Real Time Automation and Ratio Control Using PLC & SCADA in Industry 4.0

Industrial Control Systems (ICS) and SCADA (Supervisory Control and Data Acquisition) systems play a critical role in the management and regulation of critical infrastructure. SCADA systems brings us closer to the real-time application world. All process and equipment control capability is typically provided by a Distributed Control System (DCS) in industries such as power stations, agricultural systems, chemical and water treatment plants. Instead of control through DCS, this paper proposes a SCADA and PLC (Programmable Logic Controller) system to control the ratio control division and the assembly line division inside the chemical plant. A specific design and implementation method for development of SCADA/PLC based real time ratio control and automated assembly line system in a chemical plant is introduced. The assembly line division is further divided into sorting stage, filling stage and the auxiliary stage, which includes the capping unit, labelling unit and then the storage. In the ratio control division, we have defined the levels inside the mixer and ratio of the raw materials through human machine interface (HMI) panel. The ratio of raw materials is kept constant on the basis of flow rates of wild stream and manipulated stream. There is a flexibility in defining new levels and the ratios of the raw materials inside the mixer. But here we taken the predefined levels (low, medium, high) and ratios (3:4, 2:1, 2:5). Control valves are used for regulating the flow of the compositions. In the assembly line division, the containers are sorted on the basis of size and type of material used i.e., big sized metallic containers and small sized non-metallic containers by inductive and capacitive proximity sensors. All the processes are facilitated with laser beam type or reflective type sensors on the conveyor system. Building a highly stable and dependable PLC/SCADA system instead of Distributed Control System is required to achieve automatic management and control of chemical industry processes to reduce waste manpower and physical resources, as well as to improve worker safety.