What is Industrial Automation…?
Industrial automation is a crucial aspect of modern industrial facilities. In today’s fast-paced and competitive business environment, companies are constantly seeking ways to improve productivity, efficiency, and safety.
Industrial automation provides a solution to these challenges by utilizing advanced technologies and systems to streamline processes and optimize operations.
In this blog post, we will explore the definition and importance of industrial automation, as well as its benefits and common applications. We will also delve into the different types of industrial automation systems, challenges in implementing automation, and successful case studies of its implementation.
Additionally, we will discuss the considerations in choosing the right industrial automation partner and provide insights into the future of industrial automation.
Whether you are a manufacturing company looking to enhance your production processes or a logistics company aiming to improve your material handling and control, this blog post will provide valuable information and guidance on how industrial automation can revolutionize your operations.
So, let’s dive in and discover the transformative power of industrial automation.
What is Industrial Automation? What does it do?
Industrial automation refers to the use of advanced technologies, such as robotics, computer systems, and electrical control systems, to operate and control industrial processes and machinery. It involves the integration of various components to automate tasks that were previously performed by humans, thereby increasing efficiency, productivity, and safety.
The importance of industrial automation cannot be overstated. It offers numerous benefits for industrial facilities, including:
Increased productivity
By automating repetitive and mundane tasks, industrial automation allows for faster and more accurate production. This leads to higher productivity levels and improved overall efficiency.
Improved efficiency
Automation streamlines processes by eliminating human errors and reducing material waste. It also enables real-time monitoring and optimization of operations, ensuring that resources are utilized effectively.
Enhanced safety
Automation minimizes the risk of accidents and injuries by reducing the need for human intervention in hazardous environments. It can also incorporate safety features and protocols to protect workers and assets.
Cost savings
Although the initial investment in automation systems can be significant, the long-term cost savings are substantial. Automation reduces labor costs, improves energy efficiency, and minimizes operational downtime, resulting in significant financial benefits.
Quality control
Automated systems can perform tasks with a high level of precision and consistency, leading to improved product quality. This ensures customer satisfaction and helps maintain a competitive edge in the market.
Flexibility and scalability
Industrial automation systems can be easily adapted and scaled to meet changing production demands. This allows for increased flexibility in operations and the ability to quickly respond to market trends or customer requirements.
Enhanced value and human potential
Automation is crafted to free workers from repetitive tasks, enriching their roles by letting them focus on intricate creative activities. Merging top-tier industrial automation tools with skilled human work significantly boosts human potential.
Advanced data assistance and improved traceability
Data collection through automation, especially in Industry 4.0, is pivotal. Cutting-edge systems that gather and scrutinize diverse data in real-time open up unprecedented opportunities. These systems empower businesses to heighten traceability, curtail waste, and perpetually refine all operational processes.
Live tracking and foresight-based maintenance
One noteworthy benefit of industrial automation is its capability to consistently oversee all procedures in real time. Owing to the precision of sensors in contemporary industrial equipment, production glitches are swiftly spotted and rectified. This paves the way for reduced upkeep expenses, extended equipment longevity, and a decline in unexpected breakdowns.
Common Applications of Industrial Automation
Industrial automation has a wide range of applications across various industries. Here are some common applications of industrial automation in industrial facilities:
Assembly line automation
Industrial automation is extensively used in assembly line processes to streamline production and improve efficiency. Automated robots and machines can perform repetitive tasks, such as assembly, welding, and packaging, with precision and speed.
Material handling automation
Automated systems are commonly used for material handling tasks, such as loading and unloading, sorting, and transportation. This helps reduce manual labor, improve workflow, and minimize the risk of accidents or injuries.
Quality control automation
Industrial automation plays a crucial role in quality control processes. Automated inspection systems can detect defects or inconsistencies in products, ensuring consistent quality standards are met. This helps minimize product recalls and customer complaints.
Packaging automation
Automation is widely used in packaging processes to optimize productivity and accuracy. Automated machines can handle packaging tasks, such as filling, sealing, labeling, and palletizing, efficiently and reliably.
Machine maintenance and monitoring
Industrial facilities can benefit from automation in machine maintenance and monitoring. Automated systems can perform regular maintenance tasks, such as lubrication and calibration, and monitor equipment performance in real-time.
This helps prevent breakdowns, reduce downtime, and improve overall equipment effectiveness (OEE).
Energy management automation
Automation systems can be used to optimize energy usage in industrial facilities. Through real-time monitoring and control, energy-intensive processes can be adjusted to minimize
Types of Industrial Automation Systems
Process Plant Automation
In industries where processing is key, products emerge from various chemical reactions that utilize specific raw materials. Examples of such industries include the pharmaceutical, petrochemical, cement, and paper sectors. To ensure optimal quality, productivity, and reliability in controlling physical process variables, these plants employ automation systems.
The diagram provided illustrates the hierarchy of the process automation system, made up of multiple layers that denote different elements of a processing plant.
Level 0 or Plant Base
At this foundational level, machinery directly involved in processes is present. It uses sensors and actuators to convert machine signals and physical variables for analytical purposes and to generate control directives.
Direct Process Oversight
Here, automated controllers and monitoring mechanisms gather data from sensors and, in turn, power the actuator mechanisms. Activities associated with this tier include:
• Gathering data
• Overseeing plant operations
• Verifying data
• Executing open and closed-loop controls
• Documentation
Operational Plant Control
This stage sets targets or benchmarks for the automated controllers. Its primary function is to ensure that control equipment is utilized for the best possible process management. Its responsibilities encompass:
• Monitoring plant efficacy
• Ensuring process optimization
• Coordinating plant activities
• Recognizing operational failures, and more.
Production Planning and Oversight
This tier tackles decision-making challenges such as resource distribution, defining production goals, overseeing maintenance, and the like. Activities at this level involve:
• Directing production
• Managing inventory
• Supervising and documenting production activities
Business Plant Management
Positioned at the apex of the automation hierarchy, this level predominantly handles business operations rather than technical ones. Its main tasks include:
• Evaluating markets and clientele
• Tracking orders and sales data
• Outlining production strategies
• Balancing capacity and orders, and more.
Manufacturing Automation
Manufacturing sectors produce goods from materials with the assistance of machinery and robotics. Industries like textile and apparel, glassware and pottery, food and drinks, and paper production fall under this category. Contemporary manufacturing practices have incorporated automation at every step, from material processing to packaging.
Leveraging computer-assisted controls alongside industrial robots enhances the adaptability and efficiency of manufacturing automation.
The listing provided below delineates the hierarchy of manufacturing automation systems, illustrating how each operational tier employs distinct automation instruments.
Here’s a breakdown of the tiers in the manufacturing automation system hierarchy:
Equipment Tier
This stage uses an array of sensors and actuators to oversee the manufacturing process. It’s the foundational layer for machine operation. Responsibilities at this level comprise data gathering, signal verification, and machinery management.
Cluster or Unit Tier
At this level, the focus is on synchronizing a set of machines within designated manufacturing units. Advanced control systems, such as PLCs, are used to manage these machine groups.
Workshop Tier
Serving as a regulatory automated stage, it concentrates on guiding and harmonizing multiple manufacturing units.
Facility Tier
At this automated level, tasks like observing production, regulation, and timetable management are executed. Interface systems used here allow remote management of the entire manufacturing process.
Organizational Tier
Here, management-centric functions like laying out production plans and schedules are conducted.
Water Treatment Facilities
By implementing automated control, monitoring & feedback mechanisms, process automation can simplify water treatment by giving operators a realtime sense of the undesirable elements present & dosing of the appropriate chemicals to remove unsafe components of an untreated water supply.
This can be done using instruments to measure water flow, the total solids present in said water, chemical concentrations & more. All working in concert to automate the process.
There are various types of industrial automation equipment that can be implemented in industrial facilities to enhance productivity, efficiency, and safety. Here are some common types of industrial automation systems:
Programmable Logic Controllers (PLCs)
PLCs are widely used in industrial automation due to their versatility and reliability. These computer-based control systems can be programmed to automate specific processes, monitor inputs and outputs, and make decisions based on predefined logic. PLCs are commonly used in assembly lines, material handling systems, and machine control.
What does PLC stand for?
PLC, which stands for Programmable Logic Controller, is a pivotal element in the realm of industrial automation technology. These are essentially modular industrial computing systems employed to manage a wide array of automated tasks, machines, robotics, and virtually any operation necessitating dependable control.
PLCs can be designed in multiple sizes tailored to specific requirements. A standard PLC setup comprises a microprocessor equipped with a variable number of input and output (I/O) ports. These can range from a few to several hundred or even more.
These I/O ports facilitate the connection with other devices, including additional PLCs and SCADA systems, creating a unified network.
Leading PLCs in the Market
Below is an incomplete list of the most sought-after PLCs in the industrial automation market:
Modicon by Schneider Electric
Simatic by Siemens
Allen Bradley by Rockwell Automation
Melsec by Mitsubishi Electric
Sysmac by Omron
Wago PLCs by WAGO
EH & H by Hitachi
GE Fanuc by Emerson
AC500 X20 & X90 by ABB
KV & V-8000 by Keyence
Rexroth ICL by Bosch
Robotics and Robotic Automation
Industrial robots are extensively used in manufacturing facilities for tasks that require precision, speed, and repeatability. These robots can be programmed to perform a wide range of tasks, such as welding, painting, picking and placing objects, and packaging. Robotic automation offers increased flexibility, improved quality, and reduced labor costs.
As a subset of industrial automation, robotics is a swiftly progressing domain gaining increasing significance, and it merits distinct attention.
Data from the International Federation of Robotics highlights that over 3 million industrial robots were active globally in 2020. This is a stark contrast to 1997, which saw a mere 700,000 such robots in operation. The integration of robots in industrial automation has been escalating at an estimated annual rate of 14%, with figures more than doubling between 2014 and 2020.
Contemporary robots are employed across an extensive array of industrial automation tasks and operations, encompassing activities like welding, painting, assembly, material management, packaging, pallet arrangement, product scrutiny, testing, and more.
Pioneering technological advancements, notably in machine vision, AI, and Edge computing, have given fresh momentum to the robotics industry.
This has resulted in the birth of highly advanced solutions capable of undertaking an expanding roster of jobs that were once thought to be non-automatable and therefore, necessitated human intervention.
Human-Machine Interface (HMI)
HMIs are graphical interfaces that allow operators to interact with industrial automation systems. HMIs provide real-time information about the status of machines, processes, and alarms, enabling operators to monitor and control operations effectively. HMIs enhance operator productivity and facilitate troubleshooting and maintenance activities.
Supervisory Control and Data Acquisition (SCADA)
SCADA systems are used to monitor, control, and gather data from various industrial processes. These systems utilize sensors, actuators, and communication networks to collect real-time data and provide centralized control. SCADA systems are commonly used in
What exactly is SCADA/HMI?
Having discussed the basics of industrial automation, we can now delve further into its technical nuances, focusing on key control solutions prevalent in this domain. SCADA/HMI stands out as a pivotal term in automation. Broadly, SCADA/HMI represents a category of software design tailored for crafting industrial automation systems.
These systems depend on networked data and feature a visual interface, allowing human operators to monitor and control processes effectively.
Distinguishing SCADA from HMI
SCADA, which stands for Supervisory Control and Data Acquisition, pertains to intricate industrial control systems. These systems amalgamate elements like computers, visual interfaces, and data communication networks to automate and oversee processes. On the other hand, HMI (Human-Machine Interface) typically serves as a facet of more expansive control systems, such as SCADA.
HMIs provide a user-friendly dashboard that facilitates human interaction with machinery, devices, and systems, also offering a glance at ongoing processes.
A Glimpse into SCADA’s History
Since the early 1960s, electronic systems have been steering industrial automation and process controls. By the mid-1970s, the term SCADA surfaced, encapsulating concepts of automated oversight, data gathering, and remote accessibility to diverse control modules.
First-Generation SCADA (Monolithic Systems)
Initial SCADA offerings from industrial automation vendors revolved around monolithic systems, which had constrained networking abilities. These systems functioned independently, bereft of intercommunication capabilities.
Second-Generation SCADA (Distributed Systems)
The dawn of the 1980s saw the second generation of SCADA, propelled by emerging technologies like Local Area Network (LAN) and compact MTU computers. These SCADA systems were communicative, enabling real-time data sharing across multiple stations. They were more compact and cost-efficient.
Third-Generation SCADA (Networked Systems)
The late 1980s and early 1990s heralded the third generation, leveraging evolving networking technologies. These SCADA systems incorporated extended LAN integrations, enabling control across various locations. Multiple SCADA systems could now operate under a single central master system.
Fourth-Generation SCADA (IoT Systems)
The 2000s witnessed the advent of the fourth SCADA generation. With advancements in cloud technology, IoT, and protocols like Internet Protocol (IP), SCADA transitioned to an open system architecture. This evolution ensured real-time component communication, ease of maintenance, integration, and cost savings.
Understanding SCADA Historian
One integral component of SCADA systems is the “Historian”, also termed “process historian”. This entity collects and archives SCADA data within a database. Historians play a pivotal role in monitoring and analytics, granting stakeholders access to automated system data.
They often possess reporting features for both automated and manual report generation. Originating in the late 1980s, Historians initially catered to sectors like oil, gas, pharmaceuticals, pipelines, and refining. However, today, they find relevance across industries, assisting in monitoring, control, analytics, and quality assurance.
Historians empower stakeholders, engineers, and operators to harness data for diverse purposes.
Modern Historians also incorporate functionalities related to data application, including advanced reporting tools. Explore more about data historians in our comprehensive guide.
Historian vs. Database
From the foregoing, it’s evident that a Historian mirrors a local database, akin to SQL. However, Historians do more than mere data storage – they process and structure it into actionable insights. Yet, at its core, a SCADA Historian is fundamentally a time-series database, refined to meet industrial automation’s unique requirements.
Time series refers to a set of data points gathered for an individual subject at various moments, arranged in a sequential manner. Across diverse sectors, time series databases have found extensive applications, with SCADA’s process historians being a notable instance of time series data usage in automation.
Notable Data Historians in Industrial Automation
The market presents a myriad of process historians and time series data solutions from several vendors. Highlighted below are some prominent process historians in the realm of industrial automation:
AVEVA Historian (Previously Wonderware)
AVEVA Historian, initially launched as Wonderware, ranks among the veteran data historians. Introduced in 1987 by Wonderware Corporation, established by software experts Dennis Morin and Phil Huber in California, Wonderware underwent multiple ownership transitions.
Post its 2018 merger with Schneider Electric Software, AVEVA Group took ownership. The contemporary AVEVA iteration is a potent data historian, offering sophisticated data storage, compression, and an industry-standard interface for seamless data retrieval. It is proficient in accumulating time-oriented process data and also alarm and event data.
Canary Enterprise Historian
Another forerunner in the data historian segment is the Canary Historian, an invention of Canary Labs, known for their enterprise data management tools. Since its inception in the late 1980s, the Canary Historian has found its way to over 19,000 installations across 65+ nations.
Operating as a NoSQL time series database, it employs impeccable compression techniques for optimal performance and data protection. The database boasts an impressive read speed and supports rapid data logging, achieving data resolutions up to 10 milliseconds.
OSIsoft PI Historian
Recognized as the inaugural process historian in the market, the OSI PI Data Historian forms a component of the PI System by OSIsoft – a suite dedicated to real-time data management. Established in 1980, OSIsoft was assimilated by AVEVA in 2021 in a transaction valued at nearly $5 billion. Subsequent to this acquisition, plans to amalgamate their product offerings were revealed.
Presently, the PI System continues to be an independent product and is reputed as a globally favored industrial data management tool, overseeing data from billions of sensors.
Proficy Historian by General Electric
Brought forth by GE Digital (an offshoot of the General Electric conglomerate), the Proficy Historian has garnered widespread utilization. Designed for capturing industrial time series and A&E data, it excels in storage, distribution, quick data extraction, and analysis.
It synergizes with the Proficy Operations Hub and Historian Analysis applications to furnish users with consolidated data, asset model definitions, and advanced trend evaluation.
FactoryTalk Historian by Rockwell Automation
Crafted by Rockwell Automation and rooted in OSIsoft’s PI Server solution, FactoryTalk Historian caters to Rockwell’s comprehensive suite of industrial automation tools. Consequently, it mirrors several features inherent to OSI PI Data Historian.
FactoryTalk Historian excels in collecting, structuring, and storing vital plant performance metrics, vital for oversight, performance assessment, and quality checks. Integrated analysis and visualization tools empower users to effortlessly transform raw historical machine data into visual dashboards and summaries, which can then be disseminated among relevant stakeholders who need this data.
Different data historians applied in industrial automation come with diverse attributes and functionalities. While some primarily focus on capturing time series data, they may lack comprehensive data processing abilities.
To analyze and utilize the data amassed by these historians, companies frequently employ supplementary tools or dedicated platforms that facilitate the assimilation, structuring, and depiction of industrial data, an example being Clarify.
What does SCADA alarming entail?
It’s vital to highlight the role of alarm management within the SCADA systems in the context of industrial automation.
An alarm is essentially a signal or alert dispatched when specific alarm criteria are met, notifying the human monitor. Alarming stands as a pivotal feature of SCADA systems. The criteria prompting these alarms can be both overt (definite regulations setting off the alarm) and covert (the SCADA system independently supervises various metrics and sounds alarms upon detecting irregularities).
The nature of these alarms can span a broad spectrum, from standard upkeep and periodic cycle alerts to critical emergencies. Typically, a human overseer monitors these alarm events, determining their continued activation. Indications of a SCADA system alarm can vary — from a mere flashing segment on the monitoring display to an audible alarm during crisis situations.
Widely-adopted SCADA systems
In present times, SCADA systems find applications across numerous governmental and private industrial domains. A multitude of SCADA software options are at organizations’ disposal.
Highlighted below are some prevalent SCADA systems:
DCS (Distributed Control System)
The Distributed Control System (abbreviated as DCS), emerged as a response to the evolving needs of large-scale industrial operations that required comprehensive management, intricate controls, and the ability to handle a plethora of simultaneous operations. DCS, as the name implies, decentralizes control mechanisms, distributing them throughout an industrial plant, but still retains a cohesive and harmonious orchestration of the entire operation.
DCS systems are commonly used in power generation facilities, water distribution systems for large municipalities & petrochemical production plants where simultaneous orchestration of multiple systems must occur to achieve an optimal outcome for operational goals.
Further information concerning DCS and how it differs from standard PLC controls can be found here:
https://celtex.ca/what_is_the_difference_between_plc_and_dcs
Structure and Components
DCS is inherently more complex than its PLC counterpart, consisting of:
Control Nodes or Controllers: Similar in function to the PLC’s CPU, these nodes process the data and execute control commands but are strategically distributed across the facility.
I/O Modules: Just as in PLCs, these facilitate interaction with external devices. However, in a DCS, the I/O modules are often spread out and closely aligned with the distributed control nodes.
Control Stations: These are human-machine interfaces (HMIs) allowing operators to monitor, control, and interact with the processes under the DCS’s purview.
Communication Networks: The backbone of a DCS. These networks, often redundant for reliability, link the distributed nodes, ensuring synchronization and efficient data exchange.
Operational Characteristics
Integrated Operation: DCSs are designed for a high degree of integration, allowing for seamless management of extensive and interdependent processes across a facility.
Advanced Control Strategies: DCSs can handle sophisticated control paradigms like ratio control, advanced PID algorithms, and multivariable control, tailored for intricate process demands.
Safety and Redundancy: Given their application in large-scale operations where faults can lead to significant repercussions, DCSs incorporate layers of safety features and redundant systems to ensure continuous, fail-safe operation.
Applications and Use-Cases
DCS systems dominate sectors where large-scale, integrated processes are prevalent:
Oil & Gas: For managing refinery operations, pipeline distribution, and offshore drilling stations.
Power Generation: Overseeing entire power plants, especially nuclear and thermal stations.
Chemical & Petrochemical: Orchestrating complex chemical reactions, distillation processes, and product batching.
Pharmaceuticals: Ensuring precision and adherence to stringent standards in drug manufacturing processes.
Evolution and Modern Adaptations
Modern DCS platforms are a testament to the advancements in control theory, computing power, and networking. With the integration of Industry 4.0 concepts, today’s DCSs offer enhanced data analytics, cloud connectivity, and interoperability with other enterprise solutions. Furthermore, their scalability ensures they remain future-proof, capable of adapting to expanding or diversifying industrial operations.
In the grand tapestry of industrial automation, DCS stands out as the maestro, conducting vast and intricate symphonies of processes, ensuring harmony, precision, and optimum productivity.
The following are a series of examples of commonly used DCS systems:
PlantPAX by Rockwell Automation
Schneider Ecostructure Foxboro DCS
What is the Industrial Internet of Things (IIoT)?
The Internet of Things (IoT) encompasses a range of computing devices equipped with sensors, software, and other automation tools, enabling them to connect and share data amongst themselves and with external systems.
As a pivotal element of Industry 4.0/5.0, IoT is also deeply integrated into contemporary industrial automation processes. The specific term for the incorporation of IoT principles into industrial automation is the Industrial Internet of Things (IIoT).
IIoT highlights the comprehensive integration of IoT in industrial solutions, characterizing the network of sensors, machinery, robots, and other equipment that are interlinked, sharing and receiving data with both in-house and external automation software platforms.
Presently, IIoT is prevalently implemented across various sectors, facilitating enhancements in productivity, operational efficiency, and analytical insights by blending cutting-edge technologies, shaping the next phase of industrial automation.
A glimpse at the core Industry 4.0/5.0 technologies interwoven within IIoT includes:
- Artificial Intelligence (AI) & Machine Learning (ML),
- Computing at the edge,
- Cyber-physical integrations,
- Analysis of vast data,
- Machine-to-machine (M2M) interactions,
- Robotic systems,
- SCADA frameworks, PLCs, human-machine interactions (HMIs), along with other industrial control mechanisms (ICSs).
A look back at IIoT’s inception
Interestingly, the emergence of programmable logic controllers (PLCs) in 1968 marked the genesis of IIoT. The advent of the first distributed control systems (DCSs) in 1975 signified a milestone in the progression of industrial automation and adaptable process management.
The 1980s witnessed a surge in the sophisticated networking capacities of intelligent devices, spurred by the debut of Ethernet and the onset of the first internet-linked apparatuses.
The progression of organizational networking and communication tools amplified the allure of IoT as an idea towards the end of the 1990s. The manifestation of cloud computing in the initial part of the 2000s was a defining factor in sculpting the present-day IIoT framework.
Introduced in 2006, the OPC Unified Architecture protocol facilitated secure, direct communication amongst devices, applications, and data reservoirs, bypassing the need for human mediation or interfaces.
Leading IoT platforms and structures today
In the present IIoT landscape, IoT structures and platforms are instrumental. They act as an intermediary layer, streamlining the interaction amidst IoT ecosystem components and facilitating the functioning of intricate industrial automation systems.
Outlined below are some leading IoT platforms gaining traction in today’s industrial automation realm:
What are IoT gateways?
From the earlier sections, it’s evident that the Internet of Things (IoT) serves as a cornerstone technology that drives the fourth iteration of SCADA systems and remains a significant player in today’s automation sphere.
IoT gateways, be it tangible devices or software-based platforms, function as a bridge between edge systems and cloud platforms. These gateways seamlessly integrate sensors, IoT units, smart gadgets, backend frameworks, and the cloud, facilitating communication and data filtration.
Additionally, they come equipped with computational capabilities, permitting users to adjust data, security, and communication preferences of the gateway.
Why do we need IoT gateways?
On the surface, IoT gateways might resemble rudimentary routers that also act as liaisons between various protocols and devices. However, their role is substantially more profound.
Some prevalent applications of IoT gateways include:
- Facilitating device-to-device interactions
- Assisting device-to-cloud communication
- Transcoding communications across IoT gadgets from diverse manufacturers or operators
- Filtering data
- Consolidating data
- Enhancing security measures
- Introducing edge intelligence
Their pivotal role in directing, gathering, and sifting through vast amounts of data from interconnected devices and sensors in an IoT network is undeniable. These gateways preprocess data in-house before relaying it to cloud systems and fetch information from the cloud to dispatch to devices. This empowers the self-sufficient governance of devices and systems in industrial IT setups.
In the context of industrial automation, the influence of IoT gateways is felt across various domains:
- Empowering AI-driven machinery and systems by feeding them real-time data from interconnected sensors monitoring myriad production facets
- Facilitating advanced IoT monitoring and pinpointing techniques for production and storage functions, by allotting each item a unique scannable SKU
- Providing data to fleet oversight platforms overseeing product transport and dissemination
- Accumulating vast IoT data conducive to drawing multifaceted business conclusions
- Assisting intelligent logistics solutions in product demand surveillance and shipment coordination
- Safeguarding the organization’s IoT infrastructure against assorted security perils
How are IoT gateways structured?
IoT gateways, given their multi-functional nature, can vary in their design based on their specific role in industrial automation.
Delving into the core components of a standard IoT gateway
Hardware Layer: Typically includes a microprocessor or a controller, connection modules (like cellular, Wi-Fi, Bluetooth), and IoT sensors.
Communication Protocols: Depending on the role, they might employ TCP IP, MQTT, ZigBee, Bluetooth, XMPP, DDS, AMQP, OPC UA, Sparkplug, or LwM2M.
Operating Systems: While IoT gateways are versatile enough to operate on varied operating systems, Linux-based OSs are predominantly favored in industrial automation scenarios.
Device Management & Configuration Layer: Oversees the configurations and settings of the linked devices and sensors.
Security Layer: Incorporates encryption, verification, and other cyber-defensive measures.
Data Management Layer: Supervises data from sensors, connected gadgets, and the cloud, which encompasses data filtration and traffic regulation.
Cloud Connectivity Coordinator
Facilitates smooth integration of the internal IoT framework with cloud systems.
Sensor and Module Interfaces
A platform that allows the device to interact with sensors and modules.
Tailored Software Tools IoT gateways can be equipped with specialized software tailored to enhance interaction with specific segments of an enterprise’s IT system. To deploy these custom applications, a container runtime like Docker, runC, containerd, or Windows Containers is typically incorporated.
Top-Ranked IoT Gateways
Below are some frequently used IoT gateway offerings from diverse manufacturers in the realm of industrial automation:
Eurotech’s ReliaGate 20-25
HPE’s Edgeline Gateways
Dell’s Edge Gateway 500
Kontron’s KBox A-201
FlexaGate’s FG400 IoT Analytics Gateway
B-Scada’s Wireless Ethernet Gateway
Advantech’s WISE-3310
Adlink’s MXE-5400i Gateways
Huawei’s AR Series IoT Gateways
From the discussion, it’s evident that current industrial automation blends numerous techniques and technologies to refine an array of processes. This refines the levels of efficiency and productivity, which serve as pillars for our economic framework. We delved into the paramount technologies and tools vital to today’s industrial automation.
It’s imperative to note that automation is an ever-evolving domain with swift advancements. The prowess of Industry 4.0/5.0 revolutionizes industrial automation solutions. Entities that swiftly adopt these advancements gain a competitive advantage. Real-time Big Data collection and analysis stand central to digital transformation.
Celtex offers teams in the industrial domain a cutting-edge approach to time series intelligence, ensuring data from historians, SCADA, and IoT devices benefit everyone, ranging from on-ground staff to data specialists.
Instrumentation & Sensors
Instruments & Sensors transform physical attributes like flow, pressure, or temperature into electric or pneumatic signals. Examples of such instruments are thermocouples, RTDs, and strain gauges. The outputs from these detectors undergo processing, analysis, and decision-making to generate control outcomes.
Various control strategies are employed to achieve the desired results by juxtaposing the detected current process values with preset parameters. Subsequently, controllers generate the necessary outcomes which are delivered as electric or pneumatic signal inputs to the execution mechanisms.
Execution mechanisms, like control valves, relays, and motors, transform these signals back into physical attributes.
A distinct class of instruments, termed as smart instruments, merges detection or execution elements with communication abilities linked to field networks. These intelligent units possess internal signal modulation circuits, allowing direct connections to the communication pathways in the industrial networking system.
Challenges & Considerations in Implementing Industrial Automation
While industrial automation systems offer numerous benefits, there are also challenges and considerations that need to be addressed when implementing them in industrial facilities. It is important to be aware of these challenges and take them into account during the planning and implementation stages. Here are some key challenges and considerations to keep in mind:
Initial Investment
Implementing industrial automation systems often requires a significant initial investment. This includes the cost of purchasing the necessary equipment, software, and hiring skilled professionals to design and install the system. It is important to consider the return on investment (ROI) and long-term benefits that automation can bring to your facility.
Integration with Existing Infrastructure
Integrating new automation systems with existing infrastructure can be a complex process. It is crucial to ensure that the automation systems can seamlessly communicate and integrate with the existing machinery, control systems, and databases. Compatibility issues can arise if proper planning and coordination are not carried out.
Workforce Training
With the implementation of automation systems, employees may need to acquire new skills and knowledge to operate and maintain these systems. It is important to provide adequate training and support to employees to ensure a smooth transition and effective utilization of the automation systems.
Proper training can help address resistance to change and ensure the workforce is equipped to handle the new technology.
Data Security and Cybersecurity
Industrial automation systems rely on data collection, storage, and communication. Protecting sensitive data and ensuring cybersecurity is crucial to prevent unauthorized
What is an automation company?
Every sector is swiftly gravitating towards heightened automation application due to the vital advantages it brings. These advancements empower companies to achieve heightened efficiency and productivity, quintessential for the demands of the Industry 4.0/5.0 phase. Industrial automation is leading this transformation by embracing contemporary technologies to enhance production operations.
It’s a given that entities spanning various sectors urgently require top-notch automation tools and knowledge to remain at par with the swiftly advancing technologies.
Enter automation enterprises, which aim to cater to this escalating demand for automation. They supply both hardware and software solutions to augment the precision, quality, and accuracy of industrial automation setups.
Here are a few firms well known for manufacture & design of industrial automation services:
A global industrial manufacturing and engineering giant, Siemens delivers an array of solutions in automation, digitalization, and electrification to sectors like manufacturing, energy, and infrastructure. A few of Siemens’ automation offerings include:
- SIMATIC industrial automation setups,
- RUGGEDCOM and SCALANCE networking tools,
- SIRIUS control instruments,
- Systems for operator control and supervision,
- Systems for identification and positioning,
- Digital corporate solutions.
Headquartered in Europe and with a global footprint, ABB boasts a vast suite of automation tools extensively employed across different sectors. Their noteworthy products include:
- ABB Ability manufacturing operations management tools
- Mechanical energy transmission items
- YuMi, a dual-armed programmable industry robot
- Control chamber solutions
- Solutions for both high and low voltage
Originating from Japan, Yokogawa Electric excels in delivering intelligent control systems for industrial automation and diverse test and measurement tools. Among their top products are:
- CENTUM VP factory automation security
- SCADA control setups
- Partnered information servers
- DCS systems
- SIS (Safety Instrumented Systems)
- PLCs
- Integrated Controllers
An American entity, Honeywell International produces a vast range of consumer and commercial products in various technological arenas, including industrial automation. Honeywell Robotics, a Honeywell branch, specializes in crafting industry-specific robotic solutions to boost efficiency, pace, and precision. Their significant offerings include:
- Robotic solutions for warehouse automation
- AMRs (Autonomous Mobile Robots)
- Systems for control, safety, and surveillance
- Tools for industrial protection and security surveillance
- Robotic solutions for palletizing and depalletizing
- AS/RS (Automated Storage & Retrieval System)
- Systems for conveyors and pallet conveyors
What are system integrators and automation engineers?
Talking about automation companies, we should also cover how various industrial automation solutions are delivered. There are two main roles responsible for the implementation of automation products: system integrators and automation engineering experts.
What is an automation system integrator?
System integrators, whether entities or individuals, excel in system integration offerings. Their main responsibility is to amalgamate various industrial automation setups and components, ensuring seamless functioning. Within the industrial automation sector, these integrators either supply automation products or affiliate with such providers, extending intricate automation solution applications as a service.
What is an automation engineer?
While the term can refer to either an organization or an individual, it commonly alludes to a person. Automation engineers drive automation projects internally within implementing companies. They handle everything related to internal automation engineering tasks tied to automation tool and component applications.
This spans from requirement collection and harmonizing diverse automation software and hardware to probing and rectifying system glitches and conflicts that might hamper automation system efficiency.
Additional Sources:
The Complete Guide to Industrial Automation (clarify.io)
Industrial Automation: What is it? (Basics & Types) | Electrical4U
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