PlantPAx modernized DCS system

In recent years, the call for the “factory of the future” has been growing in various industries, and a wave of digital technology has been created to protect against risks and upgrade and empower. In the post-pandemic era, users' increasing demand for flexibility and flexible supply, as well as rising social uncertainty, are making it harder to build the factory of the future.

Rockwell Automation PlantPAx system utilizes a plant-wide automation platform that enables seamless integration of critical process areas with plant auxiliaries, as well as industry solutions ranging from safety instrumented systems and batch control to advanced controls and thin clients. This can help companies improve efficiency and productivity at all levels of operations and help them move toward differentiation, refinement, intelligence and high-end development.

System Features

● Performance-defined system architecture

The PlantPAx system selection tool generates a clear system architecture, free of charge, to help users design a DCS system that minimizes risk and delivers reliable performance according to their needs.

Easy Design, Configuration and Integration

Convenient system configuration supports the primary integration of motor control and field instrumentation, and the system can be easily interconnected with OEM systems.

● Flexible and Scalable

The same platform can be expanded according to actual needs, i.e. from a single stand-alone device to a large distributed architecture.

High Availability

Redundancy at all levels of the system, from I/O to controllers, networks and servers, meets high availability requirements.

● Virtualization Technology

The industry's first virtual image template designed specifically for system servers and workstations allows for rapid system deployment and easy maintenance.

● Support for data analysis

Easily connect valuable data from DCS systems to reporting and analysis tools for efficient plant operations.

● System ID

System ID creates a record of installed products in the system, as well as a dashboard that displays hardware lifecycle status, update and patch notifications, compatibility information, and more, helping to simplify full lifecycle application project management.

Intelligent Power and DCS System Integration

The Smart Power and DCS System Integration Solution seamlessly integrates smart electrical and process control, saving significant amounts of cabling, DCS system I/O cabinets and implementation time, and reducing investment and total cost of ownership. At the same time, it can shorten the switchover time of faulty equipment and quickly restore production operations.

The PlantPAx system provides real-time access to rich and valuable electrical data, which facilitates system control and visualization of plant operations. Users can use the DCS system and information technology system to analyze equipment operation and maintenance and efficiency in multiple dimensions, helping enterprises realize intelligent inspection, energy management and predictive maintenance, and improve asset utilization and intelligent operation and maintenance.

Batch Management and Control

Rockwell Automation batch control solutions, designed based on the ISA-S88 standard, have industry-leading comprehensive, flexible and scalable batch management and control capabilities that enable enterprises to achieve flexible production, accelerated product development and rapid time-to-market.

● Scalable batch solution for efficient and predictable control

● Batch interface is web-based on HTML5 technology for intuitive deployment and operation

● Handles complex unit coordination, resource arbitration, and path optimization

● Manage recipes, including recipe planning, configuration ratios, security approvals, and version control

● Enables material tracking and management

● Complies with regulatory industry codes and protects data integrity

Includes extensive batch reporting, and Golden Batch, developed specifically for domestic users, enhances batch production analysis to optimize batch production.

Advanced Process Control

Rockwell Automation offers multi-tiered advanced control solutions based on PlantPAx systems that integrate advanced control capabilities into DCS systems. The PlantPAx MPC, a rack-mountable module with the Logix platform, enables extended analysis using predictive and prescriptive models for optimized control of critical processes in linear or, under certain conditions, nonlinear processes.

Rockwell Automation has also developed modeling, multivariable control and optimization software packages for complex and variable nonlinear processes, such as Pavilion8. which offers the world's first neuron network-based Model Predictive Control (MPC) technology and the world's first neuron network-based Model Predictive Control (MPC) software. “Pavilion8 provides the world's first neuronal network-based Model Predictive Control (MPC) technology and Product Quality Prediction - Soft Sensor Instrumentation technology. Pavilion8 provides powerful data analysis and pre-processing, linear and linear modeling techniques, steady state and dynamic models, multivariable controller development, and process optimization, providing real-time predictive product quality and calibration to help companies achieve better process management and optimal control.

Process Safety Solutions

Rockwell Automation offers a full range of safety solutions for machinery, equipment, processes and more, with solutions to meet SIL2 and SIL3 requirements in a variety of settings:

ControlLogix SIL2 Solutions

ControlLogix control systems are based on Rockwell Automation's Logix control platform, which is highly modular, flexible in any combination, and expandable according to user needs.

ICS AADvance SIL2/SIL3 Process Safety Solutions

The AADvance solution is a decentralized, scalable architecture that includes hardware controllers and software environments that can be flexibly configured according to the level of reliability and availability required by the plant. In addition, AADvance offers options ranging from small I/O to large systems, from non-safety to SIL3 safety levels, and from fail-safe to multi-fault tolerant.

ICS Trusted SIL3 Process Safety Solutions

High-availability SIL3 safety system that truly meets the requirements of a triplexed hardware HIFT voting redundancy system with TüV SIL3 certification for plant applications with up to 5 fault-limited zones, high availability, and full compliance with the TüV standard 3-2-0 degradation model.

Industrial Data Center + Thin Client Management

With the growth and development of enterprises, the number of control systems and servers required for automation control centers and information technology centers proliferates and requires a lot of capital and manpower for operation, management and upgrading, which poses a great challenge to the development of enterprises.

So, how to optimize the layout space of the server room, reduce the number of servers, and extend the service life of the equipment? How to reduce operating costs? How to improve operation and maintenance efficiency? How to rapidly deploy new systems to meet the needs of business operations? Rockwell Automation's Industrial Data Center + Thin Client Management (IDC+ThinManager) integration provides effective solutions to these challenges.

● TCO savings of 35-75 percent

● Improved operational efficiency

● Improved service levels

● Investment in old hardware and operating system is protected

System Value

Plant-wide control and optimization

By implementing a single plant-wide control system, you can improve efficiency and productivity at every level of operation. Integrating process control, discrete control, electrical control, information control, and safety control into a plant-wide infrastructure eliminates differences between different control systems, dramatically improving plant-wide operational efficiency and reducing total cost of ownership (TCO).

Scalable, Modular Architecture

The PlantPAx system offers multiple architectural options for greater flexibility. Whether you are building a single workstation or a large distributed architecture, you can use the same platform.

Open, Safe, and Informed

Plant-wide network standardized with safety certified industrial communication protocols and standard Ethernet media, seamlessly connecting to plant MES and ERP, and providing real-time DCS information to the business layer at any time, helping users to build a safe, intelligent and modern working environment.

Flexible Delivery and Service Network

Users can choose the best implementation and support team for their needs. They can choose Rockwell Automation to deliver their systems and best-in-class solutions, or they can choose local process system integrators and partners.

What Rockwell has to say

As a leader in intelligent manufacturing, Rockwell Automation provides intelligent power and DCS system integration solutions that seamlessly integrate intelligent electrical and process control through advanced automation, digitalization and intelligent technologies, making enterprise intelligent operation and maintenance more efficient and flexible, empowering intelligent flexible production in depth, and further assisting enterprises to achieve cost reduction and efficiency in full lifecycle operations.