InnControl: Real-time Visibility into and Control of Critical Process Variables

InnControl is a computer-based SCADA system for implementing real-time process control and automation. Developed using an integrated modular software concept, InnControl helps to monitor and control all types of remote units and programmable logic controllers (PLC). Built on the Microsoft platform using RDBMS methodologies, InnControl is compatible with Windows XP, Windows 2000 and Windows 2003, and allows integration with third party systems. It has built-in secure role-based user access controls with multi-level protection.

InnControl provides an operator view of critical process variables, and provides a dashboard with vital information for effective process control and automation, enabling significant improvement in operational efficiency. It gathers accurate intelligence on process variables at the equipment level, enabling real-time monitoring of events occurring at machine and device levels, and allowing fine-tuned process control using complex logic. The Extended System includes Data Collection, Report Generator, Curve Presentation, various Alert Settings, and Watch Call definitions for sending notifications over cell phones and pagers.

An OPC driver interface enables communication with various devices in real-time. Enterprise Control Integrator (ECI) interface allows real-time data exchange with other enterprise systems. A graphic interface allows presentation of real-time reports in charts and curves. The report configuration feature allows definition of charts and curves to generate easily understandable historical reports. The system automatically carries out backup and restore of configurations, pictures, and collected data values.

InnControl is an ideal lean manufacturing and process control optimization tool for industries where accurate control of variables is critical. It enables synchronous data collection and storage from multiple nodes and variable measuring tags. It allows improved operational visibility to enable a fact-based decision making. Data collected from programmable logic controllers, computer numerical controllers, automated assembly equipment, quality assurance and manual entry points can be used across a broad range of production management and enterprise level systems.

InnControl automates the following activities:

• Real-time process control
• Automated process scheduling
• Automated capacity and resource planning
• Computer integrated lean manufacturing
• Integration of plant data with external systems
• Validation for statutory compliance

Main modules of InnControl include the following:

• Graphic View
• Alarm Configuration
• Calendar and Scheduling
• Data Collection and Consolidation
• Report Generation and Configuration
• Device Control
• Watch Call - alert over pagers / cell phones
• Component register
• Preventive Maintenance Alerts