engineering networks and systems.
engineering networks and systems.
Automation of manufacturing process is a part of almost all production fields. The variety of sensors and programmable login controllers (PLCs) minimizes the human participation in processing equipment operation. It minimizes but does not dismiss as the enterprises usually use different technological and engineering systems that cannot be interconnected properly (because of old but not critically worn-out expensive equipment, economic inexpediency of extensive renovation in the moment). Moreover, time-honored approach of “we feel more secure if someone human is there” still exists (but it demands an extra employee). However, automation systems solve many problems and reduce the prime cost of a product or a service.
The automation of pumping stations is a sure choice. Pumping stations may be used for water supply, sewage water pumping, heat supply and warm water supply, transfer and supply pumping of fluids and products. If you have a pumping unit that operates in water supply or other network with alternated of constant load the automatic holding of the rated water pressure or flow in the checkpoint is the best decision. Firstly, you save the electric power. Secondly you prolong the life cycle of the pump and its’ electric motor, and at last you increase the potential and operating reliability of the pipeline system. Moreover, this stage of automation does not need to be separated as an individual centralized control and signaling systems (as pump stations are usually small) but it can be connected to them if necessary. For instance, the pumping unit holds the rated pressure in the checkpoint with the help of frequency converter with feedback from pressure converter. The control engineer just needs to set the required pressure in the converter and the system operates automatically. In addition, if there will be the need to place the control and monitoring of this system in the control room it can be easily done by means of data exchange protocol of Modbus RTU type or other and twisted pair data cable line. Obviously, the automation can be gradual and flexible when it comes to communication capabilities.
It is necessary to mention the role of automation parts in the work of diagnostic and breakdown preventive system. Unlike the scheduled maintenance of equipment this system stops the device (or signals without a stop) when one or several parameters controlled by the system are out of tolerance limits. For example, the temperature sensor of the electric motor winding can be not only contact but also temperature sensitive. Thus, we can set prior light or sound warning in the controller if the temperature of the winding is higher than 70 degrees centigrade and lower than 78 degrees centigrade. The operation department understands that overheating is not critical but it takes place and will take the device out of service for scheduled repair, stress-free and without unnecessary haste. In the same time, it is possible to set time-delay for this or that action for manual or automatic shift to the standby equipment taking in account the physics of the effect.
The core element of the automation system is a programmable login controller (PLC), it is the “brain” of the whole process and the controller of accuracy as well. Controllers may be free programmable in the standard programming languages and have pre-set program for a specific task (ventilation as an example).
The price for PLC boards depends on the controller and sensors manufacturer, PLC input/outputs quantity, its’ communication capabilities. It often happens that Schneider Electric (France) controller may cost almost the same as the controller produced by Raut Automatic (Ukraine). That is why it is necessary to make calculations for the specific task to make the right choice. To feed the controllers and sensors the low voltage is needed (24 V DC). The power units are installed, sometimes – powerful ones, besides there have to be many clamps that make the connection inside and outside the cabinet possible and electric circuits can be connected and controlled while in operation. If the PLC is installed in the same cabinet as the power equipment (circuit breakers under the load, frequency converters etc.) the temperature inside the cabinet has to be maintained at a certain point. That is why the ventilation or heating or even air conditioning system, temperature sensors have to be installed inside the cabinet. If the box is placed in dusty environment or in the place with high or low temperatures, the IP of the shield has to be high. The higher IP the higher the price. All these factors influence the final cost of the device.
Our experts have good experience in production of automation boards for different purposes. We are always willing to go into your technical task and to solve it in the shortest terms and at the highest professional level.