How can you design custom data acquisition and processing solutions for industrial automation?

The first step in designing a data acquisition solution is planning. Are you upgrading a system or commissioning a brand new process? If upgrading your system, there needs to be an inventory of the process and all data collected from it. The type of data and measurement tools should be identified so newer components can be analyzed for compatibility and replacement. Correct software specifications are crucial. Aspects like memory, communication protocols, and automated reports should be priority topics. If commissioning of a new process, which can take years to research and study, it's best to look to experts and examples already in the field so known issues can be avoided prior to installation. A new non-working SCADA system is the worst.

First and foremost should be understanding specific needs of client/end user which includes: 1. What kind of data are you trying to acquire? (eg: Sensor data, machine performance metrics, etc.) 2. What are your goals for processing the data? (eg: Monitoring, Controls, optimization, etc.) 3. Are there any constraints of your application and infrastructure? (eg: Cost, size, power consumption, etc.) 4. What are the existing infrastructure or protocols you need to integrate with?

When defining objectives for a data acquisition and processing solution, it is essential to meticulously identify the variables to be measured, including but not limited to temperature, pressure, flow, level, and vibration. A clear specification of the sampling, storage, and analysis frequencies is vital to ensuring efficient data management. Additionally, determining the required accuracy, resolution, and range of sensors and devices is imperative for precise data acquisition.

Identify the variables you want to measure (e.g., temperature, pressure, flow, level, vibration). Determine the sampling frequency, storage requirements, and analysis frequency. Specify the accuracy, resolution, and range for each sensor and device. Define communication protocols and standards (Ethernet, Modbus, OPC, etc.). Decide on data visualization and reporting requirements. Establish error handling, alarm, and event notification protocols.

I usually start with understanding the clients information needs. How do you expect to use data acquisition (e.g., fault diagnostics, health monitoring, efficiencies, billing, supply chain acquisitions, operator monitor and control, anomaly detection for cybersecurity, etc. this gives me a scope for data acquisition technology requirements, content requirements, and analytics and visualization.

En el escenario, que el hardware pueda otorgarnos confiabilidad, es esencial, es por eso que los equipos puedan ser redundantes, tengan la comunicación adecuada, y que puedan soportar los escenarios de la planta, harán que la instalación prospere de buena forma.

When selecting the hardware components for data acquisition and processing, it is crucial to choose sensors and devices aligned with the specific measurement objectives and specifications, encompassing thermocouples, pressure transducers, flow meters, and other relevant equipment. In addition to these sensors and devices, the selection of suitable data acquisition (DAQ) devices to facilitate seamless connectivity between the sensors and devices and the designated computer or controller is imperative.

Na etapa de escolha de harware, pensando em um empreendimento existente, devemos incialmente lembrar que os instrumentos/sensores fonte destes dados existem para controlar e/ou monitorar um determinado processo, desta forma tudo que deverá ser adicionado n?o poderá impactar o sistema existente, neste ponto na escolha deve ser avaliado funcionalidade, robustez, manutenibilidade, suporte técnico para o hardware escolhido, expansibilidade, tecnologia a ser aplicado, bem como avaliar a possibilidade de melhorar o processo existente.

La elección de un hardware versátil que cumpla con los requisitos necesarios para gestionar las entradas y salidas. Igualmente debe de cumplir con los estándares de comunicación con diferentes tipos de fabricantes con el fin de que se integre de la mejor forma posible.

Selecting the appropriate software tools for programming and configuring the data acquisition and processing solution is a critical consideration at this stage. Careful selection of the software platform that aligns with specific development needs and preferences, such as LabVIEW, MATLAB, Python, or other relevant platforms, is essential for streamlined implementation.

Assim como na escolha do hardware, o software a ser escolhido n?o poderá impactar nos sistemas existentes, neste ponto teremos uma outra variável, que s?o os padr?es de softwares existentes na companhia, bem como o atendimento às políticas existentes de ciberseguran?a (se elas existirem?), avaliar sistema operacional, protocolos de comunica??o necessários bem como restri??es devido as condi??es de local e equipamentos existentes, aplica??es necessárias para realizar a coleta , processamento, armazenamento e publica??o dos dados e/ou informa??es, assim como garantir a perfeita transparência e confiabilidade do sistema.

When designing your data acquisition and processing solution, adherence to industry- and application-specific best practices and standards is imperative. This includes considerations for safety, security, documentation, and rigorous testing procedures to ensure the robustness and reliability of the solution.

Connect Hardware: Wire sensors and hardware components. Set Up Communication: Configure communication protocols. Deploy Software: Install and configure data acquisition software. Test Functionality: Perform functional and performance tests. Troubleshoot: Monitor and address issues. Validate and Accept: Conduct validation tests for stakeholder acceptance. Document and Train: Update documentation and provide training.

O desafio da manuten??o do sistema, para algumas empresas existe um time de engenharia que concebe e implanta o projeto e posteriormente a opera??o e a manuten??o do sistema é delegada para um novo time e dependendo do sistema, a bola ainda fica dividida entre IT e muitas vezes o pessoal de elétrica, nem equipe de automa??o existe para manter o sistema. Posto estes desafios, come?amos a sina: definir sobressalentes estratégicos conforme criticidade, garantir e manter a última vers?o do aplicativo em local de fácil acesso e íntegro, estar atualizado quanto ao ciclo de vida do sistema, o período de obsolescência, bem como entender possíveis melhorias incrementais a serem implantadas e garantir o treinamento e atualiza??o das equipes atuantes.