Process control technology monitors sensors and adjusts variables to ensure efficient operation. There are four types: single-loop, sequence controllers, distributed control systems, and supervisory control and data acquisition (SCADA). SCADA is the most complex, allowing for scheduling and monitoring of many sensors and variables.
Process control is used extensively in factories and other automated environments to keep systems running efficiently. In general, process control technology is meant to monitor sensors and adjust important variables based on the readings. This technology enables complex operations to be handled by a relatively small group of people and helps ensure that the desired result is consistently achieved. There are four main types of process control technology, each with different capabilities.
Single-loop process control is a relatively simple form of automation. This approach uses basic controllers to turn processes on and off in a very linear and predictable way. Simple electronic relays are an example of components commonly found in a single loop system. This type of process control is often used to move a part through the sequential stages of an assembly line from start to finish, with very little variation in the “loop” of the cycle. Single-cycle technology typically only allows the automated cycle to start or stop, but not change it.
Sequence controllers are a class of process control technology that allow an automated cycle to be regulated or redirected. A programmable logic controller (PLC) is often used for this type of control. PLCs and other similar devices can monitor sensors and trigger a different sequence of operations outside the main automated loop. A factory that can detect a defective product and then reroute the assembly line to a different area for inspection is an example of sequence control.
Distributed Control Systems (DCS) are capable of monitoring and controlling very complicated processes. While a sequence controller is typically able to change an automated sequence in one location, a DCS can control many different process variants or “branches”. A distributed control system is often capable of stopping and starting an assembly line, redirecting products to multiple locations, and varying the speed of an assembly line as needed. A DCS allows for a wide variety of variables to be automatically adjusted, which usually improves the quality of a manufacturing system.
Supervisory control and data acquisition (SCADA) systems consist of the most complex process control technology. A SCADA system is usually used in large-scale factories and is often monitored and regulated from a manned central control center. In addition to the standard features of a DCS, a SCADA system also allows operations to be programmed on a schedule. For example, this program can be used to activate a diagnostic sequence every hour in order to automatically check for machine malfunctions. SCADA technology is designed to monitor a wide variety of sensors and regulate many different aspects of an automated process.
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