The difference between the three major control systems of DCS, PLC and FCS 

We already know that FCS is developed from DCS (Siemens 6ES7322-1HH01-0AA0 SIMATIC S7-300 Digital Output Module)

and PLC(Allen Bradley 1785-L60B Enhanced Ethernet Controller). FCS (B&R X20CS1070 Communication Module)not only

has the characteristics of DCS and PLC, but also takes a revolutionary step. 

At present, new DCS and new PLC have a tendency to move closer to each other. The current DCS has a strong sequence

control function; and the new PLC is not bad in handling closed-oop control, and both can form a large network. The scope of application of DCS and PLC has a great overlap.

1. Main points of difference

1. DCS (Siemens 6ES7407-0KA02-0AA0 SIMATIC S7-400 Power Supply)

The key to the DCS system is communication. It can also be said that the data highway is the spine of the distributed control

system DCS. Since its task is to provide a communication network between all components of the system, the design of the

data highway itself determines the overall flexibility and security. The media of the data highway can be: twisted pair, coaxial

cable or fiber optic cable.

The relative strengths and weaknesses of a particular DCS system can basically be understood through the design parameters

of the data highway.

TO BE CONTINUED...FOR more information, contact with Vivi (sh_plc@163.com).  

With the continuous development of industrial automation, the industrial control machine industry is also growing.

How  to create a more accurate production control system is one of the current hot topics in the industry.

● Embedded industrial controllers: small size, low power consumption, good heat dissipation, high integration, suitable

or applications with limited space.(B&R X20DO4332 Digital Output Module)

● Wall-mounted industrial controllers: easy to install, take up less space, beautiful and generous features, suitable for

offices, production lines and other applications.(Allen Bradley 1746-A4 4 Slots Chassis)

● Desktop industrial controllers: easy to operate, performance, strong expansion capabilities and other characteristics,

suitable for applications with high performance requirements.(Siemens 6ES7322-1BL00-0AA0 SIMATIC S7-300 Digital

Output Module)

● All-in-one, anti-notebook, ruggedised portable and server products provide more comprehensive solutions for different

application scenarios.(B&R X20CP1485-1 CPU I/O Processor)

By choosing different types of industrial computer products, you can achieve accurate matching of the needs of different

applications, so as to create a more accurate and efficient production control system.

● In the production process, when you need to collect and process the data of each link in order to accurately control the

production process, you can choose embedded industrial controllers. Embedded industrial controllers have efficient and

stable data acquisition and processing capabilities, enabling precise control of the production process.

● In the office or production line and other occasions need to integrate and co-operate with multiple devices to achieve

efficient operation of the production process, you can choose wall-mounted industrial controllers. Wall-mounted industrial

controllers have good equipment integration and synergy capabilities, and are able to achieve close connection between

equipment.

●In applications with high performance requirements, you can choose desktop industrial controllers or servers. Desktop

industrial controllers and servers have a more efficient and stable operating environment and can provide more accurate

production control.

The mentioned parts are for sales now, if you need it, contact with us. --

Vivi (sh_plc@163.com).   

The model parameters can be continuously identified based on the input and output data of the object, a process known

as online system identification. As the production process continues, the model becomes more and more accurate and

closer to reality through the online debate. Since the model is constantly being improved, it is clear that the control action

based on this model synthesis will also be constantly improved. In this sense, the control system has a certain adaptability.

For example, (Siemens 6ES7322-1BL00-0AA0 SIMATIC S7-300 Digital Output Module)when the system is designed,

the initial information on the characteristics of the object is lacking, so the system may not perform well

when it is first put into operation, but after a period of operation, through online identification and control,(B&R

X20CP1485-1 CPU I/O  Processor) the control system gradually adapts and eventually adjusts itself to a satisfactory

working state. For example, the characteristics of some control objects may change significantly during operation, but

through online identification and change of controller parameters, the system can also gradually adapt.

Conventional feedback control systems have a certain ability to suppress changes in the internal characteristics of the

system and the influence of external disturbances, but because the controller parameters are fixed, (Allen Bradley

1762-IQ16 MicroLogix Input Module)when the internal characteristics of the system change or the external disturbances

change by a large margin, the performance of the system （Siemens 6ES7321-1FH00-0AA0 Digital Input Module) often

decreases significantly, or even is unstable. Therefore, adaptive control is appropriate for systems with a wide range

of object characteristics or disturbance characteristics, while requiring frequent maintenance of high performance specifi-

cations. However, it should also be noted that adaptive control is much more complex and costly than conventional feed[-

back control, and is therefore only considered when the desired performance cannot be achieved with conventional feed-

back.

The interested persons of mentioned parts may relate with me, price liberally. --

Vivi (sh_plc@163.com).   

PLC technology, as an important technology in modern industrial control, is widely used in all walks of life and in all aspects

of production, and has received widespread attention and importance. Along with the depth of the application field, the

price of PLC systems is becoming more and more the focus of attention, effectively controlling the cost of the system will

greatly promote the popularity of this technology. Combined with the application of practice from the hardware and soft-

ware wo spects of reducing the cost of the PLC system, introduced some design skills, and with the principle of wiring dia-

grams and adder diagrams in different forms to make specific analysis, these skills in the application of PLC system, has a

good practical value.

First, the need to reduce costs

PLC as a new, universal automatic control device, with strong functions, high reliability, flexible and convenient to use, easy

to program and industrial environment adaptability and many other characteristics. Therefore, in industrial automation,

mechatronic and traditional industrial technology transformation and other aspects of the application is becoming more

and more  widespread, has become one of the three pillar of modern industrial control.

With the continuous improvement of PLC products and the development of network technology, PLC in the field of produ-

ction has also started to develop in the direction of networking, and a large number of PLCs are used in various aspects of

enterpriseproduction; in this context, the price of PLC products and the cost of the control system have become the focus

of attention of enterprises, which will also fundamentally affect the promotion of the application of PLC technology; based

on this, this paper provides some simple design techniques that can To a certain extent, this article provides some simple

esign techniques that can reduce costs and promote the widespread use of PLC.

In the actual use of PLCs, the cost of I/O points takes up a lot of money, and the average price of each point of a current PLC

can be hundreds of dollars, with imported models costing up to a thousand dollars. Reduce the number of I/O points

required is the main measure to reduce the cost of the system hardware, in most cases, the object to be controlled by the

output points less than the input points, to achieve the control task requires more detection points, or the need to operate

more buttons, so that in the selection of the number of PLC output points easier to meet the requirements of the input points

may not be easy to meet.

Therefore, the reduction in the number of I/O points is mainly in reducing the number of input points, if you can reduc the

overhead of input points, you can well reduce the cost.

The below PLC parts will you need?  Contact with Vivi (sh_plc@163.com).  

B&R X20AO2632 ANALOG OUTPUT MODULE

Siemens 6ES7221-1BH22-0XA8 SIMATIC Digital Input EM 221

Allen Bradley 1762-OW8 8 Point VAC/VDC Relay Output Module,

Siemens 6ES7541-1AB00-0AB0 SIEMENS S7 1500 Communication Module

In the Mud mix Silo equipment, if it is necessary to replace the Siemens 6ES7135-4GB01-0AB0 electronic module, the following solutions and disadvantage analysis can be considered:

Alternative solutions and disadvantages

Simplified version module of the same series (such as 6ES7135-4GD00-0AB0)

The number of channels in this module may decrease, resulting in reduced control flexibility and requiring additional expansion of modules to meet multi-channel requirements, increasing costs and system complexity. In addition, its cycle time may be extended to more than 2ms, affecting the real-time control accuracy of the mixer.

Rockwell like modules (such as 1769-OF2)

Communication with Siemens PLC through an adapter may introduce communication delays or configuration conflicts, reducing system stability by 12. In addition, the protection level of Rockwell modules (such as IP20) is usually lower than the industrial grade protection design of Siemens original modules, with a higher failure rate in dust and vibration environments.

summarize

Although alternative solutions can reduce costs, they generally have problems such as poor compatibility, reduced control accuracy, and increased maintenance difficulty, which may affect the stability and production efficiency of the Cement silo for liquid mud machine. If replacement is needed, it is recommended to prioritize the high-end models of Siemens in the same series (such as 6ES7135-4MB02-0AB0) to minimize performance loss

Installation procedure

The 6ES7315-2AH14-0AB0 is a CPU module of the Siemens S7-300 series. To install it in an air-cooled rectifier control system, first ensure that the rectifier is de-energised. Carefully insert the CPU module into the standard DIN rail, which is usually installed at a suitable position in the control cabinet, and pay attention to aligning the slot when inserting it to push it in smoothly, and then fix it with screws or clips to ensure that the module is stable. Next, connect the power supply, input/output signals and other cables according to the wiring diagram, and make sure the connections are secure and avoid short circuits.

Role

In the air-cooled rectifier system, the CPU module plays the role of core control. It receives signals from the rectifier sensors (e.g. temperature, current and voltage sensors) and performs rapid calculations and analyses of the data. Based on the preset control strategy, it can accurately adjust the operating parameters of the air-cooled rectifier, such as adjusting the fan speed for efficient heat dissipation and controlling the rectifier's output voltage and current to ensure stable and reliable operation. At the same time, it can also communicate with the host computer to achieve remote monitoring and management.

The railway company adopts Siemens 6ES7414-4HJ04-0AB0 module, mainly because as the core component of Siemens S7-400 series PLC, it has high reliability, redundancy fault tolerance and powerful real-time control function, which is suitable for the railway automation scenarios that are complex and have very high requirements for safety. Specific features and advantages are as follows:

1, high availability and redundancy design

The module supports fault-tolerant configurations (e.g., S7-400H system). Through synchronous operation of dual CPUs and redundant I/O configurations, the module ensures that the system can continue to work in the event of a single point of failure and avoids interruptions in railway operations due to equipment downtime. For example, in train signal control or dispatching systems, the redundant design guarantees the continuous execution of key commands and significantly improves system stability.

2, Powerful processing power and multi-tasking support

The module is equipped with a high-speed processor (bit processing speed up to 18.75ns), supporting multiple computing functions, which can assign signal processing and communication tasks to multiple CPUs for parallel execution, meeting the high requirements of real-time and multi-tasking in railway systems. For example, complex operations such as track signal monitoring, train position tracking and dispatching instruction issuance are handled simultaneously.

3, flexible communication and scalability

The integration of multiple interfaces (e.g. PROFIBUS DP, PROFINET) supports efficient communication with distributed I/O devices, sensors and upper monitoring systems, which facilitates the construction of railway automation networks. In addition, the modular design allows flexible expansion of the system scale through the expansion of racks and interface modules, to adapt to the needs of railway line upgrading.

4, harsh environment adaptability

The module adopts fanless design with IP65 protection level and high vibration resistance, which can operate stably in the harsh environment along the railway line (e.g. high dust and temperature fluctuation). Its anti-interference design (such as isolated power supply and filtering technology) can effectively inhibit electromagnetic interference and guarantee the accuracy of signal transmission.

7114-NHR-147 ebmpapst perfect fit for ABB inverter

Installation steps:

Prepare for power failure: switch off and discharge the ACS800 power supply to ensure safe operation.

Remove the old fan: Remove the fixing screws and power connector of the original fan and take it out gently.

Fit check: check whether the mounting holes, size (usually 172×150×55mm) and voltage (24V DC) of 7114NHR-147 are compatible with ACS800.

Installation fixing: Align the new air blower to the cooling duct and fasten it with screws to ensure no vibration loosening.

Wiring test: Connect the power cable to the corresponding interface of the inverter control board, and observe whether the fan steering and speed are normal after power on.

Advantages of 7114NHR-147 ebmpapst:

High-efficiency heat dissipation: optimised blade design, air volume up to 230m³/h, significantly reducing the temperature rise of the IGBT module and prolonging the life of the inverter.

Low noise operation: Adopting ball bearing and dynamic balancing technology, the noise is lower than 55dB, suitable for quiet environment.

Long life design: IP54 protection level, high temperature and dust resistance, MTBF (Mean Time Between Failure) over 60,000 hours.

Strong compatibility: designed for ACS800 duct structure, installation without modification, plug and play.

Energy-saving and stable: power consumption is only 28W, supports PWM speed regulation, intelligently matches the heat dissipation demand, and reduces energy waste.

1.High reliability and safety integration

The module supports the fail-safe function (Safety Integrated), which enables safe communication through redundant architecture and PROFIsafe protocol, and is suitable for signal processing in hazardous areas, ensuring stable operation of the BOP system in harsh environments such as high temperatures and high pressures, and avoiding safety accidents caused by hardware failures.

2.Multi-Channel and High Load Capacity

The module provides 16-channel digital outputs, supports 230V AC or 24V DC load voltage, and can switch up to 3,600 times per hour to meet the frequent control needs of BOP systems for actuators. Its long-life design further guarantees continuous operation in industrial scenarios.

3.Flexible Expansion and Compatibility

S7-300 series 6ES7322-1HH01-0AA0 module, it can be seamlessly integrated with the main controller via PROFIBUS or PROFINET bus and supports distributed I/O architecture (e.g., ET200M), which facilitates the distributed layout of the BOP system in complex plants. In addition, the modules support hot-swapping and online configuration modifications, reducing maintenance downtime.

4.Easy Diagnostics and Maintenance

The module is equipped with LED status indicators, which can display input/output signals and fault information in real time. Combined with the diagnostic function of SIMATIC STEP software, the module can quickly locate the problem and improve the maintenance efficiency of the BOP system.

X20 analog input module x20ai4622. with 4 inputs, ±10 V or 0 to 20 mA / 4 to 20 mA, 13-bit.

x20ai4622 with converter resolution, configurable input filter

x20 ai 4622 accessories with: X20BM11(X20 bus module, 24 VDC keyed, internal I/O power supply

connected through)

X20BM15 (X20 bus module, with node number switch, 24 VDC keyed, internal I/O power supply

connected through)

Terminal blocks: X20TB12 (X20 terminal block, 12-pin, 24 VDC keyed)

Parameters:

B&R ID code is 0x1BAA

Status indicators is I/O function per channel, operating state, module status

Bus is 0.01 W

Internal I/O is 1.1 W  

Input is ±10 V or 0 to 20 mA / 4 to 20 mA, via different terminal connections

Input type is Differential input is

Voltage is ±12-bit

Current is 12-bit

Conversion time is 400 μs for all inputs 

Voltage is 20 MΩ 

Current is <400 Ω

Voltage is Max. ±30 V

Current is Max. ±50 mA 

Input filter is Third-order low-pass filter / Cutoff frequency 1 kHz  

Gain is 0 to 20 mA = 0.08% / 4 to 20 mA = 0.1% 

Offset is 0 to 20 mA = 0.03% / 4 to 20 mA = 0.0375%  

Insulation voltage between channel and bus is 500 Veff 

Electrical isolation is Channel isolated from bus  

Horizontal mounting orientation is -25 to 60°C

Vertical mounting orientation is -25 to 50°C 

Operation is 5 to 95%, non-condensing

Storage is 5 ~ 95%, non-condensing

Transport 5~ 95%, non-condensing 

Order 1 x terminal block X20 TB 12 separately.

Order 1 x bus module X20 BM 11 separately.

Pitch is 12.5+0.2mm

Pls contact with Vivi for more informations of this part (sh_plc@163.com)