What Does a System Integrator Do?

An Allen-Bradley system integrator connects the different components of an industrial automation system together, allowing the system to operate as an integrated whole.

Depending on the nature of the project, this can include:

PLC programming

HMI development

SCADA integration

Industrial networking

Control panel integration

Motor and drive controls

Remote I/O

Machine controls

Safety systems

Legacy system upgrades

The requirements of a project can vary widely depending on the needs of a facility. A thorough integration project will begin by reviewing the process and designing the control system based on how the equipment will need to be operated.

Why Is Industrial System Integration Important?

While a manufacturing facility can have individual components that perform reliably, a poorly integrated system can introduce new complications.

For instance, a controller may operate a production line while an HMI provides information to operators. Drives will control the speed of motors and provide information on their operation, while sensors and other equipment will provide information on the condition of equipment.

If the communication between systems is not established, operators may lack a comprehensive overview of the production process. In addition, diagnosing and solving problems in the process can take significantly longer as the information is divided between multiple systems.

With the proper system integration, the different components can be linked together to provide a more streamlined control environment.

With the integration in place, operators can have a greater overview of the equipment’s condition, alarms, operating parameters, and other information that can be useful in optimizing the process.

PLC Programming and Control

PLC programming is an important part of industrial automation. The controller determines the response to inputs and operating conditions based on a specific logic that must be tailored to the requirements of a process.

An Allen-Bradley system integrator can program new logic into new or existing PLCs, modify and troubleshoot control logic, and support the upgrade process of legacy control systems.

Programming logic should also be written in a structured and easily maintained manner. The use of proper organization, naming conventions, comments within the code, and proper documentation can make troubleshooting and maintenance far simpler.

HMI and SCADA Integration

Operators need to be able to access information on the process being controlled. HMI and SCADA systems provide a means for operators to obtain and enter data, control the process, and monitor its condition.

An HMI can display information such as the status of machines, alarms, process conditions, equipment faults, production, and operator controls.

SCADA systems can provide operators with information and control options over a broad process or the entire facility. It should be noted that the most important information should be prioritized on the interface; operators should not have to search for issues among unimportant information.

Upgrading Existing Control Systems

Industrial facilities that have been operating for a period of time may have existing equipment in place. While it may be ideal to completely replace an existing control system, this may not always be financially viable.

In such circumstances, system integration can allow a business to upgrade existing equipment without completely replacing the control system.

An upgrade project may involve replacing legacy controllers, upgrading HMI applications, updating industrial networks, adding I/O, connecting new equipment to the existing controls, updating PLC programs, troubleshooting communication and other matters, as well as modernizing legacy SCADA systems.

The specifics of an upgrade project will depend on the nature of an existing control system, the requirements of the equipment, as well as the financial and operational goals of a business.

Industrial Networking and Communication

Modern automation systems require communication between different components.

Controllers, HMIs, drives and remote I/O modules, sensors and other equipment may require a stable communication network to exchange information and operate reliably. A system integration project can ensure that all components can communicate reliably with one another.

The integration project can become more complex in installations where components from different eras and manufacturers are used. An Allen Bradley system integrator can assess the current infrastructure to determine the communication requirements and capabilities of a network.

Testing and Commissioning

The process of commissioning a new automation system is not complete with the programming and installation of a control system. The completed system needs to be tested to ensure that the I/O, sequences, alarms, communication, operator controls, and safety features perform up to expectations.

The commissioning process can ensure that the integration team identifies potential issues, resolves them, and verifies that the system meets the requirements of a facility.

Thorough testing and commissioning can reduce downtime following the launch of a new system.

When Do You Need a System Integrator?

An Allen Bradley system integrator can be involved in a variety of industrial automation projects. System integration can be useful in a variety of scenarios, including:

New production line installations

Control system upgrades

Upgrading or replacing legacy automation equipment

Adding new equipment to a production line

HMI/SCADA system improvements

Troubleshooting recurring control issues

Interconnecting electrical and process control systems

Modernizing legacy system

The involvement of an integrator at the design stage of a project is particularly important. It allows the integration team to understand the process, equipment, network infrastructure, and future requirements for expansion before the equipment is installed.

Choosing an Allen Bradley System Integrator

The selection of an Allen Bradley system integrator is crucial since every facility has unique control system requirements. Before selecting an integration partner, it is necessary to assess the integrator’s experience with industrial automation, PLC programming, HMI development, networking, system upgrades, testing, and commissioning.

It is also essential to analyze the approach to documentation and long-term service and support. A SCADA system should not only work when it is first installed, but it should continue to be useful and intuitive for operators and maintainers of the system.

An experienced Allen-Bradley system integrator can help a business interconnect their control equipment, establish communication between components, and design an integrated automation system that fits their process requirements.

Building a Better Industrial Control System

Industrial automation is more than just the installation of control equipment; programming, communication, networking, testing, and system design all contribute to the effectiveness of an automation system. The proper integration can provide operators with greater visibility, streamline troubleshooting, and establish a solid foundation for future upgrades.

Whether you have a new automation system to install or an upgrade project, working with an experienced integration team can ensure that the different components of an automation system are brought together. With the right approach, businesses can build industrial control systems that are intuitive, accessible, and easier to maintain and troubleshoot as their production process evolves.

Frequently Asked Questions

What is an Allen Bradley system integrator?

An Allen Bradley system integrator offers businesses programming, designing, integration, testing, and maintenance services for industrial automation and control systems. The systems include PLC, HMI, SCADA, industrial networks, drives, and other related equipment.

What services do system integrators offer?

The services offered by system integrators include PLC programming, HMI development, SCADA integration, industrial networks design and installation, control panel integration, troubleshooting, system upgrades, testing, and commissioning.

What is the importance of system integration?

System integration enables the connection and communication of different automation devices and control systems. This improves overall functionality by enabling operators to manage systems from a single interface, troubleshoot, and monitor system performance.

Can an Allen Bradley system integrator upgrade my system?

Yes, besides system integration, Allen Bradley system integrators offer system upgrade services. The service includes assessing control system hardware such as the controllers, HMI, networks, I/O modules, and drives. The integrators can then replace obsolete hardware and software with new advanced technology while retaining some of the existing hardware.

How does PLC programming benefit industrial automation?

Apart from enabling the operation of industrial machinery, PLC programming also determines how a machine reacts to field devices and different operating conditions. The right PLC program improves functionality, troubleshooting, and overall system performance.

What is the role of HMI?

An HMI, or human-machine interface, enables operators to monitor and control industrial machinery. It provides a single point of access to the status of machines and process variables, such as alarms and fault detection.