1. Introduction

The history of automated systems dates back to the 1960s, when US automakers decided to replace the already obsolete systems based on relay logic, electromechanical counters and single-loop regulators with the recently introduced PLCs (Programmable Logic Controllers).

Due to the limitations of relay logic, the process change required a complete overhaul and changeover of control cabinets, which became critical in the race to sell.

Although early PLCs were slow, not as reliable as modern ones, they made it possible to quickly change the technological process and in a relatively short period of time, PLCs almost completely replaced electromechanical control systems.

2. Functions of the process control system.

The main function of the process control system is to exclude the human factor in the process control. The rest of the functions only facilitate the task of controlling the technological process:

A separate subsystem is ESD - emergency protection.

The ESD system is installed additionally on especially hazardous technological processes.

The task of the ESD system is to prevent an emergency and exclude damage to equipment or injury to personnel.

3. Integration of systems.

Modern PLCs support many communication protocols. Some of them are open, for example ModBus, others are closed and are used by only one manufacturer: Profibus, Profinet.

Thanks to open protocols, the process control system can combine equipment from any manufacturer into a single system, optimally solving automation problems.

The OPC (Open Platform Communications) family of technologies is used for dispatching. When using OPC servers, the process control system can dispatch not only the technological process, but also various utilities (ventilation, climate control, power supply, control and access control systems) into a single complex.

4. MES level.

The Manufacturing Execution System guarantees minimization of losses and full control over all material flows of the plant. The operational control system of production processes can combine several factories and production facilities and easily integrates with equipment, controllers, PLM systems, corporate business applications, quality management systems, laboratory data management systems and many other applications.

As a result, MES guarantees complete transparency of all production and processes in the enterprise and the ability, if necessary, to quickly and effortlessly conduct both audit and optimization based on the obtained data.

5. Internet of things in the process control system.

The next step in the development of the process control system is the support of the Internet of Things technology.

All leading manufacturers allow you to approach the process of data analysis using artificial intelligence and the latest cloud technologies.

As a result, the process control system is able to analyze the progress of the technological process in real time, visualize all the processes in a convenient form, localize critical points, prepare in advance for servicing the nodes and exclude the possibility of downtime for technical reasons.

6. Completed projects