Hardware automation platform

Overview
Senbo's Industry 4.0 Digital DCS automation solution delivers an integrated Distributed Control System platform with MES integration to centralize device management, remove information silos and implement process automation combining batch control and DCS.

Key offerings

• Integrated DCS automation implementations across major platforms (DeltaV, PCS7, Experion PKS, etc.).
• Centralized device management and full device control chain to enable process automation.
• Combined Batch control + DCS for automated production execution and recipe management.

Main benefits

• Compliance with ISA-88 standards for batch control.
• Data centralization consolidates process and equipment information for operational visibility.
• Modular and flexible control architecture improves resilience and reduces production risk.
• Automated procedures reduce human errors and increase equipment utilization and production stability.
• Flexible deployment supports multiple formulas and process combinations.

Process automation control design principles

• Design of control system network architecture for process areas (feeding, extraction, concentration, alcohol precipitation, online cleaning, etc.).
• Large-screen integrated monitoring and on-site process information displays for operators.
• Production and process control schemes based on economic rationality, modular unit design, full quality control and computer system validation.

Security & access management

• Complex password policy: complexity rules, length, scheduled changes, prevention of reuse, automatic logout and account lockout.
• Multi-level role and permission allocation for screen access, parameter entry, alarm handling, manual/auto mode switching, configuration, debugging and security settings.

Equipment & instrumentation examples

• Large-screen operator displays and configuration panels.
• System cabinets with organized cable and piping routing (cable trays, trunking).
• Valve and actuator examples: communication valve islands, solenoid valves, pneumatic diaphragm valves, pneumatic ball/angle-seat valves, steam control valves.
• Sensors and transmitters: armored Pt100 temperature probes (A-grade accuracy), pressure transmitters (0.5% accuracy), capacitive level transmitters (accuracy: 5 mm ≤2 m, 15 mm >2 m), electromagnetic and vortex flowmeters, density meters and level switches (imported brands where specified).

MES / Recipe, weighing and production execution

• Modular MES architecture with formula/recipe design and execution, BOM and device definitions (ERP integration available).
• Graphical sequential model with version/change control (pre/post approvals, material feed verification, production execution tracking).
• Recipe management: independent recipe production, parameter import/selection, automatic material identification and recipe versioning.
• MES weighing: role-based workflows guiding weighing operations, automatic scale selection, predefined weighing methods, QR-code device selection and deviation handling procedures.
• Open interfaces for third‑party device integration; support for S88 control recipes and real-time weighing interfaces.

Visual & 3D capabilities

• Factory 3D design content (equipment diagrams, layouts, 3D process views, main/utility pipelines, instrument and valve distribution) to support guided installation, quantity take-off and visual review.

Technical specifications

• Supported DCS platforms: DeltaV, PCS7, Experion PKS (examples).
• ISA-88 compliance for batch control implementations.
• Temperature sensor: armored platinum resistance (Pt100), A-grade accuracy.
• Pressure transmitter: domestic high-quality brand, accuracy 0.5%.
• Level transmitter: capacitive type, accuracy 5 mm (≤2 m), 15 mm (>2 m).
• Flowmeters: electromagnetic and vortex flowmeters (imported brands where indicated).
• Density meter and level switch: recommended imported brands where specified.
• Valve types: steam control valves (imported), pneumatic diaphragm valves, pneumatic ball/angle-seat valves (domestic & imported).
• MES functions: BOM definition, graphical sequential model, operation interface definition, Electronic Batch Record, device definition, ERP plan reception and automatic decomposition of production instructions.