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What is a distributed control system

2023-01-09
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An automatic control system in which multiple computers control multiple control loops in the production process, while allowing centralised access to data, centralised management and centralised control. Distributed control systems use microprocessors to control each loop separately, while small and medium-sized industrial control computers or high-performance microprocessors are used to implement the upper level of control. Information is exchanged between the circuits and between the upper and lower levels via high-speed data channels. Distributed control systems have functions such as data acquisition, direct digital control, human-machine interaction as well as monitoring and management. Distributed control systems are developed on the basis of computerised supervisory control systems, direct digital control systems and computerised multi-level control systems and are a more complete control and management system for production processes. In a distributed control system, microprocessors are installed near the measuring devices and control actuators by area, spreading the control functions as far as possible and concentrating the management functions relatively . This decentralised control method improves the reliability of the control and does not cause the whole system to lose control due to computer failure. In the event of a failure at the management level, the process control level (control loop) still has independent control capability and the failure of individual control loops does not affect the overall situation. Compared to computerised multi-stage control systems, distributed control systems are more flexible in structure, more rational in layout and less costly. 


DCS is the abbreviation of Distributed Control System (DCS), which is generally used to be called a distributed control system in China. It is a multi-level computer system consisting of process control level and process monitoring level with communication network as the link, integrated computer (Computer), communication (Communication), display (CRT) and control (Control) and other 4C technology, its basic idea is decentralised control, centralised operation, hierarchical management, flexible configuration, convenient configuration. has the following characteristics.
(1) High reliability
As DCS decentralises the system control functions on each computer, the system structure is fault-tolerant, so that the failure of one computer does not lead to the loss of other system functions. In addition, as the tasks undertaken by each computer in the system are relatively single, special computers with specific structures and software can be used for the functions that need to be realised, so that the reliability of each computer in the system is also improved.
(2) Openness
DCS adopts open, standardised, modular and serialised design, and each computer in the system communicates by means of a local area network to realise information transmission. When the functions of the system need to be changed or expanded, the new computer can be conveniently connected to the system communication network or removed from the network, hardly affecting the work of other computers in the system.
(3) Flexibility
The software and hardware can be configured according to different process application objects through the configuration software, i.e. to determine the measurement and control signals and interconnection relationships, to select the applicable control laws from the control algorithm library and to call the basic graphics from the graphics library to compose the required various monitoring and alarm screens, thus conveniently forming the required control system.
(4) Easy to maintain
A small or micro special computer with a single function has the characteristics of simple and convenient maintenance. When a part or a computer fails, it can be replaced online without affecting the operation of the whole system and quickly eliminated.
(5) Coordination
Various data are transmitted between workstations through the communication network, and the whole system shares information and works in coordination to complete the overall function of the control system and optimise processing.
(6) Complete control functions
Control algorithms are abundant, integrating continuous control, sequential control and batch control, allowing advanced control such as cascade, feed-forward, decoupling, adaptive and predictive control, etc., and the required special control algorithms can be easily added.

The DCS is flexible and can be composed of dedicated management computer stations, operator stations, engineer stations, recording stations, field control stations and data acquisition stations, or general purpose servers, industrial control computers and programmable controllers.


The process control level at the bottom is generally achieved by decentralised on-site control stations, data acquisition stations and other local data acquisition and control, and is transmitted to the production monitoring level computer through the data communication network. The production monitoring level provides centralised operation and management of the data from the process control level, such as various optimisation calculations, statistical reports, fault diagnosis and display of alarms. With the development of computer technology, the DCS can be networked with higher performance computer equipment as required to achieve more advanced centralised management functions, such as planning and scheduling, storage management, energy management, etc.


Since the introduction of Honeywells first distributed control system, TDCS-2000, in 1975, distributed control systems have been widely used in various fields of industrial control, and have gradually become the mainstream system for automatic control in the process industry with its high reliability, convenient configuration software, rich control algorithms and open networking capabilities.


To date, hundreds of manufacturers around the world have developed more than 1,500 types of distributed control systems of various types. DCS is favoured by industrial users for its advanced, reliable, flexible and easy control as well as reasonable price, and is widely used in metallurgy, power, chemical, petroleum and paper industries. 


Translated with www.DeepL.com/Translator (free version)

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