DT023/4 10990 AUTO 4111 © 2016 DIT [P.T.O DUBLIN INSTITUTE OF TECHNOLOGY BOLTON STREET, DUBLIN 1 ——————- Bachelor of Engineering in Manufacturing & Design Engineering —————— STAGE 4: JANUARY 2016 SEMESTER 1 —————— INDUSTRIAL NETWORKS AND INTEGRATED AUTOMATIONS SYSTEMS Ger Reilly B.Tech. (ed), M.Tech. David Kennedy, Leah Mitchell, B.Eng., M.Sc. DATE AND TIME HERE Answer 4 of the following 6 questions All questions carry equal marks Time Allowed: 3 Hours Given:DT023/4 10990 AUTO 4111 © 2016 DIT [P.T.O 1 Specify the hardware requirements for the networked control system outlined below: Mini Cake production line oven: The Oven will receive filled cake pans from a dosing system. The cakes will be cooked by transporting the pans through a 20 metre long oven with 12 individually controlled zones. The temperature in each zone will be monitored and flow of gas to the burners in each zone can be controlled to adjust the temperature if required. The speed of the oven conveyor and the temperature in each zone will be automatically adjusted by a control system using predefined rules based on the colour of the cakes leaving the oven. (Note: Each burner will require an output to the gas valve, an input to monitor flowrate and an output to ignite the burner) The system is to allow for automatic and manual control. The system will allow for real time monitoring and connection to a Manufacturing Execution Management, MES system. Outline any assumptions and justify any selections made within your answer (25 marks) 2 Industrial controllers such as the Programmable Controller, PLC or the Programmable Automation Controller, PAC are at the heart of most control applications, and programming these control systems is a time consuming task. Quality, efficiency, and the need to achieve higher levels of automation are the driving forces behind the adoption of software standards in all areas of computing. Discuss the role of the IEC61131-3 standard in programming industrial controllers. In your answer make reference to the following; (i) Software architecture and execution control (7 marks) (ii) Standardisation (5 marks) (iii) Programming (8 marks) (iv) User derived elements (5 marks) 3 Discuss how you would design a user interface for the system outlined in question 1. Your discussion should include appropriate reference to the following fundamentals of good User Interface Design: • Situational awareness. • Reduction in cognitive load • Ease of Navigation (information hierarchy). Outline with examples to illustrate your approach; (25 marks) 4 (a) Early versions of Ethernet such as 10BaseT shared Ethernet, were developed for an office environment and were not suitable for industrial applications. (i) Discuss the problems that made early Ethernet unsuitable to industrial applications (5 marks) (ii) How do modern Ethernet and in particular, Industrial Ethernets differ from early versions of Ethernet that makes Ethernet based systems a suitable choice for a modern industrial network? (10 marks) (b) Discuss the role of Open Platform Communications, OPC standards in industrial control systems. Within your description make reference to the following; (i) Functionality & Operation (5 marks) (ii) The merits (benefits) of OPC standards (5 marks)DT023/4 10990 AUTO 4111 © 2016 DIT [P.T.O 5 Information Technology, IT systems employ the best practices associated with the "Confidentiality, Integrity, Availability" (CIA) triad model – in that order of importance, when considering network security. The needs of an Industrial Control Systems, ICS differ and here the best practices associated with the CIA triad model is employed in the reverse order; AIC- 'Availability, Integrity, Confidentiality'. (i) Discuss the threats that may apply to the Availability, Integrity, and Confidentiality of an ICS. (10 marks) (ii) Discuss how you can improve the security of an existing ICS to mitigate the damage from these internal and external threats. (15 marks) 6 Programmable electronic systems are being used increasingly, to perform functional safety that may in the past have been carried out by systems comprising of mechanical electrical and/or electronic elements. How do you evaluate and assure the safety of industrial machinery that includes the uses of programmable systems to perform functional safety? In your answer make reference to appropriate standards and directives. (25 marks)