Facilities Based on the Lego® Principle

Modular Automation for Multi-Stage and Flexible Water Treatment

Process industries face growing market demands that require systematic management, including fluctuating water consumption and rapid contamination of water sources. The response to this demand is to build facilities based on the "Lego®" principle. Users can add modules to these facilities according to their needs or disable these modules. This operation can only be performed with modular automation. Festo's CPX automation platform is a central element of this concept and reflects the theme of "multiplying rather than scaling up." Multiplying rather than scaling up: With modular automation, facilities can be expanded or modified according to individual requirements. The figure above shows different unit options ranging from pump units to filter module units and CIP units. Flexible and modular production facilities require autonomous intelligent units. This is where the process industry and manufacturing industry worlds converge in their approach to Industry 4.0, the fourth industrial revolution. Digitalization and networking enable automatic modules at the field level to be connected simply and reliably to a central control system and also enable communication between them. Just as Lego® bricks combine to form a solid yet still flexible structure.

Industry 4.0 as a Solution

As expressed in the "Industry 4.0" model, in an increasingly variable market, the process industry needs flexible production processes to maintain its competitiveness. A prerequisite for this is highly networked, self-configuring and self-regulating flexible water treatment systems. For systems with process-related and functional units, compartmentalization in the facility is a logical step.

Example: Beverage Production

Depending on the location of the factory, the contamination status of raw water varies. For this reason, several different treatment steps are required to obtain high-quality water. These can be achieved through the combined use of various subsystems such as sand filters, ion exchangers, ultrafiltration or reverse osmosis systems, and a pump station. In the consumer goods market, since the sales volume of the end product rises and falls significantly, the consumption quantities of the product and process water also fluctuate. For this reason, flexible water treatment based on modular automation is becoming increasingly important.

Modular and Intelligent

Each module will contain all the automation functions it needs to perform its own process. Automation functions can also be provided by a central control system. These highly flexible units are fully portable filter units suitable for situations where water demand is low, requiring 1,000 m³ of treated water per day. With portable filter systems, water production can be started very quickly. However, a central control system is not designed for modular facilities that require easy replacement of individual modules. On the other hand, process-related modules require a small, adaptable and independent automation system. When implementing decentralized intelligent solutions for individual modules, application software does not need to be reprogrammed or reconfigured. Modules can be integrated into the overall automation solution with minimal effort for the production process. This allows several automatic modules to be added to the facility without the facility needing to expand its automation technology. Dr. Eckhard Roos, Key Customer and Industry Segment Manager for Festo Process Automation, comments on this: It is important to be able to expand or modify facilities without immediately having to move to large-scale systems. In other words, multiplying rather than scaling up.

CPX Automation Platform

The Festo CPX automation platform once again proved its ideal suitability as a central element of a modular automation system. This platform not only accepts pneumatic equipment with IP65/67 characteristics, but also accepts different controllers and remote access IOs for numerous sensors on a modular basis for pressure monitoring and temperature measurement purposes. For example, in water treatment facilities, units can be created in different configurations depending on the application. These fully portable filter systems are particularly attractive in situations where water demand is low and 1,000 m³ of water treatment is required. With portable filter systems, water production can be started very quickly.

Unit Options

For example, pump units with simpler structures require only a few valve sections in the pneumatic part of the CPX/MPA, while filter module units require analog inputs and outputs for pressure monitoring. More complex modules, such as a CIP unit containing facility sections and containers for cleaning agents and for mixing cleaning solutions, require additional automation modules on the CPX/MPA, such as analog inputs for temperature measurement or a controller for proportional technology. These units must operate independently and be highly reliable. They communicate continuously with a main controller that manages the entire system. Another advantage of these units is that costs for cable routing and wiring are relatively low.

Advantages for Engineering

The advantages of modular automation are not limited to these. Using modules for a complete process industry facility makes the engineering process faster and more cost-effective. This means that only the relevant automation modules need to be connected to the control system, and there is no need to expand the complete facility and change the entire automation concept. This ensures seamless communication between the various levels of the automation pyramid. For OEMs, the modular concept also means it is possible to produce uniform modules in low volumes and even produce units for stock. As a result, they can reduce costs in production and assembly. At the same time, increased delivery capability for manufacturers enables end users to reach their markets more quickly with new products in the correct production quantities. Automation specialist Roos comments on this: "If we can also be successful in operating process industry facilities through mobile terminals, this would be an additional step in line with Industry 4.0." Festo San. ve Tic. A.Ş.