Industrial control computers (ICCs) are computers specifically designed for industrial control, used to monitor and control machinery, processes, and data parameters used in production. ICCs often operate in harsh environments and have higher requirements for data security; therefore, they typically feature ruggedized, dustproof, moisture-proof, corrosion-resistant, and radiation-proof designs. ICCs also have very high requirements for expandability, and their interfaces need to accommodate specific external devices. Therefore, in most cases, ICCs need to be custom-designed to meet specific needs.
Currently, the main categories of industrial control computers are: IPC (PC bus industrial computer), PLC (programmable control system), DCS (distributed control system), FCS (fieldbus system), and CNC (numerical control system).
IPC: Industrial PC, based on the PC bus. Industrial PCs are characterized by their ability to quickly diagnose and maintain environments with dust, smoke, high/low temperatures, humidity, vibration, and corrosion. Their Mean Time To Repair (MTTR) is typically 5 minutes, and their Mean Time To Repair (MTTF) exceeds 100,000 hours, while ordinary PCs only have an MTTF of 10,000 to 15,000 hours. Industrial PCs perform real-time online monitoring and control of industrial production processes, responding quickly to changes in operating conditions, promptly collecting and adjusting data (a watchdog function not found in ordinary PCs), and automatically resetting in case of emergencies to ensure normal system operation.
Industrial PCs, employing a baseboard + CPU card structure, possess strong input/output capabilities, allowing for expansion with up to 20 cards. They can connect to various peripherals and cards in the industrial field, such as road controllers, video surveillance systems, and vehicle detectors, to complete various tasks. They can simultaneously utilize ISA, PCI, and PICMG resources and support various operating systems, multiple assembly languages, and multi-tasking operating systems.
PLC: Programmable Logic Controller, is a digital electronic system designed for industrial applications. It uses a programmable memory to store instructions for performing logical operations, sequential control, timing, counting, and arithmetic operations. It controls various types of mechanical equipment or production processes through digital or analog inputs and outputs.
Programmable logic controllers (PLCs) are a new type of general-purpose automatic control device developed by combining computer technology and automation control technology, suitable for industrial environments. They emerged as a replacement for traditional relays. With the rapid development of microelectronics and computer technology, PLCs have acquired more computer functions, not only performing logic control but also data processing, communication, and networking. Because the control process can be modified through software, and because they are characterized by small size, convenient assembly and maintenance, simple programming, high reliability, and strong anti-interference capabilities, they have been widely used in various fields of industrial control, greatly advancing the process of mechatronics.
DCS: Distributed Control System. It is a series of high-performance, high-quality, low-cost, and flexibly configurable distributed control systems that can form various independent control systems, DCS systems, and Supervisory Control and Data Acquisition (SCADA) systems. It can meet the process control and information management needs of various industrial sectors. The system's modular design, reasonable hardware and software configuration, and easy expandability make it widely applicable to distributed control of various large, medium, and small power plants, the upgrading of power plant automation systems, and process control in industries such as steel, petrochemicals, papermaking, and cement.
FCS: Fieldbus Control System. It is a fully digital serial, bidirectional communication system. Measurement and control devices within the system, such as probes, actuators, and controllers, can be interconnected, monitored, and controlled. In the hierarchical structure of factory networks, it serves as a local area network for process control (such as PLCs, LCs, etc.) and intelligent instruments (such as frequency converters, valves, barcode readers, etc.), and also has embedded functionality for distributed control applications on the network. Due to its broad application prospects, many powerful foreign manufacturers are investing heavily in product development. Currently, there are over forty known fieldbus types internationally, with typical examples including FF, Profibus, LONworks, CAN, HART, and CC-LINK.
