Learn About Industrial Control Systems

Meet Maddy (Madeline Whittier), a 17-year-old literary protagonist from the book Everything, Everything. She has a rare disease - Severe Combined Immunodeficiency (SCID), that requires her to stay indoors 24/7, with filtered air. This immune disorder prevents her from leaving her house and interacting with others. Her life is about books, her mom (Anika Rose) and her nurse - Carla. Her nurse has been with Maddy for 15 years and she's her only company apart from her mother. 

Just like, Carla ensures that Maddy stays healthy and monitors her health regularly; ICS controls and maintains processes by measuring process variables to keep the factory running efficiently and safely. These systems can increase safety in operation environments with high risks of danger in factories, mines, or power plants. Besides, ICS also reduces costs by monitoring performance and detecting anomalies automatically, so human operators need not be present 24/7. Carla plays a role of an advisor to the patient, caregiver and friend to Maddy; ICS is the supervisory control and data acquisition (SCADA) systems, monitors and remote controllers to you.

Read on to learn more about Industrial Control Systems and why they are essential for the third industrial revolution we're living in right now. 

Fun fact - This book was later adapted into the movie and just like the movie this article is worth Everything, Everything; so, take a chill pill and delve right in.
 

What Is Industrial Control System (ICS)?

"Every day, you get up and learn something new. Everything you find something to be happy about…." Today is about learning ICS in detail.

Industrial Control System, or ICS, is a network system that monitors and controls industrial automation processes. The process can be anything from a manufacturing assembly line to a natural-gas pipeline. Industrial Control Systems monitor signals from sensors in real time and record them for later analysis to adjust the process accordingly.

These systems also monitor other outside factors, such as vibration, light, heat or pressure, that could adversely affect the operations of a system. In response to changes or new conditions, the Industrial Control System activates an appropriate response that may involve changing valve settings, increasing production speeds, or some other action. Industrial Control Systems use computers and software to manage and monitor manufacturing processes. With an ICS, you can track essential indicators like speed and accuracy and react quickly if operations have problems.

With that, it's time to rewind the past and discover how Industrial Control Systems evolved.
 

How Did Industrial Control System (ICS) Evolve?

"Everything's a risk. Not doing anything's a risk; it's up to you." 
 
It was 1620 when Cornelis Drebbel decided to do something and designed the first closed-loop control system to operate a furnace, thus introducing the first thermostat. Between 1683-1757, Rene Antoine Ferchault de Reaumur proposed an idea to automate devices to regulate the temperature of incubators. This idea was also based on a closed-loop control system.

Moving ahead, in 1745, Edmund Lee invented a feedback control device to monitor the gap between stones driven by rotating sails. Fast forward to the 1900s, when relay logic was created. Even today, industries use the same relay logic in almost all computational designs and electrical devices. During the same 1900s, ship stabilization and autopilot techniques were developed. In 1932, the concept of negative feedback was introduced for industries; these evolutions altogether played an essential role in the growth of ICS.

Digital control systems were like a revolution that stepped-in in 1956 and were put out for use in 1959 and by the 1960s, direct digital control was developed. Manufacturers used the same control devices in transistors and other computation components we use today.

All these developments were the toward introducing Industrial Control Systems and then there was no looking back. Slowly, ICS became an inseparable part of the industrial sector, which is how it works for them.
 

What Is The Process Of Industrial Control System (ICS)?

 

"Sometimes you do the things for the right reason and sometimes for the wrong ones and sometimes it's impossible to tell the difference." For now, the right thing to do is to decode the process of Industrial Control Systems.

• Planning

  Industrial Control Systems offer a more strategic approach to production planning and control. These systems maximize production capacity and output and schedule maintenance and downtime.

• Auditing 

  ICS audits network architecture, servers, safety instrument systems, controllers and smart sensors. This step helps you audit how many computers you have. How are your networks connected? Do you have safety instrument systems and does it integrate with your ICS? What kind of controllers do you use? Are your smart sensors and actuators digitally accessed?

• Monitoring And Controlling

  Industrial Control Systems have operational technology that includes hardware and software systems. These systems monitor and control physical devices at the stage of the industrial process, from conveyors and robotics to monitors, sensors and control panels.

• Remote Diagnosis

  Industrial Control Systems steps in with remote diagnosis. It can examine, identify and predict the maintenance requirements of your systems. Apart from that, ICS also prevents and recovers abnormal operations and failures.

That's all about the process of the Industrial Control System now; let's take a look at how these systems can be beneficial to you.

What Are The Benefits Of An Industrial Control System (ICS)?

 

"Wanting just leads to more wanting. There's no end to desire." Just like the endless benefits of Industrial Control Systems.

• Ensuring Safety

  For any industry, the health and safety of its workers are a primary responsibility. Industrial Control System ensures maximum safety in the industries and factories. These systems step in with automated sensors and safety alarms that help businesses analyze whether the manufacturing unit is safe and free from any spontaneous combustion.

• Allowing Efficiency

  Industrial Control Systems help manufacturers monitor and control different processes throughout production. These systems can monitor everything from a room's humidity to a factory's temperature. They can also control the flow of materials, output and other variables to meet quality standards.

• Increasing Efficiency

  ICS increases efficiency while reducing waste and the cost of goods sold. These systems schedule production tasks, monitor inventory levels and keep tabs on quality standards and maintenance alerts on machinery parts. They help you replace units before breaking down and alert operators when raw materials are low so that the next batch can be ordered before shutting down equipment for routine maintenance.

That's all about the past and present of ICS; now, let's raise the curtains on its future.
 

What's In The Future Of Industrial Control Systems (ICS)?

 
"Maybe we can't predict the future but we can predict some things." For example, the future of ICS. So, put on your glasses as the bright-bright future of the Industrial Control System (ICS) is glaring at you.
 
Be prepared to welcome the better version of programmable logic controllers (PLCs). It's a technology that regulates and automates the functions in the process of manufacturing. In the future, PLC will mature and use different sensors connected to record actionable information. PLCs will also improve with AI (Artificial Intelligence), cloud computing and big data analytics.

IIoT, AKA Industrial Internet of Things, is another breakthrough and how. This trend will ensure robust interrelation and correspondence between instruments, sensors and other devices. Besides, IIoT will enhance industrial operations' performance, visibility and insights. Long story short, these trends are all set to level up the efficiency of Industrial Control Systems.

Let's Call It A Wrap!

From factories to power plants to oil refineries to mining operations to any other industrial facilities – Industrial Control Systems are everywhere. These systems are not only helpful in monitoring sensors on machinery and process inputs but are also essential for detecting a sensor that has failed. Just like Carla took care of Maddy and ensured that she was safe from any infection, ICS checks breakdown problems and alerts you by triggering an alarm to prevent unsafe conditions. With that, it's time to call it a wrap!