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Xiamen Xiongba Group is committed to providing high-quality industrial automation products and solutions to customers around the world. As an industry leader with many years of rich experience, we focus on core products such as ABB brand PLC systems, DCS systems, robot systems and large servo control systems. We carefully select from world-renowned brands to ensure that each product undergoes strict quality testing to meet the stringent requirements of various industries for efficient, stable and intelligent equipment.

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Construction Engineering

abbcontrollers

Project Background

As the existing automation system ages, equipment communication and data collection become unstable, a chemical plant faces problems such as low production efficiency, high failure rate and potential safety hazards. To this end, the plant plans to introduce the ABB AC500 series PLC control system, which uses a new communication architecture and intelligent monitoring platform to achieve precise control of process parameters, real-time sharing of production data and remote diagnosis, ensuring production safety and improving the level of factory modernization.

Main transformation goals

Core equipment replacement: Replace traditional control equipment with ABB AC500 series PLC and its supporting I/O modules; Improvement of process control accuracy: Accurate control of key process parameters is achieved through high-precision modules and advanced control algorithms; Communication system optimization: Build an industrial Ethernet architecture with redundant backup to achieve high-speed data transmission and real-time monitoring; Human-machine interface upgrade: Integrate the SCADA platform to achieve remote monitoring, alarm prompts and data trend analysis; System reliability and security enhancement: Ensure continuous and stable operation through hardware redundancy, isolation design and industrial-level protection measures; Post-maintenance and upgrade: Establish a complete technical archive and training system to ensure the long-term use of the transformation system.
  • Control system requirements
    Core controller: ABB AC500 master controller (such as PM595 or equivalent) is used, supporting multiple protocols such as Modbus TCP/IP and PROFINET; I/O module: The configuration module should meet the mixed requirements of analog (AI, AO) and digital (DI, DO), and support hot-swap replacement and online diagnosis; Programming standard: The system needs to support IEC 61131-3 standard programming language (including ladder diagram, structured text, etc.), and have a good debugging and maintenance platform; Anti-interference design: All equipment and modules should meet industrial-grade anti-interference requirements and be suitable for chemical environments with high dust and humidity; Environmental adaptability: The control equipment should have working stability in harsh environments such as wide temperature and high humidity.
  • Communication and network architecture
    Network solution: Establish a redundant industrial Ethernet ring network, and each node is connected through an ABB dedicated communication module (such as CS31 or PROFINET module); Data acquisition and processing: All data points are collected uniformly and uploaded to the central control platform through the SCADA system, and local caching and distributed processing are realized; Instrument docking: Field instruments (such as temperature sensors and pressure transmitters) use 4-20mA or HART protocol and are linked with PLC in real time; Network security: Firewalls, virtual private networks (VPNs) and permission management are used to ensure that the system is protected from network attacks and illegal intrusions.
  • Control cabinet and field wiring
    Control cabinet design: Layout in accordance with ABB design standards, with 10% expansion space reserved internally to ensure compatibility with future process upgrades; Cable management: All wiring uses flame-retardant sheathed cables, and is reasonably classified and anti-electromagnetic interference treated; Protection level: The cabinet should meet IP54 and above protection standards, and be equipped with overload protection and emergency power-off devices; On-site installation: The installation location must avoid high temperature and corrosion areas, and maintain good heat dissipation and ventilation conditions.
  • Requirements for the upper monitoring system
    System interface: Support configuration software such as ABB Compact HMI or WinCC, with multiple data interfaces and historical data storage capabilities; Functional requirements: Realize process flow monitoring, alarm management, report export and automatic identification of on-site faults; User experience: Provide Chinese interface and permission management functions to ensure simple operation and intuitive information; Remote access: Support remote fault diagnosis and system maintenance through VPN or dedicated line.