RheinhardtP
Lifetime Supporting Member + Moderator
Are control system stuck in the 90s
I read a lot of forums and blogs on the future of control systems and these got me thinking more about our line of work. The more I thought about it the more concerned I got.
The beginning
I started my engineering career in January of 2002. Being fresh out of a tertiary education I was amazed at the technology I got to see and play with with as part of the learning curve.
There was the joy of programming my first PLC, SCADA and touch panel HMI. Designing my first instrument control loop, The joy of figuring out protocols like Modbus, deviceNET and profibus. I will never forget the first time I managed to pull in a deviceNET modules contactor next to me on my desk after multiple failed attempts and hours spent deciphering documents directly translated from Japanese. This was my first experience with fieldbus, the world was green and I was learning quickly.
Mobile phones were simple then, touch screen HMIs were the only link to modern touch pad devices and I found them fascinating, I felt privileged to be in my line of work, I felt like i was part of the future!!!
Fast forward to 2016
14 years later im looking around me and not much has changed. We have controllers that run microprocessors built in the 80s. SCADA pages that look exactly the same as when VGA graphics first came around and interfaces which dont drive adequate operator response in my opinion.
Some questions I would like you too consider...
What about the next generation of control engineers?
Firstly I would say again when I entered the job marked the technology fascinated me, touchpad devices for your home were not around at that point, and part of that is what made me embrace control systems. How will the next generation experience our current technology in the market? Will they find it boring, how will current technology inspire the next generation of control system engineers, when they have newer and greater technology in their own homes?
How can we keep up with Big Data?
In a world where statistical analysis forms the mathematical base of how we analyse processes I think big data will become a problem. Prior to PLCs alarms and processes needed a lot more consideration to be functional and efficient. Although PLCs have made engineers live easier, I think it has made controllers lives a nightmare. We poll tons of information from the controllers and smart devices because we are able to easily and don’t get me wrong I am a big fan of data but how much of this data adds value? I already see system lag due to hardware not being able to keep up with the amount of information systems want to poll. Current process control hardware is lacking in this regard. And our hardware does not keep up with the greater demand in the world for more data.
Years of PLC and SCADA, why are alarms still an issue?
Alarms are no longer designed, they are enabled. This causes flooding in alarming systems and takes away from the controller efficiency. How is it that after countless years of controllers and SCADA systems we as system developers are still bad at this. I find it mind blowing that we still see control system where alarm flooding is a major issue. Don’t we learn from our past experiences?
Food for Thought
One of my primary tasks in my current occupation is developing control system standards for big companies. Alot of these system are new and I look at an estimated life of plant/system. As I have gone through the process I realized that control systems as an industry need to look ahead to the future.
It is up to us to design effective, practice systems that will have a 20 year life-cycle or possibly beyond.
Currently we are not catering for the next generation, would you work in an industry where the technology is old and fast becoming redundant.
I certainly know I wouldn’t.
Would love your thoughts on this.
I read a lot of forums and blogs on the future of control systems and these got me thinking more about our line of work. The more I thought about it the more concerned I got.
The beginning
I started my engineering career in January of 2002. Being fresh out of a tertiary education I was amazed at the technology I got to see and play with with as part of the learning curve.
There was the joy of programming my first PLC, SCADA and touch panel HMI. Designing my first instrument control loop, The joy of figuring out protocols like Modbus, deviceNET and profibus. I will never forget the first time I managed to pull in a deviceNET modules contactor next to me on my desk after multiple failed attempts and hours spent deciphering documents directly translated from Japanese. This was my first experience with fieldbus, the world was green and I was learning quickly.
Mobile phones were simple then, touch screen HMIs were the only link to modern touch pad devices and I found them fascinating, I felt privileged to be in my line of work, I felt like i was part of the future!!!
Fast forward to 2016
14 years later im looking around me and not much has changed. We have controllers that run microprocessors built in the 80s. SCADA pages that look exactly the same as when VGA graphics first came around and interfaces which dont drive adequate operator response in my opinion.
Some questions I would like you too consider...
What about the next generation of control engineers?
Firstly I would say again when I entered the job marked the technology fascinated me, touchpad devices for your home were not around at that point, and part of that is what made me embrace control systems. How will the next generation experience our current technology in the market? Will they find it boring, how will current technology inspire the next generation of control system engineers, when they have newer and greater technology in their own homes?
How can we keep up with Big Data?
In a world where statistical analysis forms the mathematical base of how we analyse processes I think big data will become a problem. Prior to PLCs alarms and processes needed a lot more consideration to be functional and efficient. Although PLCs have made engineers live easier, I think it has made controllers lives a nightmare. We poll tons of information from the controllers and smart devices because we are able to easily and don’t get me wrong I am a big fan of data but how much of this data adds value? I already see system lag due to hardware not being able to keep up with the amount of information systems want to poll. Current process control hardware is lacking in this regard. And our hardware does not keep up with the greater demand in the world for more data.
Years of PLC and SCADA, why are alarms still an issue?
Alarms are no longer designed, they are enabled. This causes flooding in alarming systems and takes away from the controller efficiency. How is it that after countless years of controllers and SCADA systems we as system developers are still bad at this. I find it mind blowing that we still see control system where alarm flooding is a major issue. Don’t we learn from our past experiences?
Food for Thought
One of my primary tasks in my current occupation is developing control system standards for big companies. Alot of these system are new and I look at an estimated life of plant/system. As I have gone through the process I realized that control systems as an industry need to look ahead to the future.
It is up to us to design effective, practice systems that will have a 20 year life-cycle or possibly beyond.
Currently we are not catering for the next generation, would you work in an industry where the technology is old and fast becoming redundant.
I certainly know I wouldn’t.
Would love your thoughts on this.
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