You’ve invested in control engineering devices. How can you be sure you’re getting the most out of them?

Scope, scope, scope this is the most important part of any project including selecting automation devices you need to know what you want to achieve and then you choose the right device for the job there is no point driving a super car on the school run and device selection is similar there is no point having a plc with all the whistles to turn a lamp on

Safety aspect also needs to be considered while selecting the devices. Protection class needs to be selected based on the location of the devices. Hazardous area Zone 0/1/2, Group I/II/III, Gas group A/B/C and temperature class T1/2/3/4/5/6 needs to be considered.

It’s better to define expectations about your process. You could go for cheaper ones or really expensive ones. It depends also on your environment maybe you need IP54, IP 68 protected devices that kind of things as well. It is not easy to select one device directly you have to check electrical connections, network requirements, fieldbus connectivity etc. so again you have to define what’s beneficial for you.

Automation equipment can be really expensive, and not only them but also licenses and associated software. That's why it's so important to have a clear understanding from the beginning of what the scope of your project will be, because otherwise it can become extremely expensive very fast.

Don't let your control project fizzle out! Equip it with the right tools. Mismatched devices are like mixing wrenches and paintbrushes. Analyze your project's needs: simple temperature control? A thermostat's your knight in shining armor. But for a robot dance-off? You'll need a multi-sensor, actuator-wielding champion. Research features, compare specs, and choose the device that'll make your project sing. Bonus tip: think ahead! Pick something with space to grow, so your creations can evolve to epic proportions. Unleash the control magic within!

Got the perfect control device? Don't let its superpowers fade! Calibration is your secret weapon – it fine-tunes its senses to match your project's reality. Think of it as calibrating a telescope: blurry stars become vibrant galaxies! Testing is your training ground – throw different scenarios its way to ensure it dances under pressure. Every tweak, every test unlocks its full potential. Remember, regular calibration and testing are like oil changes for your control device – keep it running smoothly and avoid unwanted wobbles! Your project deserves the best performance, so fuel its control magic with precision and testing!

Calibration is nothing but a process of comparing and adjusting w.r.t any reference and all devices require adjustments in their service life.Even the calibration equipment requires adjustments. Calibration ensures your expectations from the equipment, device or machine. Calibration also protects you from financial losses e.g. in cutting machines where length is crucial therefore calibration is necessary to cut at the right spot.

Don't let your control device become a museum piece! Its software holds the code to its superpowers, and keeping it fresh unlocks hidden potential. Think of it like upgrading your phone: bug fixes, new features, even security boosts! Optimization is like tuning up a race car – squeeze out extra speed, minimize energy drain, and watch your project zoom ahead. Download manufacturer updates, dive into code tweaks, and unleash the hidden magic within. Remember, a little software TLC helps your control device stay relevant, powerful, and ready to conquer any engineering challenge!

Usually we get firmware updates. If you’re a big customer for that company, you’ll get reliable support about these kind of changes. Bug fixes, recommendations as well.

Firmware….I like devices with well-tested firmware and backwards compatibility, but this seems akin to unicorns. The reality is that firmware mods and bugs are a product of expansion or component obsolescence more so than the complexity of the inherent design. Often, the changes are made, and testing the newest version of the firmware does not happen, so the folks in the field become unpaid testers. Last year, we had a challenge with load-sharing VFDs where the follower failed, and we had to replace it with the newest model. It just did not work. The brand support was in such denial that the problem was the firmware, and they made us waste several days. We finally loaded the firmware ourselves from about five years ago, and it worked fine.

Got your control device humming, but something feels off? Don't fret! Monitoring and troubleshooting are your detective workhorses. Think of it like watching a detective show: data is the case file, alerts are the flashing sirens, and troubleshooting is the "aha!" moment that solves the mystery. Monitor inputs, outputs, and logs – your device talks through data! Look for inconsistencies, glitches, or resource drains. Then, like a skilled detective, use diagnostics and feedback to identify the culprit: faulty hardware? Software hiccups? External interference? With targeted troubleshooting, you'll have your control device back to peak performance in no time, ready to tackle any engineering challenge!

La mejor forma de optimizar la arquitectura de control de planta es ser eficiente en los procesos a través de métodos o técnicas ,por ejemplo midiendo el OEE , evitar las perdidas y tiempos muertos,aplicando mapeo en los procesos automatizados para detectar oportunidades de mejora continua .

This is incredibly important in today's world where the purpose of automation is to improve efficiency of your process There are so many ways to achieve this but one fundamental way that I see barely mentioned now is "diagnostic defensive coding" Examples like using the current feedback on a VFD to understand if the motor and gearbox is performing correctly or if something is making it draw more current possibly indicating an issue Or using an I/O link sensor and using all the diagnostics to understand if it may be dirty and likely to start reading incorrectly These small things give you system the greatest chance to meet the ever demanding OEE needs of your end user

Unleash the hidden potential of your control devices! Tip 5: Be a control champion - Learn, Grow, Adapt! Control engineering is a dance, not a waltz. Things change, challenges evolve, and your devices hold secrets waiting to be unlocked. Embrace discovery! Research new tech, tweak your approach, and share your lessons with fellow engineers. Collaborate, experiment, and watch your projects reach new heights. Remember, the best control comes from curiosity, not a set-and-forget attitude. So, dive into the data, explore the possibilities, and keep learning. Your engineering magic awaits!

It really comes down to one word "Data" And it can come from many forms 1 lessons learnt How did the device commissioning go was it working as expected and issues with it 2 data capture If you build in data capture into your system via the cloud or a SCADA then you can use this data to understand the device performance and target improvements 3 maintenance capture Using a good CMMS package can really inform how devices are performing over a longer period and help to direct new upgrades, functions or devices

I think the other thing to consider is the power of "standards" Now there are some negative ideas about standards such as it removes creativity in engineering or once a standard is made it never changes. But in the VUCA world we now live in standards cannot be fixed unmoving monoliths they have to evolve and have the agility to solve problems as they arise. What a standard truly does for you is make the 80% to 90% of your project certain and reliable allowing you to concentrate you time and effort into the 10% to 20% that is new or changing to meet a new requirement or technology. I short good standards allow you the freedom to be creative where needed but without the chaos of Re-inventing the wheel every project.

Perhaps the most important aspect to remember is that third party perspective is always important if not critical. The task you are trying to accomplish or perfect has likely already been accomplished elsewhere either in or out of your company. Do not fall into the trap of thinking a system has to be designed a certain type of way solely as a result of a set of given conditions; either seek to gain additional perspective for your design or bring in another perspective to evaluate if there is a better way to accomplish your goal. At the worst you may discover that you are indeed creating a radically new system, and at the least you are maintaining important industry connections!

Selection of control equipment is crucial task of project engineering. You have to know what you measure and why you measure in order to decide how to measure. Next stage will be Selection of suitable devices, calibrate correctly and integrate in the control system as its intended to function. For each stage in projects life cycles, should be a metrics or KPIs that tells you if your functions deviate from the goal it was made for.