In today's efficiency-oriented industrial era, the automation of a single device can no longer
meet the complex and changing market demand. The real competitiveness comes from the synergy
and optimization of the whole production process, and behind this, it is the industrial automation
system is playing a core role. It is like the enterprise's “neural network” and “skeleton”, the independent
equipment, workstations and workshops are connected into an organic whole, to achieve efficient
synergies between information flow and control flow, driving the manufacturing industry to
intelligent, digital leap.
I. What is industrial automation system?
Industrial automation system is a comprehensive technical system, which realizes all-round monitoring,
control and optimization of industrial production process by integrating control theory, instrumentation,
computer technology and communication technology. Its core goal is to replace or assist manual labor,
to achieve “unmanned” or “less humanized” efficient, stable and safe production. The system is not a
single product, but rather a layered architecture that typically includes the following key layers:
Field Equipment Layer: This is the “senses and arms and legs” of the system, interacting directly with
the production site. This includes:
Sensors: such as temperature, pressure, flow, vision sensors, etc., responsible for collecting a variety of
data from the physical world.
Actuators: such as motors, valves, robotic arms, etc., responsible for receiving instructions and perform specific actions.
Intelligent instrumentation: Field devices with preliminary data processing and communication capabilities.
Control layer: This is the “spinal cord” of the system, responsible for real-time logic control and operation.
The core equipment is:
Programmable Logic Controller (PLC): As the most reliable control core, PLC is responsible for the
implementation of specific logic, sequence, timing and counting and other control functions, fast response
speed and excellent stability.
Distributed Control System (DCS): More suitable for chemical, electric power and other process industries,
focusing on the analog continuous process control, to achieve multi-loop, complex coordinated control.
Monitoring layer: This is the “operation and visual center” of the system, providing human-computer
interaction interface for operators. Mainly includes:
Data acquisition and monitoring system (SCADA): responsible for collecting data from a wide range of field
devices (such as multiple PLCs), centralized monitoring, data logging and alarm management, and providing
a dynamic graphical interface to enable the operator to overview the overall situation.
Human Machine Interface (HMI): A localized terminal for the operator to interact with the control system to
display equipment status, set parameters and perform simple control.
Management: This is the “brain” of the system, responsible for advanced computing, data analysis and
decision support. This layer is deeply integrated with enterprise-level systems, including:
Manufacturing Execution System (MES): Acts as a bridge between the control layer and Enterprise Resource
Planning (ERP), responsible for production scheduling, material tracking, quality management, equipment
management, etc., which is the key to realizing lean production.
Enterprise Resource Planning (ERP): Manage orders, finance, supply chain, etc. from the business level,
while MES transforms the production plan of ERP into executable and detailed instructions to be sent
to the control layer.
II. Core Components and Technologies of Industrial Automation Systems
In addition to the hierarchical architecture, the following key technologies and components together form the
cornerstone of the system:
Industrial network communication: This is the “neural network” that connects all layers. This includes fieldbus
(e.g. PROFIBUS, Modbus), industrial Ethernet (e.g. PROFINET, EtherCAT), and wireless communication technologies,
which ensure that data is transmitted reliably and in real time.
Drive technology: The conversion of control signals into precise mechanical movements is the essence of
automation execution, e.g. servo drives and inverter drives.
Industrial software: In addition to SCADA and MES, configuration software, simulation software, digital twin
platforms, etc., which greatly expand the planning, analysis and optimization capabilities of the system.
Third, the core value of industrial automation system
Deployment of a set of mature industrial automation system, can bring immediate and sustainable competitive
advantage for the enterprise:
Maximize production efficiency: The system achieves 7x24 uninterrupted operation, significantly improving
equipment utilization and overall production capacity by optimizing production beats, reducing line changeover
time, and avoiding human delays.
Product Quality and Consistency: Automated control eliminates the volatility and subjectivity of human operation,
ensuring that each product is produced in strict accordance with preset process parameters, significantly reducing
the defective rate and ensuring superior and consistent product quality.
Operation Cost Optimization: Although there is an upfront investment, in the long run, the system reduces reliance
on skilled labor and lowers labor costs. At the same time, total operating costs are effectively controlled through
scrap reduction, energy savings and preventive maintenance.
Safety and Reliability: The system frees employees from dangerous, harsh and repetitive work environments, while
improving production reliability through real-time monitoring and alarms to detect hidden equipment problems
in advance and avoid major safety incidents.
Data-driven decision-making: the system is a natural data convergence point, through the analysis of production,
energy consumption, equipment status and other massive data, enterprises can accurately locate bottlenecks,
optimize the process, predict equipment failures, to achieve scientific and accurate decision-making.
Enhanced production flexibility: modern automation systems can quickly adjust the production process and
parameters through the software, easily adapt to the small batch, multi-species customized production needs,
and quickly respond to market changes.
Fourth, the future trend: towards intelligent and adaptive Industry 4.0
Industrial automation systems are deeply integrated with cutting-edge technologies, moving towards a more advanced stage:
The deep integration of the Industrial Internet of Things (IIoT): more devices will be connected to the cloud to
achieve a wider range of data collection and interoperability, providing fuel for advanced analysis.
Artificial Intelligence and Machine Learning: AI algorithms are being used for visual inspection, predictive
maintenance, process parameter optimization, etc., giving systems the ability to learn and adapt themselves,
moving from “automation” to “autonomy”.
Digital Twin: Create accurate mapping of physical entities in virtual space to simulate, debug and optimize
production lines, dramatically shortening new product introduction cycles and reducing risk.
Edge Computing: Processing real-time demanding tasks close to where the data is being generated,
collaborating with the cloud to create a more efficient computing architecture.
Conclusion
Industrial automation systems are no longer simple control tools, but strategic building blocks that will
shape the future of manufacturing competitiveness. It builds an efficient, transparent, flexible and
sustainable production environment by seamlessly integrating information technology with operational
technology. For any manufacturing company wishing to stay ahead in the global market, in-depth
understanding and successful deployment of advanced industrial automation systems is the way to move
from “manufacturing” to “smart manufacturing”. Investing in systems is investing in the future.