Industrial Control Systems

Industrial Automation is Nothing Without Finely Tuned Control Systems

Midwest Engineered System’s high-performance automation solutions make connecting your machines, data and people simple. MWES industrial control systems provide greater flexibility, increased productivity, less risk and lower costs by visualizing and running processes with state-of-the-art operator interfaces, keeping critical systems up and running, and leveraging the latest functional and process safety systems.

As an automated production line integrator, MWES understands the industrial sector’s need for high-quality, effective automation control systems is becoming increasingly apparent. The right industrial automation control systems can create new paths for organizations to grow and become more interconnected.

The goal of industrial control systems (ICS) in automation is to integrate functions and processes between industrial machines, equipment and devices within manufacturing plants. With automation control systems, repetitive tasks can be easily handled while other resources are used to optimize industrial production-level processes. This capability will cover repetitive tasks such as the creation and maintenance of batch information records, batch changeovers, the creation of schedules for periodic machine maintenance and many other tasks.

Automation control systems can also be used to streamline the process of scaling a plant’s production up or down or to ease the process of incorporating new products into a plant’s production line. Whether the automation control system is a robotic, manufacturing machine or assembly line system, there are many ways to make each of those systems more efficient and profitable through better automation control systems.

Advanced communication and data transmission for industrial automation control systems depends on smart devices, sensors on equipment and data security measures. These automated actions could allow the plant’s production levels to be scaled automatically based on the most up-to-date collected distribution channels and sales information. Another example would be machines moving from one batch to the next batch without interruption.

Benefits of Automation Control Systems

There are a number of benefits for organizations when they integrate automation control systems into their manufacturing plants.

Greater accuracy – Larger amounts of data can be collected. This can lead to extensive gains in terms of both individual product and batch traceability.
Integration – Automation control systems can create greater cohesion between the plant and supply chains, research and development, sales, compliance processes and other business sectors within an organization.
Resource efficiency – With fewer resources needed for tracing industrial products and batches, other departments such as customer service can benefit.
Competitive adaptability – Automated control systems offer more flexibility in manufacturing processes and improve an organization’s competitiveness within tumultuous industrial markets.

Types of Industrial Control Systems

Industrial control systems are organized into several classes by reference to their control action’s relative complexity of the overall functions of the ICS.

Programmable Logic Controllers (PLC)

PLCs are solid-state control systems with sturdy, robust construction and a suite of special functionalities. Some of these functionalities include an intuitive programming interface, I/O control, three modes (PID) control, arithmetic, counting and timing mechanisms and sequential control. PLCs are crafted to be highly resilient and capable of holding up to extreme weather conditions such as very high and low temperatures, high humidity, electrical noises and strong vibrations. These controllers are designed to monitor and manage large numbers of actuators and sensors, and they stand out when compared to typical computer and processor systems due to their high amount of I/O setups.

Human Machine Interface (HMI)

HMIs are hardware and software-based means of communication and information exchange between human operators and machines and/or computerized systems. With an HMI, various device processes can be controlled, visualized and managed through interactions between people and machines. HMIs can display data, track performance, control settings, and more. They can also be used in industrial processes, such as manufacturing, energy, transportation, and recycling, to monitor and optimize operations. HMIs can also be used in other domains, such as healthcare, education, entertainment, and gaming, to enhance user experience and engagement. HMIs can communicate with PLCs, sensors, actuators, and other devices through wired or wireless networks.

Distributed Control System (DCS)

In a DCS, there are various control systems distributed in a way that they can be individually controlled. Distributed Control Systems are systems of controllers, sensors and specialized computers that are distributed through industrial plants. Each component of the DCS has a unique function, such as graphical display, process control, data acquisition and data storage. The DCS serves as the industrial plant’s “central brain,” with the system’s elements communicating with each other through a centralized control computer network, a type of local area network. The DCS can track industrial processes and make automated, real-time decisions using the production matrices and trends that the system notes throughout the entire plant.

Data Collection System (DCS)

Industrial data collection systems are software solutions that enable the acquisition, storage and analysis of data from various sources in an industrial environment. Such sources may include sensors, controllers, machines, test systems, and enterprise systems. The Industrial DCS can help improve the quality, efficiency, and productivity of industrial processes by providing real-time insights, identifying root causes of problems and optimizing performance. The DCS also supports data visualization, reporting and integration with other applications. Our data collection systems are designed to ensure secure, accurate data collection and capture quality, and translate the information into rich data analysis while meeting ITAR compliance.

Industrial Automation & Control Systems (IACS)

IACS are an assortment of solid-state, electromechanical and mechanical devices that perform several control, monitoring and actuation processes on many logic devices and intricate process-type systems. IACS can track and control many processes through sensors on machines, smart devices, and software and hardware that turn sensor information into different control outputs. IACS systems consist of various components, such as sensors, actuators, controllers, communication networks and human-machine interfaces. IACS can improve the efficiency, quality, safety and reliability of industrial operations by automating tasks that would otherwise require human intervention or manual labor. IACS can also provide real-time data and feedback to optimize performance and reduce costs.

Intelligent Electronic Devices (IED)

Intelligent Electronic Devices are electronic devices manufactured for many purposes in the areas of communication, metering, power monitoring and controlling. IEDs are incorporated into ICS structures to facilitate highly sophisticated power automation capabilities. They typically are electronic components with microprocessors, such as a circuit controller and regulator device. These electronic devices can communicate through several different protocols, such as through real-time Ethernet or Fieldbus, a digital communication method. IEDs can be found in many processes and industrial control systems such as DCS and SCADA.

Programmable Automation Systems (PAS)

PAS allow for machine configurations and operation sequences that can change based on signals sent from electronic controls. With a programmable automation system, products can be produced in batches through the reprogramming of machine operations and sequences. The products created in this process typically are batch quantities, and these batches can be as low as just a few dozen products and as high as thousands of units produced at a time. Whenever a new product batch is required, the programmable automation equipment can be changed and reprogrammed to handle the new and different product types. The automated production line process cannot continue while the reprogramming and changeover processes are occurring. After these changes, the production of a new type of batch runs. As these factory automation processes are not changed often, programmable automation systems are usually less expensive than fixed system automation to operate over time. However, production rates are lower for programmable automation than for fixed automation due to the equipment’s changeover-optimized design, as opposed to being designed to work best for product specialization. Programmable automation systems are best used in settings with medium-to-high production level requirements and low product variety.

Programmable Automation Controllers (PAC)

PAC enable systems to provide higher-level, complicated instructions to various automated equipment. These types of controllers are well-suited for a variety of industrial and infrastructure sectors and applications. PACs often have more connectivity options and a wider capability of controlling systems than most PLC systems. PACs have five main elements: one multi-discipline development platform, enterprise network compatibility, adaptable software tools that improve process flow, multi-domain functionality and a modular open architecture. PACs are also used for controlling and monitoring complex industrial processes, such as manufacturing, energy, and transportation. PACs offer more flexibility, scalability, and performance than PLCs, as they can run multiple programs and support various communication protocols. PACs also have more memory and processing power than PLCs, which enables them to handle large amounts of data and complex algorithms.

Remote Terminal Units (RTU)

RTU is an industrial control system that is microprocessor-based. RTUs electronically connect various kinds of hardware to other control systems such as SCADA systems or DCS. These electronic units carry sensor data through input and output streams, which are transmitted to a centralized ICS through a control loop. RTUs also manage connections to remote or local controls, which is why they are known as remote units of Telecontrol or remote units of telemetry. RTUs collect data from sensors, valves, actuators and other field devices and send that information to a master system. It also receives commands from the master system and executes them on the field devices. RTUs are used in industrial applications such as power generation, oil and gas, water treatment and transportation. An RTU consists of a central processing unit (CPU), a power supply, a communication port and input/output (I/O) modules. The CPU is a microprocessor that performs data processing and logic functions. The power supply provides the necessary voltage and current for the RTU and its connected devices. The communication port enables data exchange with the master system using various protocols such as RS-232, RS-485 or Ethernet. The I/O modules interface with the field devices using analog or digital signals.

Supervisory Control and Data Acquisition (SCADA)

SCADA is a computer system that processes and gathers data that exercises high-level operational controls over significant distances. SCADA systems were designed to solve communication issues, particularly data integrity and delay issues stemming from the various communication forms. SCADA systems can monitor, control and gather data from sensors, valves, pumps, motors and other devices that interface with process plants or machinery. SCADA systems are widely used in various industries such as energy, manufacturing, oil and gas, water and wastewater, etc. For example, a SCADA system can maintain the refrigeration systems at a local supermarket, ensure production and safety at a refinery, or regulate water levels in dams. SCADA systems can improve efficiency, reduce downtime, and support smarter decisions by providing real-time information and feedback to operators and managers.

Contact us today to see how we can help your firm through the process of designing and implementing an automated control system.