Managing Tool Data in Real Time
Access to real-time, actionable data is a key element in smart manufacturing. That is why supervisory control and data acquisition (SCADA) systems, comprising both hardware and software components, are the nucleus of today’s smart factories.
SCADA systems are used for the supervision and control of manufacturing facilities. They also are used to collect, process, and analyze data in real time. They rely on a human machine interface (HMI) to interact with field devices such as pumps, valves, motors, and sensors.
Remote terminal units (RTUs) and programmable logic controllers (PLCs) are microprocessors that communicate with HMIs and field devices, and route data to SCADA computers for analysis and action. Communication can be hard wired or remote using virtual network computing (VNC).
Kinetics offers a full suite of SCADA and controls solutions designed to work in concert with the Mega Fluids Systems product line.
Mega Fluid Systems offers PLC- or PAC-based control systems for the control and automation of both Chemical and Slurry Blend and Distribution systems. Choosing the control system that makes sense for the individual tool, we utilize rack and/or distributed input/output (I/O), and internal and external networking and communications to control and monitor the tool’s key devices — pumps, valves, tanks, metrology (pH, saturated gas units, concentration, particle size, titration, and temperature).
- Built using same software tool as system HMI
- Remote option using VNC
- Web-client option
- Paging/e-mail options
- Increased functionality and flexibility
Mega Fluid Systems Controls Engineering Group supplies turn-key control, monitoring, and automation solutions for molecular delivery tools. Our team of controls and electrical engineers have extensive experience in the following applications:
- Automating chemical and slurry blending and distribution systems
- Designing intuitive HMI and SCADA applications
- Providing plug-and-play network connectivity solutions, and
- Providing alarm, graphing & charting, and reporting services.
Utilizing state-of-the-art visualization software, our team creates graphical user interfaces that show the user the information they need, when they need it — information, which when the application requires it, is always clear and intuitive. System overviews, drilldowns to P&ID-based details, set point and recipe control, alarm monitoring and acknowledgment, and special custom features implemented after extensive collaboration with the system users are all part of the Mega Fluid Systems HMI experience.
The MegaLink 2 is a system that provides interfacing for status and demand handshake signals between chemical dispense units (CDUs) and multiple point-of-use (POU) tools. The system provides status and valve control interfacing between Mega dispense tools and valve manifold boxes (VMBs), which feed the POU process equipment by using advanced Ethernet communication. The system is designed to take control and automate factory chemical delivery, and can support up to 8 remote units per host.
In the highly configurable MegaLink 2, chemicals or slurry run from the CDU through the VMB and return to the CDU through a global loop. A signal is sent to the host when chemicals or slurry are available in the CDU. When the POU is ready for chemicals or slurry, it sends a demand signal to the host. If no alarm is present, a signal is sent to the VMB to open a single-stick automatic valve allowing chemicals or slurry to flow to the POU inlet.
Standards and Features:
- Fully configurable I/Os, such as safety interlocks and valves
- Can control VMBs from multisource delivery solutions
- Hardware or software handshake signals interface
- Touch-screen monitor included with host
- Host controls up to 8 remote units
- Multiple I/O configuration sizes to fit large- or small-scale factories
- Supports up to 128 different global loops and associated CDUs & POUs
- Supports up to 128 VMBs with a maximum of 12 fully configurable sticks, or 128 manually controlled TVBs
- Redundant DC power
- Supports up to 32 CSS points
- Redundant Communications
- Redundant AC Power Supply
- Redundant PLCs
Supervisory control and data acquisition (SCADA) is a critical, nearly inescapable, component of next-generation factory automation. Not as a replacement to human planning, process management, or timely intervention, but as a means to both stabilize, then elevate, line and plant performance.
That said, the systems being utilized to capture, analyze, and report a multiplicity of data types range from primitive to elegant. From Kinetics’ experience extending from research settings to high-volume manufacturing (HVM) environments, data acquisition is close to irrelevant if the human machine interface (HMI) fails to interact effectively with field devices including pumps, valves, motors, and sensors.
To make better decisions, including how and where remote terminal units (RTUs) and programmable logic controllers (PLCs) communicate with devices and route data, an exploration of three real-time options is warranted. While connecting with a Kinetics’ team member is the next logical step, this telegraphic overview represents a strong start to your evaluation.
PLC- or PAC-based CONTROL SYSTEMS both control and automate chemical and slurry blending as well as distribution systems. Rack or distributed input/output (IO) allow internal and external networking and communications: At stake is monitoring of process-critical devices to include pumps, valves, tanks and metrology. In this scenario, the control system is built using the same software tool as system HMI. Increased functionality and flexibility are two outcomes connected to the resulting smart factory performance.
MEGAVIEW tackles SCADA with a robust suite of turnkey control, monitoring, and automation products connected to molecular delivery. It thrives on delivering systems based upon insight — for more intelligent specifications, on-line monitoring, and uptime analysis and correction on the plant floor. Additionally, monthly reports give customers confidence in their decisions across automated chemical, slurry blending, and distribution systems. A world of possibilities is reduced to high-performing recommendations formulated by Kinetics’ team of control and electrical engineers.
MEGALINK 2 is considered by some customers to be startling in its simplicity, profound in its ability to be configured right down to the safety interlocks and valves. Here, status and valve control interfacing feed the POU process equipment via advanced Ethernet communication. Dialed in to small- and large-scale factories, up to 128 different global loops get the support they warrant as redundant DC power keeps the ability to know, decide, and act within reach. From a few meters to miles away, handshake signals interface reliably and accurately.
If the relentless pursuit of intelligent factory operation is central to your team’s KPIs, Kinetics extends your reach now and in the future. With PLC Controls, MEGAVIEW, and MEGALINK, smarter performance is about probability today, along with potential in the tomorrows to come. Learn more by emailing firstname.lastname@example.org.