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26/02/2015 - Profibus technology: The Benefits of Industrial Networks in the Sugarcane Industry in Brazil

The sugarcane industry in Brazil has been standing out as bioenergy plants, producing through sugarcane Ethanol, being the world's second largest producer with 26.52 billion liters, sugar with 37.76 million tons, being the world's largest exporter and installed capacity of 9,339 MW of electricity generation with burning of sugarcane bagasse after juice extraction, with annual sales in the industry sector of 43.36 billion dollars.

With those numbers, the sector is highlighted in the world, since it is a "green" industry and highly strategic for the government because it is robustly positioned in our energy matrix.

One of the greatest challenges of the sector is the management of industrial costs, requiring plants with automation to enable high availability production during the harvest period, around eight months, with high scale gains, besides controlling the process variability because the loads vary throughout the production period and ending with high operational safety systems.

The sugarcane industry has undergone a major investment phase to reach these numbers and the challenges, around the year 2006, there were massive investments in new plants and upgrading of existing ones where the technology of Industrial Networks with the Profibus protocol were highlighted and it was adopted on 6 of 10 automation projects.

One of the main points that characterize the process of plants is that their plants need since discrete signals on the lower level of command, to redundant control systems with intelligent field instrumentation, through motor command center coming to the management of assets.

The Profibus technology has allowed attending all signal levels and control, where in profile Profibus DP we have the MCC Motor Control Center and connections to remote, very used in these industry architectures.

Regarding the profile Profibus PA, intelligent instrumentation met all the process control part, highlighting also to service in classified areas, mostly in the ethanol distillation sectors that need this requirement.

Complementing the control signals and plant interlock, the ASI Bus networks, stand out with the sensors in valves, position indicators, drives and signaling accessories, reaching the conversions of discrete signals for network connection.

The benefits of using Profibus networks were many and we can highlight the ease of installation of large command and control systems, reducing installation time in new plants, ease of development of logic in standard systems with communication blocks, additional information of devices and tools for configuration and management of online assets, simplicity, robustness and information, leveraged the Profibus applications in the industry.

The industry still demands many technologies, as it still is in mature growth phase, the networks certifications, profiles standardizations, training and professional qualification and asset management; continue highlighted on current needs for this protocol.

The Profibus protocol changed operational control model of the sugarcane industry, the industry has become a global benchmark in energy production with high level of security automation, production and management, placing the sector among the most important in Brazil and also highlighting in the world.

 

Source: automacaoindustrial.info

 

25/02/2015 - Industry 4.0: A View of Industrial Automation

Weather forecast is for rain in two days, the government needs to expand ethanol inventories by 10% by the end of the harvest, the value of sugar has 3% rise prediction by the end of the harvest, the supplier of inputs does not have enough stock for the production at the peak, two valves and two critical frequency inverters for plant availability are planned for maintenance a week from now ... imagine all these data, communicating online, in a single database of ethanol production plant and sugar in the sugarcane plant, we have a scenario where we have to make decisions.

So the SYSTEM relies on decision-making and makes an automatic setup of production control variables, changing parameters of PLC or DCS, drawing production to impound the rains provided, directs the production increase of 10% ethanol under contract government, directs primary juice for sugar production increase seen raising the offer price, contingency purchase alternative supplier of inputs, makes a scheduled stop for event-based maintenance, contingentiated to support the demand, in a possible rain already provided these decisions were made, all automatically, based on a database Big Data ... this is the industry of the future, this is the Industry 4.0.

When we say that the internet is in the industry, in the production environment, we must think in an environment where all equipment and machines are connected in networks and providing information in a unique way, this concept is called Internet of Things. Industry 4.0 is still more a concept than a reality, but is being driven by three major changes in the productive industrial world, the exponential progress in the ability of computers; the vast amount of digital information and new innovation strategies (people, research and technology).

Understanding the Industry 4.0 as an evolution of industrial production systems, we can list some predictable beneficial and have already studied and based on the impact on plants: cost reduction, energy savings, improved safety, environmental conservation, error reduction, end of waste, transparency in business, increased quality of life, customization and unprecedented scale.

The base technology responsible for this concept is the IoT - Internet of Things (IoT) and M2M - Machine to Machine (Machine to Machine).

The Internet of Things, as previously mentioned is the logical connection of all devices and media related to the production environment in question, sensors, transmitters, computers, cell production, production planning system, strategic industry guidelines, government information, climate, suppliers, everything being recorded and analyzed in a database. Currently the automation systems must be oriented to increase production, reduce costs and technological changes in vision, for that the technical platform should be structured with industrial networks, optimization systems and database.

Understanding that from the use of the above premises, the operational maturity, will lead to this new demand, where the Industry 4.0 vision is oriented to energy efficiency, integration of the production chain and production guidance via BI (Business Intelligence), where the structuring technique will lead to the control of decentralized processes, all assets will be online and decision making will be based on Big Data.

With this, the Industry 4.0, from our present, leads us to understand their tendency in the production environment and we propose to observe the following trends that are already in motion in the industrial environment:

Interconnection "The Things" into a Single Network (Internet) through IPv6 in the Cloud; Generation, shipping, accumulation and analysis of data in Big Data - modeling for making autonomous decisions;

Omnipresence of information, no matter where you are, the interaction is in real time.

We conclude that the Industry 4.0 is a new concept that will surely be a reality, will change the way we deal today with the production of consumer goods and materials, having a better distribution of wealth and a more sustainable planet.

 

Source: automacaoindustrial.info

 



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