The concept of technology levels.
Projects running late, all must be done by Christmas.
Too much coffee, not enough sleep. Stress way up.
Sanity threatening to go on strike.
Cause, put two new high tech machines in a low tech plant.
So, what do you do?
Put in a new plant, the best that technology can provide, only to hear the operator say "Flashing lights, oh no, Grog hate flashing lights" then watch him run away and try to hide.
Or do you create something powered by a water wheel that, while low tech and inefficient, can at least be understood by the plant operators?
So, last night my sleep deprived mind came up with the concept of technology levels (actually, it stole them from a computer game, but never mind).
Now, it is just a matter of classifying you end users plant and you know what level to design at.
The levels:
Level 0, Unpowered hand tools only, such as saws, hammers, chisels etc. Some of these places still exist, and can be prevalent in the lower tech places in the world. Human muscle is the power and skill is the control system.
Level 1, Powered tools. This can be as low as an electric drill, or as high as electric pumps and lathes, and other powered tools. At this level, most things are powered but entirely under manual control. The skill of the operator entirely governs the output.
Level 2, Low tech automation. This would be your drum or relay control. Perhapse stand alone pid control. Could even be machine tools run off a template. Sections of the plant will need to be started and stopped by the operator, but generally the operator can turn his back on them for a moment and still have the machine run OK. In some cases the operator will have to control some deviced or processes manually. No PLC here.
Level 3, PLC, DCS or CNC machines. The level 2 processes are taken over by full central computer control. Since this is a PLC site, I will concentrate on the PLC component. Control is similar to level 2, but tends to be easier, with more indicators and instrumentation. Positioning control would be by either single or pole changing DOL motors, or basic VSD.
Level 4, HMI. The machine is PLC controlled as per level 3, but has an addition of a HMI panel of PC based SCADA system. The HMI would be either a touch panel, or a key operated panel with a display screen of 6 inches or larger. This level greatly improves diagnostics and ease of operation, but is not for the more technophobic cultures.
Level 5, Advanced positioning control. Positioning control is via either a servo controller, or encoder (incremental or absolute). Movements are faster and more precise, productivity goes up, but well trained technicians are required to maintain and fault find these systems.
Level 6, Field Bus. Device net, profibus, ethernet - and others. Easy to install and wire up, can be hard to maintain for lower tech inclined personnel.
Other levels can be added for areas currently outside my experience.
My problem, tried to install a level 6 machine (with all the level 5 stuff) in a level 2 plant.
Should have limited it to a level 3 max.
Projects running late, all must be done by Christmas.
Too much coffee, not enough sleep. Stress way up.
Sanity threatening to go on strike.
Cause, put two new high tech machines in a low tech plant.
So, what do you do?
Put in a new plant, the best that technology can provide, only to hear the operator say "Flashing lights, oh no, Grog hate flashing lights" then watch him run away and try to hide.
Or do you create something powered by a water wheel that, while low tech and inefficient, can at least be understood by the plant operators?
So, last night my sleep deprived mind came up with the concept of technology levels (actually, it stole them from a computer game, but never mind).
Now, it is just a matter of classifying you end users plant and you know what level to design at.
The levels:
Level 0, Unpowered hand tools only, such as saws, hammers, chisels etc. Some of these places still exist, and can be prevalent in the lower tech places in the world. Human muscle is the power and skill is the control system.
Level 1, Powered tools. This can be as low as an electric drill, or as high as electric pumps and lathes, and other powered tools. At this level, most things are powered but entirely under manual control. The skill of the operator entirely governs the output.
Level 2, Low tech automation. This would be your drum or relay control. Perhapse stand alone pid control. Could even be machine tools run off a template. Sections of the plant will need to be started and stopped by the operator, but generally the operator can turn his back on them for a moment and still have the machine run OK. In some cases the operator will have to control some deviced or processes manually. No PLC here.
Level 3, PLC, DCS or CNC machines. The level 2 processes are taken over by full central computer control. Since this is a PLC site, I will concentrate on the PLC component. Control is similar to level 2, but tends to be easier, with more indicators and instrumentation. Positioning control would be by either single or pole changing DOL motors, or basic VSD.
Level 4, HMI. The machine is PLC controlled as per level 3, but has an addition of a HMI panel of PC based SCADA system. The HMI would be either a touch panel, or a key operated panel with a display screen of 6 inches or larger. This level greatly improves diagnostics and ease of operation, but is not for the more technophobic cultures.
Level 5, Advanced positioning control. Positioning control is via either a servo controller, or encoder (incremental or absolute). Movements are faster and more precise, productivity goes up, but well trained technicians are required to maintain and fault find these systems.
Level 6, Field Bus. Device net, profibus, ethernet - and others. Easy to install and wire up, can be hard to maintain for lower tech inclined personnel.
Other levels can be added for areas currently outside my experience.
My problem, tried to install a level 6 machine (with all the level 5 stuff) in a level 2 plant.
Should have limited it to a level 3 max.