DAS is a Distributed Antenna System that addresses poor in-building coverage by setting up a network of small antennas functioning as repeaters. Deployments can be passive or active, with passive DAS capturing signals via antennas on the roof and active DAS passing signals through fiber cables. DAS is ideal for densely inhabited indoor spaces like malls and medical centers.
For those exploring alternatives to DAS, options encompass RTU, BAS, SCADA, ICS, PLC, DCS, MES, IoT, ERP, OPC, MQTT, and many more.
RTU
Welcome to the realm of the RTU (Remote Terminal Unit) – a rugged solution designed to thrive in extreme environments. With its advanced microprocessor-control, the RTU operates as the go-between for real-world objects and your distributed control or SCADA system.
RTU Top Features
- An innovative communication interface using RS485 or wireless links.
- Operates in harsh conditions, making it applicable to difficult-to-access locations and extreme environments.
- Boasts an energy-efficient design, often solar-powered, for optimal performance.
- Supports IEC 61131-3 programming standard – a game-changer for programmable logic controllers.
- Highly precise monitoring via analog inputs, such as 0-1 mA, 4–20 mA current loop, 0–10 V., ±2.5 V, and ±5.0 V.
| Feature | Benefit |
| SCADA Master Station Connectivity | Seamless data streaming to the Master Station. |
| Unique addressing | Allows multiple RTUs or IEDs to share a communication line via unique addressing. |
| Autonomous modes | Redefines the user-control interface by modifying behaviour in response to physical overrides. |
RTU Limitations
- Complexity: Made up of single or multiple circuit cards, requiring technical expertise for customization and troubleshooting.
- Power constraints: Can be reliant on AC power supply, despite some offering battery and charger circuitry for backup.
- High-end cost: Premium models with advanced features like protocol alarm management can cost over $5,000.
RTU Pricing
The cost of RTUs spans a wide range. The entry-level models start from around $500, mid-range and high-end options cost more, and the premium models with extensive capabilities can price over $5,000.
RTU Use Cases
Oil and Gas Industry
RTUs shine in remote locations of oil extraction and refining, enabling real-time data monitoring and system control under extreme conditions.
Electric and Utility
Amplify your reach with RTUs offering wireless link communication for remote monitoring, ensuring seamless operation of your grid systems.
Food Processing
With the RTU’s precise monitoring capabilities, keep your food process parameters under optimal control, maintaining uncompromised product quality.
BAS
Building automation systems (BAS) have been integral to infrastructure since the 1600s. With roots in HVAC control systems, the concept of modern thermostat was birthed by Warren Johnson. Ideally, modern BAS can manage climate, light, and monitor performance and device failures. Importantly, reduction in energy use is a key benefit, yet improperly configured systems can lead to energy wastage. The BAS sector enjoys significant revenue, with an expected market value of $100.6 billion by 2022.
Top Features of BAS
- Smart climate control: Maintaining climate within specified parameters.
- Light regulation: Use of light based on room occupancy.
- Monitoring of performance and device failures: Provides malfunction alarms.
- Energy conservation: Designed to conserve energy, air and water.
- Integration: Can link with other systems including access control, security, fire alarms.
| Feature | Benefit |
|---|---|
| Pneumatic Systems | Utilizes Johnson’s thermostat concept for controlling ships. |
| BACnet protocol | Addresses interoperability issues in modern control systems. |
| Niagara framework | Allows integration of multiple protocols. Most widely adopted globally. |
Limitations of BAS
- Requires proper configuration to avoid excess energy usage which is responsible for approximately 8{66f7997927a862c9f57ec7dffc6a2fe6d405caee7001dff533b976d48fe118b1} of total energy use in the U.S.
- Many existing buildings have systems like heating, AC, lighting which operate independently, not integrated with the BAS.
Use Cases of BAS
Use Case 1: Green Buildings
For buildings designed with a focus on energy and resource conservation, BAS can help regulate climate, make optimal use of light based on room occupancy and conserve energy, air and water.
Use Case 2: Large Buildings with Complex Requirements
Modern BAS can provide an integrated control center for managing different systems including access control, security systems, fire alarm systems and elevators, providing an efficient way for controlling and monitoring the building’s operations.
Use Case 3: Future Buildings
The future of BAS envisages a scalable and energy-smart system managing heating, lighting, security, ventilation, sterilizing systems and much more, making it highly beneficial for future buildings.
MQTT
Welcome to the realm of MQTT. Born from the ingenious minds at IBM Pervasive Computing and SCADA engineering firm Arcom Control Systems, it stands as an ISO/IEC PRF 20922 standard protocol designed for low-bandwidth, high latency networks.
MQTT Top Features
- Formulated for Scalable, Reliable, and Efficient machine-to-machine communication, leveraging TCP/IP architecture.
- Allows Secure connectivity, fortified with modern authentication protocols like OAuth, TLS1.3, and Customer Managed Certificates.
- Compatible with several languages, specifically Python – easy to implement with minimal coding efforts.
- Supports Millions of connections with low-power devices on low-bandwidth networks.
- Remarkable Application versatility from Facebook Messenger to AWS IoT Core, enabling smart technology across a spectrum of industries.
| Feature | Description |
|---|---|
| Publication-Subscription Architecture | Decouples data-producing devices from data-consuming applications for seamless operation. |
| Sparkplug Specification | Enhances MQTT capabilities for mission-critical applications by offering standard topic namespace, state management, and data-rich payload. |
| Password Authentication & Token Authentication | Ensures data protection on top of today’s security protocols. |
MQTT Limitations
- Lacks native web support. MQTT data can be received in a web browser only when wrapped in a WSS envelope.
- Demands network connection, no offline access.
- Relatively complex as a protocol, needs specialized knowledge for implementation.
MQTT Pricing
Recognize the beauty of openness? MQTT was released to the public domain in 1999, and it remains so until this day. Optimized for industrial applications, this protocol is freely accessible: a resource buttoned against prohibitive costs.
MQTT Use Cases
Use Case 1: Industrial Automation
Elevate your industrial capabilities with MQTT. This protocol empowers automation on an unprecedented scale, offering efficient, secure data integration and remote accessibility.
Use Case 2: Smart Cities
MQTT shines in Smart City PoC designs, facilitating efficient message transport and managing billions of IoT devices.
Use Case 3: Distributed Multisite SCADA
SCADA systems thrive on situation awareness. With MQTT, you can achieve advanced data collection and communications across distributed sites.
SCADA
Foremost among control systems stands the esteemed SCADA, short for Supervisory Control and Data Acquisition. This computer application doesn’t merely govern from an overseer’s periphery; it delves deep into the machinery’s heart, using digital and analog sensors to collect and analyze data from within the maze of industrial equipment.
SCADA Best Features
- Automated complex industrial processes: SCADA is a maestro at the helm, orchestrating concinnity in intricate scenarios that would traditionally demand human intervention.
- Problem detection and correction: Much like an alert sentinel, SCADA can identify and rectify anomalies that threaten the flawless functioning of industrial systems.
- Scientific measurement of trends over time: Akin to a wise elder, SCADA can discern patterns in data trends, thereby enabling predictive strategies.
| Human-Machine Interface (HMI): | Enabling seamless communication between man and machine, the HMI serves as a conduit for data flow, delivering insights directly into the operator’s hands. |
| Legacy System Support: | Legacy SCADA systems may lack some features, but what they promise is a stable and widely supported structure that can’t be easily dismissed. |
| Future-proof: | With the ability to incorporate emerging technologies such as 5G networks, quantum computing, edge computing, artificial intelligence and machine learning, SCADA is an investment that’s bound to yield future dividends. |
SCADA Downsides
- Cost: Deploying Programmable Logic Controllers (PLCs) can result in considerable long-term expenditure. This cost aspect becomes a significant consideration in comprehensive, widespread applications.
- Cybersecurity concerns: As interconnected and integrated systems become the norm, SCADA faces a growing threat of cyber attacks.
- Legacy system limitations: Legacy SCADA systems fall short when it comes to scalability, interoperability, and heightened accessibility to data and controls.
SCADA Use Cases
Use case 1 – Energy Industry
Equipped to control industrial processes both locally and remotely, SCADA serves as the unblinking eye and skilled hand of the energy industry. From managing intricate power grid networks to optimizing the flow of renewable energy, SCADA’s prowess shines through.
Use case 2 – Waste and Water Industry
From monitoring water purity levels to coordinating the complex operations of waste processing plants, SCADA’s application in the water and waste industry adds an invaluable layer of automation, precision, and proactive control.
Use case 3 – Transportation Industry
Whether it’s the well-oiled choreography of an airport’s baggage handling system, or the orchestration of a city’s interconnected traffic lights, SCADA is the silent force that keeps the transportation industry ticking with clockwork precision.
ICS
Introducing the Industrial Control System (ICS) – a collective term encapsulating devices, systems, networks, and controls tailored for administering and automating industrial processes.
ICS Top Features
- IT & OT components: Operates with IT and Operational Technology (OT) variables to enhance performance.
- Control Servers & SCADA Servers: Centralizes control and supervisory systems for enhanced process visibility.
- Intelligent Electronic Devices (IED): Sophisticated gadgets for real-time, automated control.
- Versatility: Optimal for manufacturing, transportation, energy, and water treatment industries.
- Communication protocols: Utilizes PROFIBUS, DNP3, Open Platform Communication (OPC), and Modbus protocols.
| ICS Variety | Main Use |
|---|---|
| SCADA | Primarily used for long-distance process monitoring and control. |
| DCS | Best for controlling production systems within a single location. |
ICS Disadvantages
- Cybersecurity risks: The convergence of IT and OT presents larger targets for cybercriminals.
- Vulnerability: New tech like cloud computing, big data analytics, and IoT augment the propensity for targeted attacks.
ICS Use Cases
Use Case 1: Manufacturing
An ideal arena for ICS as it supports unitary control over production systems, streamlining processes and reducing the impact of potential faults.
Use Case 2: Power Generation
With the robust central control loops, ICS is instrumental in managing power generation facilities, mitigating system vulnerabilities.
Use Case 3: Transportation
ICS, particularly SCADA systems, excels in long-distance process monitoring and control, quintessential in modern transportation logistics.
PLC
PLC (Programmable Logic Controllers) are pivotal to automation, originating from the 1960s and evolving over time to imbibe advanced capabilities leveraging processor and memory technology advancements. Birthed by General Motors in 1968, they have transformed incessantly, shrinking in size, growing in power, and imparting efficiency and performance to manufacturing operations.
PLC Top Features
- Flexible Architecture: PLCs are tailored according to needs, offering scalability and extensibility.
- Advanced Capabilities: From basic functions, PLCs now offer increased speed, smaller size, and advanced features due to a decrease in size/cost of solid-state memory.
- Hardy and Reliable: PLCs offer robustness, adept at operating in harsh industrial atmospheres.
- Integration: With advancements, PLCs now seamlessly integrate with ERP, MES systems, and SCADA.
| Feature | Benefit |
|---|---|
| Ladder Logic | Eases the understanding and usage of PLC programming language. |
| HMI interaction | Interactive terminals enhancing machine-PLC interaction. |
| Standardization | IEC 61131-3 Standard guarantees consistency across PLC software. |
PLC Limitations
- Requires Skilled Workforce: Working with PLCs demands rigor and competent technicians.
- Complex Troubleshooting: Because of the sophisticated processes, identifying and rectifying issues can be taxing.
PLC Use Cases
Use case 1: Manufacturing
In manufacturing, PLCs enhance process efficiencies, especially evident in the 60{66f7997927a862c9f57ec7dffc6a2fe6d405caee7001dff533b976d48fe118b1} reduction in machine downtime experienced by General Motors post their advent.
Use case 2: Automation
From robotic arms in cars to airport runway control, PLCs drive automation rigor, enabling near-flawless operations.
Use case 3: Data Acquisition
PLCs can monitor and record run-time data like machine productivity and operating temperature; this is exceedingly useful in star-stop processes and in generating alarms during machine malfunctions.
DCS
The Distributed Control System, known as DCS, has revolutionized the automation control space. This versatile system is revered for its real-time control, enhancing productivity while reducing expenses across diverse industries.
DCS Top Features
- Advanced Process Management: The major strength of DCS is its capacity for managing and controlling complex processes.
- Flexible Integration: DCS offers easy compatibility with other existing industry architecture, making system upgrades and modifications seamless.
- Decentralized Control: It provides independent control, reporting, and monitoring components, significantly improving process efficiency.
- Robust Architecture: DCS incorporates engineering workstation, operating station, process control unit, communication system, and smart devices.
| Feature | Benefit |
|---|---|
| Database Management Tools | Convenient control logic, graphics, and system security management |
| Reliability | Efficient mitigation of single processor failure effects |
| Information Distribution | Effective use of a common command structure for correct data sharing |
DCS Limitations
- Substantial Initial Expense: The set-up cost involved in DCS installations can deter small-scale industries.
- Complex Operations: The comprehensiveness of the DCS approach demands skilled handling.
DCS Use Cases
Use case 1: Power Generation
DCS aids in effectively controlling complex grid processes in power generation, driving productivity and safety.
Use case 2: Oil and Gas
DCS enhances extraction and refining processes on significant I/O points, drastically reducing downtime and ensuring safe operations.
Use case 3: Pharmaceuticals and Biotech
In the pharmaceuticals and biotech industry, DCS ensures strict regulation adherence and smooth batch production.
MES
An integral cog in the operational wheel, MES (Manufacturing Execution Systems) are computerized systems adept at tracking and documenting the transformative journey of raw materials into finished goods. Propelled by real-time data, they’re a potent agent in decision-making and production advancement. Their vital function is to establish a conduit between ERP (Enterprise Resource Planning) systems and SCADA (Supervisory Control and Data Acquisition) or process control systems.
MES Top Features
- Effective Product Lifecycle Management.
- Streamlined Resource Scheduling.
- Precise Order Execution and Dispatch.
- Production Analysis & Downtime Management.
- Quality and Materials Tracking.
- Incisive planning of resources.
- Automation of Processes.
- Meticulous Reporting, Dashboards & Analytics.
| Top MES Benefits | Description |
|---|---|
| Reduction in waste and setup times | Optimizes production flow by minimizing waste output and reducing setup times. |
| Increased Uptime | Reduces machinery downtime, amplifying production hours. |
| Inventory Reduction | Real-time tracking reduces work-in-progress inventory levels. |
MES Disadvantages
- High Implementation Cost: Prices range between $375,000 – $1.2 million.
- Requires multiple system integration: ERP, PLC, PLM, CMMS, WMS, HRMS.
- Complex customization: Can become complex when catering to advanced manufacturing processes.
MES Pricing
The cost of implementing an MES system ranges between $375,000 – $1.2 million. The investment, while significant, pays off as it drives operational efficiency and significantly reduces operational waste.
MES Use Cases
Use case 1: Regulated Industries
Industries such as food, beverage or pharmaceuticals require stringent regulatory adherence. Here, MES becomes indispensable by providing an “as-built” record, capturing vital data.
Use case 2: Advanced Manufacturing
For complex manufacturing processes, the customization feature of MES can prove invaluable, providing advanced data protection and smooth integration with existing IT systems.
Use case 3: Large Scale Manufacturing Units
For large manufacturers, the benefits of MES in reducing waste, setup times, inventory, and increased uptime are a powerful reason to invest in such systems.
IoT
The term IoT refers to a system of interconnected devices enabled to exchange data over the Internet. Leveraging technologies such as AI, machine learning, and cloud computing, IoT offers potential solutions for various sectors ranging from healthcare to retail.
IoT Top Features
- Enables data-driven insights and operational efficiency.
- Offers potential for business model creation and new revenue stream generation.
- Facilitates connection to a mass network of devices for better control and communication.
- Adopts machine learning algorithms for detecting anomalies and predicting outcomes.
| Feature | Benefit |
|---|---|
| Wireless automation & control | Significant boost in operational efficiency in various industries such as healthcare and manufacturing. |
| Enabled connectivity | Offers continuous monitoring of machine health and product quality. |
| Machine learning algorithms | Improves machine functionality by predicting and fixing errors in advance. |
IoT Limitations
- Reliance on the Internet for functioning.
- Requires extensive infrastructure for large scale implementation.
- Potential privacy and security risks due to the open nature of IoT devices.
IoT Use Cases
Industrial Sector
IoT holds significant potential to streamline manufacturing processes and maintain continuous inventory monitoring, thereby enhancing operational efficiency.
Home Automation
In the realm of home automation, IoT devices can control various aspects such as lighting, security systems, or even air conditioning remotely, improving the overall homeowner experience.
Healthcare
IoT proves to be effective in the healthcare sector by enabling remote patient monitoring and seamless control over medical devices for enhanced patient care.
ERP
Step aside traditional DAS control systems, it’s the era of ERP – the titan of business technology. With roots tracing back to the 1960s, ERP, short for Enterprise Resource Planning, is no newbie. Created through a groundbreaking collaboration between J.I. Case and IBM, the ERP tech-wave has been on a vibrant evolution for almost 60 years.
ERP Top Features
- Incredible Business Integration – An ERP system thrives in converging various business functions for streamlined operations.
- Cloud-based Accessibility – Cloud ERP has ushered more efficiency, enabling real-time data access anytime, anywhere.
- Artificial Intelligence (AI) and Internet of Things (IoT) Enabled – Using AI & IoT, ERP can virtually breathe life into your data, offering profound insights.
| Feature | Description |
|---|---|
| Automated Reporting | Generates detailed trading reports, focusing on performance across business aspects. |
| Global Collaboration | Connects teams across geographies for seamless workflow. |
| Predictive Capabilities | Leverages AI for projecting future business trends and eliminating manual tasks. |
ERP Downsides
- High Implementation Cost – An initial steep investment is a potential limiting factor.
- Complexity – An intricate system, ERP demands skilled operators for efficient maneuvering.
- Risk of Implementation Failure – A botched implementation can backfire, leading to inefficient operations.
ERP Use Cases
Large Businesses
Thanks to its capability for high-level data management, ERP is a boon for large organizations handling sizeable datasets.
SMEs
With the advent of Cloud ERP, even small and mid-sized enterprises can leverage ERP’s capabilities, bidding adieu to heavy hardware and maintenance costs.
Manufacturing Sector
ERP aids the manufacturing industry in production scheduling, offering enhanced efficiency and productivity.
OPC
Forged by an industrial automation task force in 1996, the Open Platform Communications (OPC) is an industrial telecommunication standard initially known as Object Linking and Embedding for Process Control (OLE). Its primary function is to facilitate real-time data communication between control devices from several manufacturers.
OPC Top Features
- Real-time data reading and writing through OPC Data Access (OPC DA).
- Facilitates easy access to archived data courtesy of OPC Historical Data Access.
- Enables alarm and event messages exchange via OPC Alarms and Events.
- Security measures enriched, scalability, and flexibility through OPC UA.
- Platform Independence; works with Java, Microsoft .NET, and C.
- Enables easy access to field data from plant floor devices.
| Open Platform Communications | Industrial Automation Standard |
| OPC UA | Security, Scalability, Flexibility |
| Access Archived Data | OPC HDA |
OPC Downsides
- Some OPC specifications are only available to OPC Foundation members. This limits the deployment to system integrators with necessary training and certified products.
- Original OPC specification depends heavily on Microsoft’s OLE, COM, and DCOM technologies. This might bring compatibility issues in non-Microsoft environments.
OPC Use Cases
Use case 1
OPC is indispensable in the industrial automation sector where controllers and systems from various manufacturers need to communicate real-time data seamlessly.
Use case 2
In discrete manufacturing and process control, OPC enables easy extraction and transfer of data from control systems to other systems within the facility.
Use case 3
For building automation, OPC serves as a universal conduit, offering streamlined access to important information from hardware and other software packages in real-time.
