SCADA Explained

Supervisory control and data acquisition (SCADA) is a system of software and hardware elements that allows
industrial organizations to:

 Control industrial processes locally or at remote locations

 Monitor, gather, and process real-time data
 Directly interact with devices such as sensors, valves, pumps, motors, and more through human-
machine interface (HMI) software
 Record events into a log file

SCADA systems are crucial for industrial organizations since they help to maintain efficiency, process data for
smarter decisions, and communicate system issues to help mitigate downtime.

The basic SCADA architecture begins with programmable logic controllers (PLCs) or remote terminal units
(RTUs). PLCs and RTUs are microcomputers that communicate with an array of objects such as factory
machines, HMIs, sensors, and end devices, and then route the information from those objects to computers with
SCADA software. The SCADA software processes, distributes, and displays the data, helping operators and
other employees analyze the data and make important decisions.

For example, the SCADA system quickly notifies an operator that a batch of product is showing a high
incidence of errors. The operator pauses the operation and views the SCADA system data via an HMI to
determine the cause of the issue. The operator reviews the data and discovers that Machine 4 was
malfunctioning. The SCADA system’s ability to notify the operator of an issue helps him to resolve it and
prevent further loss of product.

Modern SCADA Systems

Modern SCADA systems allow real-time data from the plant floor to be accessed from anywhere in the world.
This access to real-time information allows governments, businesses, and individuals to make data-driven
decisions about how to improve their processes. Without SCADA software, it would be extremely difficult if
not impossible to gather sufficient data for consistently well-informed decisions.

Also, most modern SCADA designer applications have rapid application development (RAD) capabilities that
allow users to design applications relatively easily, even if they don't have extensive knowledge of software
development.

The introduction of modern IT standards and practices such as SQL and web-based applications into SCADA
software has greatly improved the efficiency, security, productivity, and reliability of SCADA systems.

SCADA software that utilizes the power of SQL databases provides huge advantages over antiquated SCADA
software. One big advantage of using SQL databases with a SCADA system is that it makes it easier to
integrate into existing MES and ERP systems, allowing data to flow seamlessly through an entire organization.

Historical data from a SCADA system can also be logged in a SQL database, which allows for easier data
analysis through data trending.

PLC stands for Programmable Logic Controller. They are industrial computers used to control different electro-
mechanical processes for use in manufacturing, plants, or other automation environments.

PLCs vary in size and form factors. Some are small enough to fit in your pocket while others are large enough
to require their own heavy-duty racks to mount. Some PLC’s can be customized with back planes and
functional modules to fit different types of industrial applications.
PLCs are widely used in a variety of industries because they’re fast, easy to operate and are considered easy to
program. PLCs can be programmed in several ways, from ladder logic, which is based on electromechanical
relays, to specially adapted programming languages of BASIC and C, to name a few. 

Most PLCs today use one of the following 5 programming languages: Ladder Diagram, Structured Text,
Function Block Diagram, Instruction List, or Sequential Function Charts.

SCADA and HMI systems enable users to view data from the manufacturing floor and provide an interface for
users to provide control input — and PLCs are an essential hardware component element in these systems. 

PLC’s act as the physical interfaces between devices on the plant or manufacturing floor and a SCADA or HMI
system. PLCs communicate, monitor and control automated processes like assembly lines, machine functions,
or robotic devices. 

A PLC’s functions are divided into three main categories: inputs, outputs and the CPU. PLCs capture data from
the plant floor by monitoring inputs that machines and devices are connected to. The input data is then
processed by the CPU, which applies logic to the data, based on the input state. The CPU then executes the
user-created program logic and outputs data or commands to the machines and devices it is connected to.

There are two main types of inputs: data inputs from devices and machines, and data inputs that are human-
facilitated. The input data from sensors and machines are sent to the PLC. Inputs can include on/off states for
things like mechanical switches, buttons, and encoders. High/low states for things like temperatures, pressure
sensors, and liquid-level detectors, or opened/closed states for things like pumps and values.

Human-facilitated inputs include button pushes, switches, sensors from devices like keyboards, touch screens,
remotes, or card readers. Outputs are the physical actions or visual results that are based on a PLC logic in
response to those inputs. Physical outputs include starting motors, turning on a light, draining a valve, turning
the heat up or a pump off. Visual outputs are sent to devices like printers, projectors, GPSs, or monitors.

PLCs operate in cycles. First, the PLC detects the state of all input devices that are connected to it. The PLC
applies the user-created logic, and then executes it based on the input states. The PLC then outputs commands
to any output device connected to the PLC either turning them on or off. After completing all these steps, the
PLC does a safety check by communicating with internal diagnostics and programming terminals, to ensure that
everything is within normal operating conditions. The PLC resumes the cycle each time the process is
completed. 

With a wide range of available Ignition device drivers, you can connect Ignition with just about any modern or
legacy PLC. Once the device driver is installed, data can be viewed or sent to the PLC. With PLC data now
available to Ignition’s tag system, you can do so much more with Ignition’s robust core modules. 

Create a comprehensive SCADA and MES system, HMI system, Alarming and Reporting solution, or an
enterprise-wide solution that allows you to view and control data on a PLC at any level of an organization. 

Traditionally, PLC’s communicate using the the poll-response method. Normally, in local plant and
manufacturing environments, this type of communication method is perfectly fine, since the communication
distances are short and predominantly hardwired. With poll-response, PLCs are constantly communicated with
to check for any data changes.

As the Industrial Internet of Things (IIoT) becomes more popular, there is an increased need for data from
remote locations. This translates to more PLCs and computing devices at the edge of the
network. Communication with edge devices involves long distances in which cellular networks are used more
frequently. Due to the high frequency of poll-response communication, cellular network would incur an
incredibly high cost. 

To address this issue, solutions such as MQTT employ a publish-subscribe protocol to streamline
communications from the edge of the network. While modern PLC’s employ modern communication protocols,
legacy PLCs that are still at the edge-of-network require additional hardware to bring them up to speed. Edge
gateways such as Ignition Edge IIoT along with an MQTT broker, pull data from legacy PLCs using poll-
response and then transmits the data using a publish-subscribe protocol. 

This IIoT architecture allows industrial organizations to build IIoT solutions on top of brownfield systems. This
improves bandwidth usage and makes PLC data from edge-of-networks widely available throughout the
organization.

The industry continues to see new products entering the market ranging from devices like Programmable
Automation Controllers (PACs) which combine the functionality of PLCs with higher-level PC functionality all
the way to industrial embedded hardware. 

Even with these new products, PLCs remain popular because of their simplicity, affordability, and
usefulness. And software like Ignition will enable organizations to maximize their usefulness for many years to
come.

HMI Defined
A Human-Machine Interface (HMI) is a user interface or dashboard that connects a person to a machine,
system, or device. While the term can technically be applied to any screen that allows a user to interact with a
device, HMI is most commonly used in the context of an industrial process.

Although HMI is the most common term for this technology, it is sometimes referred to as Man-Machine
Interface (MMI), Operator Interface Terminal (OIT), Local Operator Interface (LOI), or Operator Terminal
(OT). HMI and Graphical User Interface (GUI) are similar but not synonymous: GUIs are often leveraged
within HMIs for visualization capabilities.

In industrial settings, HMIs can be used to:

 Visually display data

 Track production time, trends, and tags
 Oversee KPIs
 Monitor machine inputs and outputs
 And more

Similar to how you would interact with your air-conditioning system to check and control the temperature in
your house, a plant-floor operator might use an HMI to check and control the temperature of an industrial water
tank, or to see if a certain pump in the facility is currently running.

HMIs come in a variety of forms, from built-in screens on machines, to computer monitors, to tablets, but
regardless of their format or which term you use to refer to them, their purpose is to provide insight into
mechanical performance and progress.

 Common Uses of HMI

HMIs communicate with Programmable Logic Controllers (PLCs) and input/output sensors to get and display
information for users to view. HMI screens can be used for a single function, like monitoring and tracking, or
for performing more sophisticated operations, like switching machines off or increasing production speed,
depending on how they are implemented.
HMIs are used to optimize an industrial process by digitizing and centralizing data for a viewer. By leveraging
HMI, operators can see important information displayed in graphs, charts, or digital dashboards, view and
manage alarms, and connect with SCADA and MES systems, all through one console.

Previously, operators would need to walk the floor constantly to review mechanical progress and record it on a
piece of paper or a whiteboard. By allowing PLCs to communicate real-time information straight to an HMI
display, HMI technology eliminates the need for this outdated practice and thereby reduces many costly
problems caused by lack of information or human error.

What is the Difference Between HMI and SCADA?

Supervisory Control and Data Acquisition (SCADA) and HMI are closely related, and often referred to in the
same context since they are both part of a larger industrial control system, but they each offer different
functionality and opportunities. While HMIs are focused on visually conveying information to help the user
supervise an industrial process, SCADA systems have a greater capacity for data collection and control-system
operation. Unlike SCADA systems, HMIs do not collect and record information or connect to databases.
Rather, HMI provides an effective communication tool that functions as part of, or alongside, a SCADA
system. For more information on SCADA, see our page, "What is SCADA?"