Kiran GS, a solution architect at Bosch, recently discussed the role of Programmable Logic Controllers (PLCs) and Supervisory Control and Data Acquisition (SCADA) systems in industrial automation. With over 20 years of experience, Kiran highlighted their evolution and significance in both academic and professional settings.
Kiran talks about positioning of PLCs and SCADA within the automation pyramid, as defined by the ISA 95 standard. This pyramid outlines different levels in manufacturing and industrial sectors, divided into Operation Technology (OT) and Information Technology (IT):
- Field Level: Includes devices like motors, valves, and sensors.
- Control Level: PLCs manage and monitor processes based on inputs from the field.
- Supervisory Level: SCADA systems and Human-Machine Interfaces (HMIs) provide monitoring and control.
- Planning Level: Manufacturing Execution Systems (MES) handle workflow and reporting.
- Management Level: Enterprise Resource Planning (ERP) solutions manage resources and logistics.
PLCs
PLCs are programmable devices that control industrial equipment based on inputs from sensors and outputs to actuators. They operate on a scan cycle and are programmed using languages like ladder logic and structured text. Major manufacturers include Siemens and Allen Bradley.
SCADA
SCADA systems offer high-level monitoring, data acquisition, and control, interfacing with PLCs and other systems. They record events, manage alarms, and enable real-time decision-making. SCADA software solutions include integrated PLC systems like Siemens’ S7 and WinCC.Communication ProtocolsProtocols like Modbus, EtherCAT, and OPC UA are crucial for communication between PLCs, SCADA, and other devices across different levels.
Transformations and Trends
Kiran discussed how PLC and SCADA technologies are evolving:
- IT/OT Convergence: There’s a growing integration of OT and IT systems.
- Smart Devices: Devices with connectivity are transforming automation.
- Digital Twins: Virtual replicas of physical machines are becoming common for simulation and commissioning.
- Edge Analytics: PLCs are evolving to handle local analytics with more powerful architectures.
Kiran also outlines several key roles like Automation Engineer, IoT Specialist, Project Manager in the field. Kiran concluded that industrial automation offers a dynamic career path where individuals can gain expertise in a wide range of areas, from traditional PLC/SCADA systems to the latest innovations in IoT and digital twins.
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