When control system projects and plant breakdowns take longer than expected (which often is the case), the business starts to lose money.
This triggers the involvement of management, trust me, this is not a pleasant situation for everyone involved.
People tend to lose jobs because of this and worst-case scenario, the business can easily lose clients and eventually close down.
One of the critical reasons for this is the lack of Standardization of the control software (Topic for today).
Standardization of hardware is also a factor (procurement of spares, training cost for many different types of products, etc. Topic it is not covered here.
What is standardization?
Standardization is the creation of your control system in object form.
It is the foundation for Digitalization (nobody wants a variation of info from one sensor type installed in various locations). Topic not covered here.
Three levels of standardization:
1. Bottom level
Imagine you have a block for each I/O object type to the plc.
e.g., one block type and one faceplate type for an analog input, one block type for an analog output, one block type for a digital input and one block type for a digital output.
Every time you have an analog input, you use the same analog input block and same faceplate for the analog input. The same goes for an analog output, digital input and digital output.
The block and faceplate type will enable you to see the status and diagnostics of the I/O. It will also enable you (with authority of course) to bypass and change warning/alarm limits and a whole lot more.
2. Middle level
Imagine you have a block for control logic for each object in the plant
e.g., one for block and faceplate type for each variable speed drive (vsd), intelligent relay (simocode), soft-starter, etc.
This will enable you to see the status (ready, running, starting, etc.), diagnostics (cause of stop, missing interlock, etc.) and you will be able to set parameters as required (nominal current, start time monitoring, etc.)
3. Upper level
Imagine combining the bottom and middle level to have a complete object that references a conveyor, guillotine, mixer, etc.
The advantage of reaching this level is:
- The software becomes more transparent for the user and thus easier to use.
- Significant reduction of error sources due to using already proven software
components.
- Minimization of the effort for program creation and commissioning with existing
standard.
- Simplified diagnosis and troubleshooting.
- Clear documentation of modules with defined behavior.
- Avoidance of "parallel engineering" of the same task.
I hope this will benefit many individuals and teams who are looking to advance the vision of their companies and careers.
It may not be beneficial to you, so please pass it on to someone who might or will benefit.
Blessed regards,
Bruce
This triggers the involvement of management, trust me, this is not a pleasant situation for everyone involved.
People tend to lose jobs because of this and worst-case scenario, the business can easily lose clients and eventually close down.
One of the critical reasons for this is the lack of Standardization of the control software (Topic for today).
Standardization of hardware is also a factor (procurement of spares, training cost for many different types of products, etc. Topic it is not covered here.
What is standardization?
Standardization is the creation of your control system in object form.
It is the foundation for Digitalization (nobody wants a variation of info from one sensor type installed in various locations). Topic not covered here.
Three levels of standardization:
1. Bottom level
Imagine you have a block for each I/O object type to the plc.
e.g., one block type and one faceplate type for an analog input, one block type for an analog output, one block type for a digital input and one block type for a digital output.
Every time you have an analog input, you use the same analog input block and same faceplate for the analog input. The same goes for an analog output, digital input and digital output.
The block and faceplate type will enable you to see the status and diagnostics of the I/O. It will also enable you (with authority of course) to bypass and change warning/alarm limits and a whole lot more.
2. Middle level
Imagine you have a block for control logic for each object in the plant
e.g., one for block and faceplate type for each variable speed drive (vsd), intelligent relay (simocode), soft-starter, etc.
This will enable you to see the status (ready, running, starting, etc.), diagnostics (cause of stop, missing interlock, etc.) and you will be able to set parameters as required (nominal current, start time monitoring, etc.)
3. Upper level
Imagine combining the bottom and middle level to have a complete object that references a conveyor, guillotine, mixer, etc.
The advantage of reaching this level is:
- The software becomes more transparent for the user and thus easier to use.
- Significant reduction of error sources due to using already proven software
components.
- Minimization of the effort for program creation and commissioning with existing
standard.
- Simplified diagnosis and troubleshooting.
- Clear documentation of modules with defined behavior.
- Avoidance of "parallel engineering" of the same task.
I hope this will benefit many individuals and teams who are looking to advance the vision of their companies and careers.
It may not be beneficial to you, so please pass it on to someone who might or will benefit.
Blessed regards,
Bruce