In brief
Industrial automation covers devices, software and methods used to control, regulate and monitor machines and processes automatically.
Contents
What is Industrial automation?
The aim of industrial automation is to carry out recurring sequences reliably without constant human intervention. It combines electrical engineering, mechanical engineering and computer science. A broad distinction is made between factory automation, for example in machine tools and packaging lines, and process automation, for example in the chemical, paper or food industries.
An automated system consists of sensors that detect states such as position, pressure or temperature, controllers such as PLCs or industrial PCs that make decisions according to a program, and actuators such as motors, valves and cylinders that intervene. Operator panels are used for interaction with personnel, while fieldbuses and Ethernet-based networks connect the levels. This is often shown as the automation pyramid, from the field level up to the enterprise level.
For maintenance, automation means a large number of electronic components with short product life cycles. Discontinuation of controllers, drive controllers or operator panels affects plants that could mechanically run for decades more. Spare parts management in automation must therefore take account of software, firmware versions and compatibility as well as mechanics. Where successor products do not fit, stockholding, alternative parts or a retrofit of the control system are planned.
In practice: maintenance and procurement
An up-to-date register of all automation components with manufacturer part number, firmware and software version and backed-up programs is the basis for rapid replacement. For critical control components, a regular check of the life cycle status is worthwhile.
Synonyms and abbreviations: automation technology · factory automation · process automation · control engineering
Frequently asked questions
What does industrial automation include?
It includes sensors and transmitters, controllers such as PLCs and industrial PCs, operator control and monitoring devices, drives with motors and inverters, valves and cylinders, and communication technology such as fieldbuses. This is supplemented by safety technology, control cabinet building and software for programming, visualisation and data acquisition.
What is the difference between factory automation and process automation?
Factory automation controls discrete sequences in which individual items are machined, assembled or packaged. Process automation regulates continuous or batch processes involving liquids, gases or bulk materials, such as temperatures, pressures and flows. Both use similar components but place different emphasis on control and safety.
Why are automation parts often difficult to source?
Electronic components have considerably shorter life cycles than the machines in which they are installed. Manufacturers discontinue product ranges, and successors are not always plug-compatible or software-compatible. Semiconductor shortages add to this. That is why inventory, life cycle monitoring and timely stockholding of critical parts are important.
What is the automation pyramid?
The automation pyramid arranges the levels of a company hierarchically: at the bottom the field level with sensors and actuators, above it the control and process control levels, and above those the plant management and enterprise levels with production and planning systems. The model illustrates data flows but is becoming increasingly permeable in networked plants.