How Systems Integrators Can Create Smarter Electrical Control Systems

Rockwell Automation

August 20, 2018

By Joe Matheys, Rockwell Automation

Industrial companies expect visibility into every aspect of new or upgraded plants, including their electrical control system. Now, the pressure is on integrators to help connect these systems and make their real-time data available to workers.

But traditional electrical control systems don’t easily integrate into connected operations. These hard-wired systems typically exist separately from a plant’s process control system. And their data is often only available in an e-house or substation, meaning workers need to enter potentially hazardous areas to access it.

Facing these challenges, more system integrators are choosing to use intelligent packaged power solutions. These systems provide state-of-the-art digital technology that can integrate with a plant’s process control solution, unifying the two into a single architecture. It can also provide access to the electrical-system information that customers want, providing far-reaching business benefits for both end users and integrators.

For End Users: Smarter Systems

About two-thirds of new plants use smart devices in their overall electrical system, according to an ARC Advisory Group study. Digitally integrating all these devices can give end users access to information like faults, operating conditions, and alarms and events.

This information can help workers more quickly identify where, when and why an issue occurred so they can resolve it faster. This includes the ability to observe power quality problems and unexpected increases in energy intensity. Visibility into the electrical system can also help workers spot problems early, before they move downstream into the control system. For example, uneven electrical distribution system loading can shut down fans on catalytic converters.

For Integrators: Faster, Better Integration

Traditionally, integrators have had to develop custom programming for every electrical control system. But some intelligent packaged power systems include standard, prebuilt faceplates that integrators can reuse across different projects. This can help them reduce programming requirements and speed up integration times.

The right technology vendor can also help integrators make sure that data from intelligent electrical devices (IEDs) is delivered at the speeds customers need. Using communications protocols like IEC-61850 and EtherNet/IP, along with interfaces to legacy networks, a vendor can connect all IEDs and provide access to real-time information on equipment and operating conditions.

Some vendors have even developed performance guidelines to help identify how different systems will perform before they’re built. This can help integrators reduce their design and testing times.

A Smart Business Model

Integrators have a vital role to play in helping industrial customers become more connected and data driven. And those that can reliably and cost-effectively give customers access to the information they need to optimize operations will have the most success. Gaining the capability to deliver an intelligent power and electrical system can open doors to new projects and new business opportunities for system integrators.

Rockwell Automation can help integrators gain this competitive edge by providing an intelligent packaged power system that unifies electrical and process control and unleashes the power of real-time electrical control system data. More information about intelligent packaged power can be found here.

Put to the Ultimate Test – Part 1: Torsion Tests by HELUKABEL

DCS Put to the Ultimate Test Part 1 Torsion Tests by HELUKABEL 1 400x275

Cables and wires in industrial robots and other moving machine parts are often required to withstand extreme stresses caused by torsion. Constant repetitive movements put materials under considerable strain. At the same time, operators expect components to function perfectly and reliably throughout their entire service life to avoid disruptions, outages and safety hazards.

For this reason, at HELUKABEL, we simulate intensive and continuous torsion stresses under realistic conditions with our high-tech testing equipment in Windsbach. We have several types of apparatus for doing this because some of our customers, for example those in the automotive industry, have very precise specifications for how a torsion test is carried out. The tests show that our cables and wires withstand speeds up to 1,000°/s, accelerations up to 2,000°/s² and torsion angles up to 720°. Hence, we make sure that each product always meets our customers’ high standards, and that they receive the impeccable quality they rightly expect from us as a leading supplier of cables, wires and accessories for more than 40 years.

What Is Torsion?

To learn the answer, click here

30 Minute Live Webinar 2:30 PM ET January 19th, 2023

With PC-based automation, you can implement applications and solutions that far exceed the functions of a classic controller. SIMATIC PC-based products offer you a flexible, innovative platform with long-term availability that give you a home field advantage when meeting the challenges of the digital factory for your machines and plants.

Festo Didactic at the Forefront of Developing Canada’s Future Work Force

DCS Festo Didactic at the Forefront of Developing Canadas Future Workforce 1 400x275

With Canadian manufacturing suffering from a growing labour shortage, the participation of industry in skills development is emerging as a vital component in hiring and retention.

The needs are stark: The Canadian Exporters and Manufacturers Association says almost 40% of its members have jobs they can’t fill. Five years from now, 60% expect to be short-staffed, especially when it comes to skilled trades. Statistics Canada forecasts the country’s labour force growth rate will remain below 0.2% for the rest of the decade, below replacement levels.

This growing shortage is affecting companies of all sizes. Already, some manufacturers acknowledge losing out on contracts because they can’t find the manpower to fulfill them.

In reality, the challenge is two-fold: to replenish and expand the workforce to help close the gap between the number of job seekers and vacancies through 2030 when the last baby boomers reach age 65, and ensure workers get opportunities throughout their careers to upgrade or add to their skillset as current technologies evolve and new ones emerge. Festo, through Festo Didactic, one of the world leading provider of equipment and solutions for technical education, intends to help Canada meet this challenge on both fronts. In essence, the approach Festo has always taken is that the learning never stops.

Product News

DCS Control Techniques Adds Wall Mount Packages 1 400x275

Control Techniques Adds Wall Mounted Packages to ...

When working with industrial pumping, such as crop irrigation or wastewater ...