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Development and Innovation of Intelligent Instruments and Fieldbus Technology in DCS

2026-04-06 05:27:46 · · #1
Introduction DCS, or Distributed Control System, is a new type of computer control system relative to centralized control systems. It evolved from centralized control systems. Since its emergence in the mid-1970s, it has undergone more than 20 years of development. It has evolved from being used only in the control systems of a few large enterprises to becoming the most common control tool in industries such as power, petroleum, chemical, metallurgy, building materials, and pharmaceuticals. The reasons for this are twofold: First, DCS manufacturers have continuously improved the reliability, practicality, advancement, and integration of their systems. The mutual penetration and competition among various control systems (PLC, DCS, IPC + controller), as well as the adoption of advanced computer and network communication technologies, have led to a continuous decline in DCS prices. Second, global market competition forces enterprises to continuously apply advanced control technologies to improve product quality and output, and reduce costs and expenses, providing a broad market demand for DCS. 1. Continuously Increasing User Requirements In the field of automatic control, application requirements are constantly increasing. It can be said that automatic control systems can never fully meet all application requirements. Whenever automatic control systems achieve new technological advancements and develop new functions, newer functional requirements are immediately put forward. For example, when control instruments could only achieve simple feedback control, a large number of PID control problems awaited resolution; and when automatic PID control became possible, the search shifted to self-tuning of control parameters to automate, quickly, and accurately complete the complex parameter tuning process. Even with today's relatively sophisticated control algorithms, many control problems still lack accurate mathematical models. Consequently, non-analytical methods such as fuzzy control theory and neural network methods have seen significant development. This is true not only for control algorithms but also for the hardware and software of control systems themselves. Consider detection and control instruments, such as water level gauges. The earliest detection element was probably the float, but its accuracy and stability were quickly found to be problematic, leading to the development of differential pressure measurement methods. These new principles and methods were significantly superior in performance to the older methods, but changes in pressure and temperature within the container caused corresponding changes in water density, resulting in measurement errors. Therefore, intelligent water level gauges that digitize measurements on-site have become widely used. They can utilize digital processing technology and algorithmic models to process and correct measurements, or add digital filtering measures, striving for objective, accurate, and reliable measurements. Looking at computers, early automatic control systems used very slow computers (only about 500,000 operations per second) with limited memory and external storage (about 64kB of RAM and about 1MB of external storage). Despite this, such computers were still used in many computer control systems and played a role in a certain historical period. Systems composed of these computers were mostly safety monitoring systems. If control was involved, the algorithms were not very comprehensive or complex. Based on the current state and development trends of automatic control systems, higher requirements will be put forward in the following aspects: 1. System functionality requirements: More algorithms can be implemented, and higher control objectives can be achieved. System functions will become more integrated, including not only classical control but also advanced control, and functions such as quality statistics, analysis, batch processing, and production scheduling, gradually developing into computer integrated manufacturing systems. 2. System reliability requirements: Longer fault-free operation time and higher system availability, reaching over 99.99%, while system maintenance should be quick and easy, minimizing downtime. 3. System usability requirements: A very user-friendly human-machine interface is required; window-based operation and on-screen operation will become mainstream. Operators require minimal training to operate the system based on graphical and system prompts. Voice, images, and other multimedia information will become an indispensable part of the human-machine interface. 4. System Security: The system provides various safety protection measures to prevent misoperation and human error. It can analyze and record various abnormal states, providing timely alarms so that operators can quickly understand the situation and handle it promptly. 5. Wide Information Sharing: The automated control system can share various real-time information with other management and scheduling systems. Not only can production leaders and managers obtain production information from their desks, but they can also obtain production information from anywhere via telephone lines and radio communication. 6. Larger System Scale Requirements: The system can include not only basic process control functions but also various aspects of production and control status information. The number of system control loops and detection points will increase significantly to achieve comprehensive management and control of complex production processes. 7. Easy System Upgrades: As production scale expands and production processes change, even changes in the production flow, the system can be adapted to new requirements with minor modifications or expansions. Simple expansion of monitoring points, control loops, and adjustment of control parameters can all be performed online. 8. Reduced System Costs: Higher automation does not necessarily mean higher costs. Science and technology themselves are creating higher functions and performance on the one hand, and lower costs on the other. Only by continuously reducing costs can automation penetrate into all aspects of production and achieve a higher level of automation. 2. The continuous improvement of application technology promotes the continuous development of DCS. The main driving forces are the continuous improvement of application requirements and the continuous improvement of application technology. These two factors are like two locomotives of a train, one pulling in front and the other pushing behind, complementing each other. The improvement of application technology is mainly reflected in the following aspects. 2.1 The development and progress of computer technology In the nearly 60 years since its invention, the computer has gone through several development stages, from vacuum tubes, transistors, integrated circuits, large-scale integrated circuits to very large-scale integrated circuits. Although its basic principles have not changed significantly, the changes in its components and system architecture have been rapid, showing an extremely fast development speed. It took about 20 years for the computer to develop from vacuum tubes to transistors, about 10 years from transistors to integrated circuits, and more than 5 years from integrated circuits to large-scale integrated circuits. Since then, the integration level of integrated circuits has doubled every 3 to 4 years. The CPU has also been improving at an astonishing speed. In the 1970s, a computer capable of performing 1 million operations per second was considered a mainframe, while today a typical microcomputer can reach 2.0 GHz. In the 1970s, computer memory was measured in kilobytes (kB), while today a typical microcomputer can reach 256 MB, and hard drives are generally 40 GB. Improved computer performance does not necessarily mean higher prices. On one hand, high technology is reflected in the functionality and performance of products, enabling the fulfillment of previously impossible requirements; on the other hand, it is reflected in cost, achieving the same requirements at a lower cost. The continuously improving performance-price ratio has promoted the widespread application of DCS (Distributed Control Systems). 2.2 Development and Progress of Network Technology DCS itself is built on the foundation of networks; it can be said that the network is the lifeblood of DCS. Having a high-speed, reliable, standardized, and practical network is half the battle won for DCS. In the early stages of DCS development, most manufacturers used dedicated networks with low performance. This created an "island" phenomenon, where a DCS built for a specific production unit or process became an isolated island unable to communicate with the outside world. With the development of network technology, various network products independent of any single manufacturer have emerged. These network products, due to their high performance, low price, and standard compliance, offer strong openness and interconnectivity. This advantage has prompted DCS manufacturers to abandon dedicated network structures and shift to general-purpose network structures. DCS systems built on dedicated networks are now virtually nonexistent. The high communication speeds of networks have expanded the development space for DCS, and their application scope has continuously broadened. It has evolved beyond traditional computers to include various instruments, meters, and equipment, all of which can be networked, with network controllers integrated into microcontrollers. Current networks can be categorized into Local Area Networks (LANs) and Wide Area Networks (WANs) based on their communication distance and range. LANs typically have a communication distance of less than 2km, using coaxial cable or twisted-pair cable as the primary communication medium. In recent years, with the development of fiber optic communication technology, fiber optic transmission media have become increasingly widely used. Because fiber optic communication is immune to electromagnetic interference and has high reliability, it has been widely adopted in industrial environments. Furthermore, wireless communication offers great flexibility, eliminating the need for cabling during network setup, and its applications are also widespread. WANs, on the other hand, have virtually no limitations on communication distance and utilize a variety of communication media, from telephone cables to satellite communication. Besides LANs and WANs, another type of network, "Metropolitan Area Networks" (MANs), with communication distances between the two, has seen significant development in recent years. This type of network has a wide range of applications, especially within a range of tens of kilometers. Many production processes require communication capabilities within this range, such as urban water supply, heating, gas, and transportation. The main communication media for MANs are telephone lines and radio waves. 2.3 Development and Progress of Software Technology Software plays a crucial role in DCS (Distributed Control Systems), with almost all DCS functions implemented through software. Microsoft is arguably the most successful software developer on the PC platform. Its Windows software is popular worldwide, with thousands of software companies developing applications for Windows. Standard software interfaces have been established, allowing software from different manufacturers to easily exchange information and operate interoperably, providing a strong and solid software foundation for application systems. DCS is no exception; various DCS manufacturers have incorporated interfaces that can interface with a wide range of software resources into their software, and in terms of hardware selection, many DCS manufacturers have chosen the general-purpose PC platform. The introduction of operator stations on this platform has made the role of CRTs increasingly important in DCS. CRTs have become the main human-machine interface device, and many operations have shifted from actual operation of physical equipment to operation of the CRT screen, significantly increasing the functionality and flexibility of DCS. 3. The Promotion and Innovation of Intelligent Instruments and Fieldbus Technology in DCS Currently, the two fastest-growing areas in the instrumentation industry are intelligent instruments and fieldbus, which are inextricably linked and mutually reinforcing. Intelligent instruments are based on microelectronics technology, integrating functions such as very large-scale integrated circuits, embedded systems, CPUs, memory, A/D converters, and input/output circuits onto a single chip, such as microcontrollers. This moves the digitization of analog signals from the computer to the field. The signals transmitted between field instruments and computers are not analog signals, but digital signals, or more precisely, information. In field-installed detection or control instruments, it is entirely possible to install a small integrated circuit chip and a few peripheral circuits to directly digitize the analog signals from sensors before sending them to the computer. This method significantly improves the accuracy and reliability of signal conversion, and the transmission of digital information completely avoids the long-standing problems of signal attenuation, accuracy reduction, and the introduction of interference signals inherent in analog signal transmission. With the development of intelligent instruments, fieldbus technology has also rapidly advanced. A fieldbus is essentially a computer network where each node is an intelligent instrument. The traditional method of using a pair of transmission lines for each analog signal has been replaced by a single fieldbus line capable of transmitting digital information from multiple intelligent instruments. Fieldbus simplifies the wiring of instrument signal lines, saving a significant amount of metal wire; sophisticated error correction technology in digital information transmission greatly reduces transmission errors. Furthermore, it allows the use of various transmission media, such as twisted-pair cables, optical fibers, radio waves, and infrared light, greatly improving the adaptability of information transmission under different conditions. The development of fieldbus networks and intelligent instruments inevitably influences the architecture of DCS (Distributed Control System), with the most significant characteristic being the promotion of DCS development and innovation. A clear trend is the further decentralization of DCS. Traditional DCS systems still maintain a centralized structure at the I/O control station layer. Some systems, for cost or other reasons, have very large I/O control stations. For example, with the price of high-performance CPUs now very low, the number of points and loops in an I/O control station can be increased to fully utilize its capabilities and reduce costs. However, this design increases the concentration of risks. Adding redundancy to improve reliability still raises system costs. Using fieldbus networks and intelligent instruments, along with general-purpose industrial microcomputers, a small-scale DCS can be formed, posing a challenge to traditional DCS systems. This transforms the centralized I/O control stations of the past DCS into distributed I/O control stations, introducing a field network layer below the traditional DCS network. Overall, a three-layer network structure is formed: a control network (based on fieldbus networks), a system network (the traditional DCS network), and a management network (an upper-layer network adapted to integrated management and control requirements), to meet ever-increasing application needs. After forming this three-layer network structure, the basic control unit of the DCS extends to the equipment control level. Moving upwards, the functions of DCS extend to the management and control level, gradually forming a relatively complete integrated control and management architecture, as shown in Figure 1. The empty boxes in Figure 1 can represent intelligent I/O, intelligent instruments, and IEDs. 4. Conclusions After improvement and innovation, DCS will have the following characteristics: 1. Openness: The equipment used in the new DCS will tend towards general-purpose products, with fewer and fewer dedicated products, especially computers and networks. High-performance industrial microcomputers and workstations will be widely adopted, and general-purpose network products will gradually replace dedicated networks. Network communication protocols are gradually converging towards universally accepted standards, and the method of forming application systems through system integration is becoming increasingly widely used. 2. Decentralization and Intelligence: Intelligent instruments and fieldbus technology are widely adopted, further decentralizing the DCS architecture. Direct digital control will penetrate into every control loop and field device. Therefore, with the development of the fieldbus networks used, the new DCS will eventually become increasingly closer to FCS (Fieldbus Control System). 3. Diversification of System Composition: The traditional DCS is almost nowhere to be seen now. The DCS we talk about now is a broad concept, actually becoming increasingly closer to FCS. This includes new-generation systems launched by traditional DCS manufacturers, as well as systems composed of PLCs, high-speed bus networks, and configuration software from professional manufacturers. The composition of DCS varies in different application areas. 4. Integrated Automation No system in the future will be isolated. DCS that cannot communicate with other systems and achieve integration will no longer be viable. The development of systems is gradually moving towards integrated automation. References: [1] Xie Tingyu. Development and application of computer network control system in large sugar factory [J]. Automation and Instrumentation, 2002, 103(5): 47-50. [2] Han Xiang. Application of Symphony control system in Yunfu power plant [J]. Automation and Instrumentation, 2002, 104(6): 26-30. [3] Zhu Zutao, Mao Jingtao. Major changes in automation instrumentation - On fieldbus intelligent instrument [J]. Journal of Shanghai University of Electric Power, 2000, 16(4): 35-40. [4] Liu Shuguang, Wang Bin. [5] Zhang Fengdeng, Ying Qiga. Fieldbus and Intelligent Field Instrument Design Technology [J]. Automation and Instrument, 2001, (5): 14-16. [6] Zhou Liqiu. Communication between Programmable Logic Controller and Distributed Control System [J]. Automation Instrument, 2002, 23 (7): 37-39. [7] He Wenmin. Application of Domestic DCS in Coking Plant [J]. Computer Measurement and Control, 2002, 10 (8): 521-523. [8] Zhang Deyu. New Developments in I/A Intelligent Automation System Application in Power Plants [J]. China Instrument and Control, 2000, (4): 42-43.
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