Overview of Industrial Optical Bus Control System (OCS)

The OCS, developed by HollySys on the HOLLiAS MACS® platform, integrates industrial optical bus technology with software-defined I/O to modernize process control. It replaces traditional copper wiring and intermediate hardware with a distributed, standardized, and flexible architecture, enhancing system reliability and scalability.

Key Components and Technologies

• Industrial Intelligent Data Transmission Unit (iDTU): A compact, all-in-one unit replacing junction boxes. Supports multiple signal types (AI, AO, DI, DO, RTD, TC, PI) via software-defined I/O. Features real-time status visualization, full redundancy in I/O, communication, and power modules, intelligent environmental and equipment monitoring, surge protection, and compatibility with traditional and intelligent instruments. Designed for harsh environments with automotive-grade components and corrosion-resistant enclosures.
• Industrial Optical Bus (Onet): Passive optical bus using physical spectral division technology, ensuring no protocol conversion or delay. Supports high bandwidth and real-time communication with only two redundant optical fibers for up to 512 instrument signals, drastically reducing cabling. Employs a redundant star network topology for fault tolerance and flexible expansion. Complies with IEC61158, JB/T 10308.3-2001, and EN50170 standards.
• Redundant Junction Unit (RJU): Aggregates signals from iDTUs and transmits via main optical fiber to controllers. No power supply needed, explosion-proof certified, uses physical optical splitting technology supporting 16 or 32 channels per fiber. Suitable for hazardous Zone 2 environments with long lifespan and low maintenance.

System Architecture and Network

The OCS eliminates central control cabinets and cross-wiring, reducing cable usage, installation complexity, and failure points. Its distributed design allows flexible addition of I/O modules anywhere in the plant without disrupting existing layouts, facilitating easy upgrades and expansions. Supports integration with third-party and traditional control systems, functioning as master or slave stations.

Application Scenarios and Customer Benefits

• Ideal for projects with remote instrument junction boxes, large cable counts, fast-paced new projects, reconstruction or expansion, and long-distance cable runs between control rooms and field instruments.
• Benefits include over 30% total cost reduction, more than 50% shorter project cycles, over 90% reduction in cabinet space, significant human resource savings, and up to 90% reduction in cable and related infrastructure costs.
• Standardized project design reduces FAT and SAT workload and enables flexible design changes.
• Controller cabinets can be located in electronics rooms without junction, terminal, or safety barrier cabinets, allowing reconstruction without space or design constraints.
• Operational convenience shortens personnel training, simplifies spare parts management, reduces cables and pipe bridges, and decreases engineering documentation.
• Environmental savings include 200,000 km of cables, 18,000 tons of copper, and 70,000 tons of CO2 emissions avoided.

Typical Industry Applications and References

OCS has been successfully deployed in coal chemical, fine chemical, petrochemical, new materials, pharmaceutical, and oil & gas industries. Projects span multiple regions in China and Southeast Asia, including Indonesia and Singapore.

Certifications and Patents

• Holds 5 invention patents, 8 design patents, and 1 software copyright.
• Certified with CCC, CEIECEX, and Anti-explosion G3 marks.
• Complies with IEC61158, JB/T 10308.3-2001, and EN50170 standards.

Summary of Critical Features

• Miniaturization: iDTU size comparable to two A4 sheets.
• All-in-One Design: Integrated aluminum die-cast enclosure with side handle and visible operating status.
• Software-Defined I/O: Remote flexible configuration of signal types.
• Redundancy and Fault Tolerance: Full redundancy in critical modules and communication links.
• Intelligent Monitoring: Real-time diagnostics with online switchover capability.
• High Reliability and Compatibility: Surge protection, isolators, supports traditional and intelligent instruments.
• Harsh Environment Suitability: Automotive-grade components, corrosion resistance, operating range -40°C to 55°C.
• High Efficiency and Quality: Optical fiber transmission with strong real-time performance and EMI immunity.
• Flexible and Scalable Network: Redundant star topology enabling safe, reliable, and expandable communication.

Project References and Locations

Notable projects include:

• Laterite Nickel Extraction Plant, Indonesia
• 1.2 MTA Ethylene Project, Tianjin
• 120 KTA Ferrous Iron Pulping, Henan
• 8 KTA Thermosensitive Paper Additive, Shandong
• NP1-3 Rolling Development, Hebei
• 1 MTA Combination Station, Inner Mongolia
• Pesticide Project, Guangdong
• 10 KTA PVDF Project, Shandong
• Multiple pharmaceutical and chemical projects across Zhejiang, Xinjiang, Jiangsu, Jilin, Gansu, Anhui, and Hubei

Company and Contact Information

HollySys Automation Technologies operates across Asia Pacific with offices in Singapore, Indonesia, Uzbekistan, India, and China. Contact via email at [email protected] and website www.hollysys.com.

Industry Focus

Key sectors served include Coal Chemical, Fine Chemical, Petrochemical, New Material, Pharmaceutical, and Oil & Gas industries.

Summary

The document highlights HollySys's Industrial Optical Bus Control System as a next-generation process control solution delivering significant cost, time, and resource savings. Its advanced architecture supports flexible project execution, easy reconstruction, and environmental benefits through reduced material usage and emissions, proven across numerous large-scale industrial projects in Asia.