Rather than the software that operates the hardware, we frequently picture a specific piece of hardware when we consider technologies that have revolutionised industrial automation. Although the SCADA software manages all the activities smoothly, the Programmable Logic Controller (PLC) significantly increases efficiency and control in factories and manufacturing facilities.
Understanding what SCADA systems are, how they work, what makes up one, and where they fit into contemporary industrial workspaces are crucial to comprehending the fundamentals of these systems.
WHAT IS SCADA SYSTEM
There's a good probability that you've heard about SCADA if you've ever worked in a manufacturing. If you are unfamiliar with factory floors, this concept could be foreign to you. SCADA systems are an industrial control system that underpin daily operations in many manufacturing plants. Supervisory Control and Data Acquisition is referred to as SCADA. SCADA systems simply collect and swiftly analyse real-time data. They are used in the manufacturing industry to monitor and automate the industrial automation's control procedures.
PLCs or Remote Terminal Units are the first components of the fundamental SCADA system (RTUs). These tiny computers relay information to computers running SCADA software after receiving it from sensors and equipment in a factory or activity. On a Human Machine Interface (HMI), the software distributes, processes, and displays data so that a human operator can use it to make choices.
After the adoption of industrial computers, particularly PLCs, SCADA systems were first introduced to the factory floor. Early in the 1970s, the term "SCADA system" was used to describe the software that enabled automatic communications to transfer data from remote sites to monitoring apparatus. SCADA is widely used in a number of major industries, including chemical, food and beverage, automotive, and oil and gas. We'll go through some of the essential parts and features of a fundamental SCADA system below.
FUNCTIONS OF SCADA SYSTEM
A SCADA system's hardware and software components cooperate to carry out the tasks of gathering, analysing, and displaying real-time data from manufacturing activities. Current SCADA systems allow for the remote monitoring and management of many different processes.
Data collection, network data communication, data presentation, and control are the four main tasks performed by a SCADA system.
ACQUISITION OF DATA
SCADA systems collect data from PLC-connected network devices and sensors. They track variables like flow rate, pressure, flow rate, temperature, weight, and gas emissions. After being processed by a PLC, this raw data is then transferred to an HMI where a human operator can review it and take any necessary action.
NETWORK DATA COMMUNICATION
While transferring data between machines and operators, SCADA systems must use wired or wireless communications technology. These networks make it possible to manage numerous systems from one location.
DATA PRESENTATION
The information is shown to a human operator using an HMI or HCI (Human Computer Interface), which receives data from SCADA systems. The operator is informed when there is a "alarm" or dysfunction—when a control factor is not operating within the expected operational range—by this master station, which continuously monitors all sensors.
CONTROL
On the basis of the information gathered from the sensors, SCADA systems can be programmed to make specific control decisions. Turning on and off the electricity, altering the temperature, reducing or increasing speed, and managing a number of industrial processes are all examples of control functions.
COMPONENTS OF A SCADA SYSTEM
SCADA systems are made up of multiple hardware and software components that cooperate to carry out the aforementioned activities. Data collection tools including sensors, relays, and switches make up the hardware. The data is translated and then translated by SCADA software, which can also be programmed to perform control and alarm operations.
The state and parameters of a machine are measured and controlled by digital or analogue inputs and sensors. Data acquisition, which is then delivered to the PLCs or RTUs, is their main duty. PLCs and RTUs are little industrial computers that gather data from sensors and inputs and present it in an understandable manner. They convey commands to control relays and act as regional collection hubs for reports. The information gathered from various PLCs is then transmitted to a central HMI.
A human operator may examine all the data gathered from networked devices and sensors thanks to HMIs, which act as the master and satellite computer stations in the system.The data is frequently shown in graphical representations of machines and devices,data charts,and performance reports,among other visual representations.The human operator can decide how to best run the production process by using the information at hand.Information may be exchanged between the machines.PLCs and operators thanks to the communication network.For connecting to local geographic areas to other geographic areas,SCADA systems often use a closed LAN or WANs.A SCADA system cannot function without a properly planned communication network.
SCADA SYSTEM IN MODERN INDUSTRIAL AUTOMATION:
PLCs are frequently employed in modern industrial workspace as the device that transmit data from sensors and inputs to an HMI ,allowing operators to make decisions regarding the manufacturing processes.To maintain effective operations,all the components operate together through SCADA software
While learning about PLCs, it is essential to comprehend the principles of software as well as the components and capabilities of a SCADA system.