Beginner's Guide to Industrial Automation: What You Need to Know Before Getting Started

Complete Guide to Industrial Automation: In Brief

In the context of Industry 4.0, industrial automation is revolutionizing modern manufacturing processes. Automated systems and industrial control technologies enable optimization of production while minimizing manual intervention. This comprehensive guide will help you understand the fundamental concepts and essential technological solutions.

What is Industrial Automation?

Industrial automation involves the use of control technologies, such as computer systems and robots, to manage industrial processes while minimizing human intervention. Modern factories typically integrate different levels of automation, whether for assembly, quality control, or logistics.

You may be wondering how to choose the right level of automation for your specific needs. Let’s explore the different options available.

What are the Different Levels of Automation?

• Fixed Automation: Systems designed for a specific task
• Programmable Automation: Reconfigurable equipment for different production runs
• Flexible Automation: Systems that can adapt in real time to production variations

How Do Fundamental Technologies Work?

The Role of Programmable Logic Controllers (PLCs)

Programmable Logic Controllers (PLCs) are the brains of automated systems. These sophisticated devices execute cyclical programs that:

• Read inputs (sensors, buttons)
• Process information based on programmed logic
• Control outputs (actuators, motors)
• Communicate with other systems via industrial protocols
• Ensure synchronization of different equipment
• Manage automation sequences
• Monitor critical process parameters

Features of M.E.S. and Quick M.E.S. Systems

Manufacturing Execution Systems (M.E.S.) provide industrial intelligence through:

Real-time Visualization:

• Dynamic dashboards
• Display of key performance indicators (OEE, efficiency, quality)
• Tracking of downtime and machine stops:
• Tool changes (e.g., die replacements in stamping)
• Machine adjustments (e.g., welding parameter adjustments)
• Scheduled cleanings (e.g., flushing painting systems)  
• Preventive maintenance (e.g., greasing conveyor chains)
• Mapping of production processes

Performance Analysis:

• Automatic calculation of OEE (Overall Equipment Effectiveness)
• Monitoring of production cycles
• Identification of bottlenecks
• Analysis of root causes of non-quality

The Operation of Industrial Networks

Communication is crucial in automation. The main protocols include:

Ethernet/IP:

Developed by Rockwell Automation, this protocol uses the Ethernet standard for industrial communications, offering great flexibility and compatibility.

Profinet:

A standard developed by Siemens, particularly suited for real-time applications and widely used in the European industry.

Modbus TCP/IP:

A widely used open protocol, ideal for communications between different industrial equipment due to its simplicity and robustness.

EtherCAT:

A high-performance deterministic protocol, particularly effective for precise motion synchronization and real-time control.

Components: Sensors and Actuators

Sensors and actuators act as the sensory and muscular organs of automated systems. They allow measuring the physical variables of the process and acting on it.

Essential Sensors:

• Position sensors (encoders, inductive sensors, capacitive sensors)
• Temperature sensors (thermocouples, PT100)
• Pressure sensors (piezoresistive, capacitive)
• Level sensors (ultrasonic, radar)
• Flow sensors (electromagnetic, Coriolis)

Main Actuators:

• Electric motors (asynchronous, servomotors)
• Pneumatic and hydraulic cylinders
• Proportional solenoid valves
• Vector speed drives

Human-Machine Interface (HMI)

HMIs are essential for allowing effective interaction between operators and automated systems. They provide clear visualization of processes and enable intuitive control of equipment.

Main Components:

• Durable industrial touch screens
• Ergonomic control panels
• Synoptic control tables
• Hierarchical alarm systems

Standardized Industrial Programming Languages

Programming of automation controllers requires specialized languages standardized by IEC 61131-3. These languages are designed to meet the specific needs of industrial automation, combining reliability, maintainability, and ease of use.

The standard defines five main languages:

1. Ladder Diagram (LD) - Schematics for simple logic programming
2. Function Block Diagram (FBD) - Programming with functional blocks, perfect for complex processes
3. Structured Text (ST) - Structured language similar to Pascal, suited for complex algorithms
4. Instruction List (IL) - List of instructions programming, optimal for small controllers
5. Sequential Function Chart (SFC) - Sequential graph, excellent for sequential processes

Trends and Evolutions in Industrial Automation

The Industrial Internet of Things (IIoT) is radically transforming industrial automation:

Modern IIoT Architecture:

• Intelligent sensors with integrated processing capabilities
• IoT gateways for data collection and preprocessing
• Secure cloud infrastructure for storage and analysis
• Business applications for data exploitation

Concrete Benefits of IIoT:

• Continuous monitoring of equipment with real-time alerts
• Dynamic optimization of production parameters
• Complete traceability of manufacturing processes
• Optimized maintenance based on the actual condition of equipment

Artificial Intelligence:

Enhances automated decision-making and optimizes production processes through predictive analytics.

Digital Twins:

Create virtual replicas of physical systems for simulation and process optimization.

Cognitive Automation:

Integrates pattern recognition and learning capabilities for complex tasks.

Edge Computing:

Processes data close to the equipment for faster response and better efficiency.

Collaborative Robotics:

Enables safe interaction between robots and operators for complex tasks.

Conclusion

Industrial automation is a fundamental pillar of Industry 4.0, combining sophisticated hardware, advanced software, and high-performing industrial networks. Programmable logic controllers, Quick M.E.S. systems, and communication protocols form the backbone of this technological revolution. A deep understanding of these elements is essential for successfully implementing effective and scalable automation solutions in the modern manufacturing environment.