provided. This helps smooth micro management of a industry. Some Interfaces may have supervisory control and others just graphs and progress charts. Depending on the person and his work or machine area.

The data and presentation of complex data (by graphs and charts) enhances analysis and timely decision making. Then these solutions will be productive, and be an asset to an existing system. To ensure that; software or webware developers have to be supported by the domain experts having decades of hands on experience on the shop floor. Else; if it is built on theory and some statistics, the result may appear good and work well for small or standard configurations, but in demanding, changing, real life scenario, it may fail to deliver the best.

WebSCADA – Automation Systems – Process Control, Historian, Event Alarm. WebSCADA provides automation platforms on the Internet.

SCADA software for industrial control systems – WebAccess supplies communications drivers that enable personal computers to communicate with automation hardware.

NetBiter – Monitoring and control through web pages – Monitor and control over the Ethernet using web pages.

Piezoelectric Energy Harvester – V20w

Converts normally wasted mechanical energy in the form of vibrations into usable electrical energy. It uses the piezoelectric effect to generate energy from Vibrations.

Piezoelectric Energy Harvester - V20w

Piezoelectric Energy Harvester – V20w

Some sources are Machinery in Oil and Gas drilling to refining. Machines in Industry and Manufacturing. Wind, Tide, streams also can be harnesses with small fixtures, jigs or devices for vibration sensor arrays.

Applications – Wireless Sensors and small instruments need a way to recharge their lithium cells or even supercaps. Using solar and vibration harvesting, enough power can be derived to power efficient electronics. Recharge small computers and tablets.

From – Mide Technology

They are specialists in smart engineering materials technology. They create state-of-the-art solutions to uncommon engineering challenges. They are also a Engineering Service and design, develop, and test a turn-key custom prototypes.

Complete Distributed Process Control System

Training Demo jig panel set that uses the DCS process management package, DeltaV of Emerson.

Complete Distributed Process Control System

Process Control : Educational Equipment

Here you can see a scaled down version of the real thing, these are ways Paper, Oil and some Materials are processed in Big Factories. Study the control of processes like Level, Flow, Temperature, Pressure and the needed Actuators used to monitor and manage a stable multi-loop system.

Process Automation is needed to ensure quality of the output and safety of plant and environment. The most important thing is to make it energy efficient.

Energy and Power Measurements

To make an analog design using log amps or multipliers, discovercircuits – four-quad is good for learning. Using a uP for math is better. Look at these links below. Build a Power Meter ! The Metrics for Going Green is with a Energy/Power/Watt meter.

enerjar - diy power meter

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