Product category:
Plantwide control
News Release from: IDC - Intelligent Distributed Controls | Subject: Simplicon
Edited by the Engineeringtalk Editorial
Team on 27 April 2004
Control system simplifies project
management
The Simplicon control system enables even the most complicated machine sequences to be broken down into simple, separate control tasks, each task having its own intelligent processor.
The ever increasing size, sophistication and complexity of sorting and handling systems, as stores strive to increase efficiency and offer greater consumer choice, is a constant problem for the OEMs and system integrators (SIs) who build such systems In particular, the growing trend towards larger capacity systems, which increase throughput rates and provide greater flexibility to deal with product variation and changing supply demand, place increased pressure on SIs and OEMs to get things right on time and within budget, often in the face of loose specifications and fiendishly large and complex software programs
This article was originally published on Engineeringtalk on 24 Oct 2003 at 8.00am (UK)
Related stories
Distributed control aids conveying applications
The Simplicon distributed control system can substantially reduce the overall project costs and complexity associated with centralised control systems in conveying applications.
Distributed system breaks down complex control
Simplicon is a novel modular control system claimed to significantly reduce both the complexity and the overall project cost of modern centralised control systems.
In view of these demands it comes as no surprise that, when designing and integrating a control scheme, control engineers prefer to use past practice to minimise risk.
In the case of materials handling and sorting control systems "past practice" for SIs and OEMs translates into a system employing standard programmable logic controllers (PLCs) and motor starters mounted within a central cabinet with point to point cabling to motors and field devices.
In the mid 1980s the emphasis was placed on reducing the cabling costs and installation times of these centralised systems, via the introduction of Fieldbus technologies and PLC remote I/O modules.
However, despite these advances and the partial migration towards decentralisation, the vast majority of installations are still designed around costly, multibay cabinets housing power distribution, motor controllers and rack type PLCs.
By adopting the centralised route, OEMs and SIs are locking themselves into an uncompetitive cost spiral as systems continue to grow in size and complexity.
Further reading
Zigbee products clear the cable clutter
IDC's family of ZigBee products is designed around the company's ZB108 OEM module, which features a complete system-on-chip (SoC).
Mobile tags accompany fridges to the grave
IDC's expertise in mobile data capture is being used for the tracking of waste refrigerators, which are being recycled under the European Directive 2037/2000.
Interface enables PC fieldbus management
Any standard desktop, laptop or single board PC with a USB port can now be used as a node in a P-Net installation.
These costs become evident in the escalating levels of software expertise required, and with the fact that, even for small systems, central software execution programs can exceed 100,000 lines of code.
In addition, the increasing requirements for high-speed sorting and complex algorithms for batch handling, data manipulation and product tracking, means that high-level languages are increasingly being employed.
This, in turn, means costly, top of the range processors with expensive software licences and, probably, specialist communication devices.
As a result of these issues software has perhaps become the major consideration for SIs and OEMs due to its impact on all stages of the project lifecycle from tendering through to commissioning.
One solution to address the software complexity issue, and, at the same time, equip the OEM and SI with far greater certainty in control system specification and manufacture, is an intelligent distributed control system architecture.
By distributing intelligence, a control system is simplified into smaller independent control nodes, communication network traffic is reduced because decisions are being taken locally, and, crucially, project costs are much reduced - anywhere between 20 to 60%, depending on the size and configuration of the system.
As a result, intelligent distributed control architectures provide the ideal solution for such tasks as high and low level conveyor control, materials handling, sorting, palletising, intelligent picking and routing.
There are, of course, many PLC vendors offering distributed control products but these are generally uncompetitive when one considers the separate processor, power and communication modules needed for every section of a conveyor system.
In contrast, modular PLCs with remote distributed I/O cards could be economically viable, but they are a compromise and do not provide the peer-to-peer communications, which are essential for an intelligent distributed architecture, enabling interlocks and sequence signals to be sent between nodes.
The alternative to the compromise of PLCs is IDC's "intelligent" Simplicon system.
UK designed and developed, the Simplicon system enables even the most complicated machine sequences to be broken down into simple, separate control tasks, each task having its own intelligent processor relating to the mechanical subassembly or plant section being controlled.
Once this is achieved, each module is networked via RS485 or Ethernet communications to provide a true multiprocessor system solution, the peer-to-peer system resulting in a more efficient communication network where traffic is reduced as a result of decisions being taken locally.
The key element of the Simplicon system is IDC's multiprocessor Windows- based Simplinet software.
With this IEC61131 compatible package IDC have overcome the cost and dependency on high-level software programming skills and in-depth communications knowledge.
Simplinet is incredibly easy to use and the fact that it is modular eliminates repetition, and the provision of preprogrammed functions provide the control system designer and system user with the benefits of tested designs and proven performance.
Where Simplicon is both different from and superior to existing technology is not in the obvious advantages of reduced cabling costs, or quicker installation times, but in the hidden benefits that extend throughout the whole lifecycle of a project.
By providing a control methodology that is modular in both hardware and software, Simplicon takes out the risks in project management.
It achieves this by fixing the costs of control systems early in a project and by facilitating standardisation of designs and documentation, from initial design proposal through to final commissioning.
What this means for the SI and OEM is that project tendering and estimating can be much more accurately defined.
In addition, bid interpretation, defining an offer and presenting a control solution can be much more easily quantified and qualified.
Finally, if a system needs upgrading or extending at any time this can easily be achieved, in contrast to centralised systems where cabinet space would otherwise prohibit. Request a free brochure from IDC - Intelligent Distributed Controls ...
• IDC - Intelligent Distributed Controls: contact details and other news
• Email this article to a colleague
• Register for the free Engineeringtalk email newsletter
• Engineeringtalk Home Page
Search the Pro-Talk network of sites
