Rabany, Michel

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8 December 1995 OCR OutputGeneva, SwitzerlandChicago, USA, October 30-November 3, 1995Systemslntemational Conference on Accelerator and Large Experimental Physim ControlICALEPCS 95equipment. Let us face the new situation.should be adjusting their needs to the existing industrial products for more generalfleading role merely to the development o necessary new technologies, whereas theylaboratories to concentrate on their own specific activity. This restricts their possible'l"oday’s economic situation forces those who work in fundamental researchthose who are confused.misunderstanding in the best of cass, to unwillingness in the worst. Let us explain tomake but buy" approach is slowed down by arguments ranging fromThere is a natural tendency to be conservative and the progress towards the ”don'tuse industrial solutions to bring savings in terms of both money and human resources.pryes are su pty, water, , um, vacuum, etc., of which the production andfor the distribution are industrial processes. Let uslied with electrici airhelioductivit. Our machinvery efficient generic control solutions in response to the present competitivearchitecture in control engineering. More than twenty years later, industry ls producingphysics were launched. They provided an incentive to the development of advancedever increasing need for data processing, large projects in the fields of astronomy andDuring the 1970’ s, whilst computer technology was developing under the thrust of theMichel RabanyIndustrial Control Solutions in Research LaboratoriesA ga E GO LtCERN-AT-95-52CERN A’"°t52 **9Il\|\\|l\\l\\\I|\|\|\\\|\|\I|\|\\|||\\\\|\\l ICERN LIBRARIES, GENEVAEUROPEAN ORGANIZATION FOR NUCLEAR RESEARCHtooth and nail with questionable arguments. OCR Outputunderstand its true meaning. Others defending their position and/or their work, in other words their motivation, resistand conservatism. ’Ih0se living in isolation as reclttses do not follow the external evolution, and may or may notthe scientific community. Engineers and technicians, x any human being, me influenced by two factors: experienceThe debates concerning industrial controls show a discrepancy in the different meanings given to these two words inThe engineer! attitudeTHE MEANING OF INDUSTRIAL CONTROLSsavings in terms of both money and human resources.developed in response to the present industrial competitive productivity. They can be used for our needs and bringpioneering engineers, is today guided by the strength of the consumer market Very satisfactory solutions have beenresearch laboratories, constitute one of their technological spin-off"s. lndustry, driven in the early days by oursending the commands to the equipment, via the distributed computers. These developments, originating from ourcommunication protocols were developed and gave the main control rooms the means of getting the data from andengineers to install computers near the equipment in order to ahem the cabling problem. Consequently, computersimple communication lines. Dining the l970‘s. the large size of the machines being built compelled controlSimilarly, computer based control systems started with a centralized architmzurre, the equipment being connected bycommunication netwcrks.and their analysis prompted the development of on-line connections, creating the first mesh of today'sgrowing to cope with all aspects of scientific work. The need to shorten the time between the production of eventsincentives for the development of computer technology during the l960’s. Main frames sizes were continuouslyof collected events. This explains why the ever increasing need for number crunching has been one of the majorParticle physics relies totally on statistics, as the precision of eqrerirnental results is primarily driven by the numberINTRODUCTIONface the new situation.whereas they should be adjusting their needs to the existing industrial products for more general equipment. Let usspecific activity. This restricts their possible leading role merely to the development of necessary new technologies,Today‘s economic situation forces those who work in ftmdamental resezch laboratories to concentrate on their ownexplain to those who are confused.down by arguments ranging from misunderstanding in the best of cases, to unwillingness in the worst. Let usThere is a natural tendency to be conservative and the progress towards the "don’t make but buy" approach is slowedprocesses. Let tis use industrial solutions to bring savings in terms of both money and human resources.with electricity, water, air, helium, vacuum, etc., of which the troduction and/cr the distribution are industrialefiicient generic control solutions in response to the present competitive productivity. Our machines are supplieddevelopment of advarmd architecture in control engineering. More than twenty years later, industry is troducing veryprocessing, large projects in the fields of astronomy md physics were launched. They povided an incentive to theDuring the 1970’s, whilst computer teclmology was developing tmder the thrust of the ever increasing need for dataAbstractCERN / AT Division, 121 l Geneva 23Michel Rabanyin Research LaboratoriesIndustrial Control Solutionschent industrv I induwv I industry I industrv I industrv I fullv industrial OCR Outputclient industrialindustry I i industry I client I clientinduS¤Y I indusclient client | industry | indusry | clientor I clientor | industrial?induSlfV I induschent client I client | induary | client or | clientorchent client I client I client I client I clientcontrolsspecific. I desizrrsystem | system | pratat. |pr0duct. | install. |c0mmis.| nature afcomplete system, production, installation and commissioning: an industrial approach.specify the system functionally with the description of the environment; ask indusuy for the design of theeventually for installation and commissioning: a partialy industrial approach.specify the system fumtionally ard physically, @@1 the system; ask industry for a prototype, production,subcontract the production, install and commission: still a home-made approach.specify the system functionally am physically, design the system, build a prototype in the laboratory, test,produce, install and commission: a fully home-made approach.specify the system functionally and physically, desigt the system, build a prototype in the laboratory, test,by industry in response to the needs of tim market. Control engineers may develop their project in different ways:Therefore, industrial controls result from functioml speciticadons. ln fact, indusuial solutions have been geruatedIndustrial controls are nothing more than technical projmts and meet the same criteria as those stated above.The case for lndustrthl C0ntr0Lr‘industrial” label, which means based on the manulactur¤·'s ideas, methods, tools and standards.functional specilications can result in handing ova full rwponsibility of a project to indusuy and thus lm to thespecitications that have to be fulfilled and which will govem the implementation of all the other phases. Onlyits execution is a process with which industry mn be enuusted. ’I`he resulting document contains all theand commissioning. ’I`he first phase obviously nms the participation of the client at least to &fine the project, butThe development of a technical project has six phases: specifications, design, prototyping, production, installationobtained whenever the elementary projects match its ability at the highest possible level in the tree structure.modularity, availability, homogeneity. ’I`he smallest objects are elementary projects. The best tit with industry isdown and so forth. Different factors influence the level at which the momposition stops: complexity, feasibility,a set of objects that may also be repM as technical projects but of a smaller size, they in turn may be brokenAny technical project has a tree structure. At the top level we find the global project. Breaking it into parts providuStructure and phases of a technical projectthey are buying industrial components and since industry is building what they design.Gentilhomme", most control engineers are convinced they are, and have always been, industrial control users sinceUnlike Mr. Jourdain who was ignorant of the fact he was talking in prose in Moliere's "Le Bourgeoisideas of outside manufacturing, subcontracting, outside procurement, etc., This last meaning creates some confusion.solutions, etc., The second meaning suggests an altemative to the uaditiottal homermax approach and conveys theoptimum design, good quality, extensive tests, large quantitiw, competitive price, suppon, long life time, tumkeymarket and med by the industrial community; the word industrial then bears a connotation of wide acceptance,c0n¤·oLs manufactured for, or by, industry. The first meaning describa control equipment currently available on theThe word industrial when associated with controls can bc imcrprcwd in two ways, depending on whcthcr it qualitiwThe coryfusianTheir share of the market is given in the chart below. OCR OutputData, Wonderware and Iconics at the forefronthave today joined the DCS heading team. 'lhe supervision market is led by the United States with lntellution, U.S.for sales respectively. ’l`he Distributed Control System was invented by Honeywell in 1975, but ABB and Baileybeing the largest PLC markets. Siemens, Allen-Bradley and Schneider are manufacturers number one, two and threeapproximately $5.5 billion today. The growth rate for revenue is around l0% per year, Europe and the United StatesFrom an economic point of view, the world-wide market for PLCs was estimated at $2.5 billion in 1987 and iseasy however, as the protocols at that level are still mostly proprietary.that may connect to PLCs from different manufacturers. Mixing different PLCs in the same application is not thatmanage data, etc. from a central location. Independent vendors offer the same features in generic supervision systemsPLCs thus allowing technicians to operate, supervise, archive, log events, analyze data, display variable trends,different PLCs. A few manufacturers are offering Distributed C0n¤·ol Systems to attach this functionality to theirCo·ordinating different processes necessitates the presence of buses and communication networking between the• peripherals like printers, hard disks,• operatmg stauons• programmmg stations• inputs and outputs which connect to sensors and actuatorsdedicated programs which control actuators according to the values of sensors. Their environment consists of:and flexibility, but because the costs of cabling were becoming too high. PLCs are built around processors executingmanufactured models. The PLCs were substituted for relays cabinets, not only because of their easy implementationof the automotive industry. 'Ihe goal was to develop automated production lines able to follow the evolution of theProgrammable Logic Controllers were bom in the United States in about the year 1969. as a response to the dzrnzrdinformaioncontrol cbvieesensorsactuators processof the process. An automatic device has the following typical structure:how to proceed in all operating conditions. An operator is often necessary to ensure the global drive and supervisionmaking its control secure with the use of technological devices [ll. 'I`he designed system is informed, and so knowsThe automation of a process, i.e., a machine, a set of machines or more generally industrial equipment, consists ofTHE MANUFACTURERS OF INDUSTRIAL CONTROLSwhich will be produced for industrial needs.come from collecting systems and components that are currently available, or generate new systems or componentsTo qualify as being "irrdustrial", the controls should have been designed by industry. The solutions should eitherfor large installations, although this restriction might be desirable at the level of each elementary project, and even OCR Outputexistent and the products proprietary. Restricting the supply of PLCs to a single source is not commercially viablesupervised. This coherence is difficult to implement at the level of the PLCs as at that level the standards are nonof coherence stems from the functional need for a single operating centre from which all the services may bcThe diversity of these services poses problems of coherence and integration in the domain of controls. 'I`he problemwhere industrial controls are in their rightful place.cryogenics, access, etc.. Apart from these services, production IBS!. benches and laboratory prototyping are activitiesequipment utilities for the machines. Diey concern: water, electricity, gas, heating, cooling, ventilation, vacuum,unquestionable candidates for industrial controls. 'Ihese wvices may be either general rmds for the laboratory orvariables that have to be controlled. This is also the case for the services in our research laboratories, which arebecoming steadily cheaper. Industrial processes are technically characterized by the rather slow evolution of theProgrammable Logic Controllers are today gaining ground because they are simple, reliable, very liexible and aeCabling or programming technologies were the alternatives given to the control engineers of the last decade.The needsINDUSTRIAL CONTROLS IN RESEARCH LABORATORIESdo not escape using PLCs to produce artificial snow.Goods stocking, parking management and building supervision are typical applications for PLCs. Even ski resortsothers: textile, transportation, handling, building, etc,.requires safe and secure industrial control systems which are now available.Today, domestic and indusuial needs are unthr the control of PLCs for production and distribution. Nuclear energy5;_t·_gices: energy supply, water supply, gas supply, etc..control and supervision, distribution of gas and liquids.PLCs are used fcr the proportioning and the mixing of ingredients, purification of effluents, oil pumping station: chemicals, petroleum, agro—food, etc..grinding, welding, etc., More than 95% of the machines—t0ols are under PLC controLPLCs are highly involved in production and on assembly lines, test benches, machines for milling, pressing,metallurgy, machines-tools, motor industry, etc.,production, processing and distribution. 'Iiie sectors that are concerned are:A picture taken of our daily life shows that industrial controls are mostly concemed with automating the domains ofTHE USERS OF INDUSTRIAL CONTROLSsource: Conuol Engineering, January 19950 I0 20 30 40 50SlemensAllen·BradleyAEG SchneiderMitsubishiWorld PLC market sharePhysics Control Systems, Tsukuba, Japan, pp 269-273. OCR Output[7] Interfacing Industrial Process Control Systems to LEP/LHC, M. Rabany, Accelerator and Large ExperimentalEngineering Conference, ICECI3, Beijing, China, 1990.D. Gilsewell, F. Haug, A. Juillerat, G. Passardi, J. Schmidt, G. Winkler, X1Hth International Cryogenic[6] The refrigeration system for the LEP upgrade, M Barranco—Luque, J.P. Dauvcrgne, W. Erdt, P. Frandsen,LEP, Ch. Bertuui, A. Guiard-Marigny, European Particle Accelerator Conference, Rome, June 1988.[5] Control Ffacilities for Commissioning and Operation of the Water Cooling, Air Handling and Fire Detection of[4] Opportunities for industry with CERN, O. Barbalat, CERN/BLITB4-04, 15 March 1994.1993.[3] The Large Hadron Collider Accelerator Project, The LHC Study Group, CERN/AC/93-03(LHC), 8 NovemberM. Rabany, This conference.[2] A Proposal to Move from the LEP Topological to an LHC Functional Con¤·ol System Architecture,Paris, 1988.[1] Les A.P.I., Architecture et applications des automates programmables industriels, G. Michel, Dunod edition,REFERENCEScontrols.defend our scientific interests it is vital to present our sponsors with good arguments. It is vital to use industrialwe can expect from manufacturers as process controls consumers is certainly better than as ordinary designers. Toactivity. This increase cannot be obtained in well explored domains like process controls today. The political supponthey give to orrr research laboratories. T`he financial investment must generate an appreciable increase in industrialGiven the present climate, our States' politicians must absolutely fmd an economical justification for the supportCONCLUSIONwith industrial controls launched an increasing interest which is today supported by a large community [6] [7].domain of cooling and ventilation [5]. The decision in 1990 to control the refrigeration system for the LEP upgradeThe first attempt by CERN to widely use industrial controls for equipment in an accelerator was made for LEP in therise to new technologies that generate employment and positive retrofit [4].is undoubtedly one of the rational answers. Our States would like their investment in fundamental research to giveneeds to prompt saving measures by limiting them to vital activities. In this context, the use of industrial controlsimpact on the way the project can be developed. The squeeze on human resources questions laboratory activities mdnot as stronger as it was fifteen years ago. We now have to cope with new boundary conditions which have a directproces of the large Hadron Collider [3] at CERN has been a lengthy md painful one. Suppon from the States is•politically, ftmdamental reseach is suffering from the current economic situation of the States. The approvalwith the increase of production. ’l`he regulating mechanism of the market gives confidence in the natural price setting•financially, the design cost is stared by the whole community of customers, md the prime cost deueases rapidlyapplications. The different phases being shorter, the development of the project requires much less time.industrial solutions gives the advantage of tried and tested solutions, as they are used a number of times in similar•technically, the services make use of industrial processes for which irrdtrstrial controls have been developed. UsingResearch should defmitely lean towards industrial controls for their services:Research laboratories facing irtdrmrial controlsand the nerve centres for each type of service.needs a functional control architecture [2], organized around Specific Centres which are technically the vantage-pointshigher for small installations. The integration of industrial control systems supporting the operation of one machine

Industrial control solutions in research laboratories

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