In the steel roaring plant, in the precision assembly line, a silent change has long penetrated
every aspect of manufacturing. Industrial automation, by no means a simple “machine for man”,
but with technology as the sinews, data for the blood, reconfiguring the production logic of the
nervous system. To understand its essence is to grasp the ticket to the era of intelligent manufacturing.
Core Definition: Beyond the mechanical “intelligent cooperative body”.
Industrial automation is a comprehensive use of control technology (PLC/DCS), sensor technology, drive
technology, computer and communication technology (Industrial Internet of Things IIoT), so that mechanical
equipment, production lines and even entire factories can autonomously complete the scheduled processing,
testing, assembly, logistics and other tasks with minimal human intervention, and realize the process of
optimization and management of the technical system. It builds a closed-loop life form that can
“sense-analyze-decide-execute”.
Key components: building automation “body” and “nerve”.
Sensory nerves (sensing and detection):
High-precision sensors (temperature, pressure, displacement, vision, RFID) act as the “eyes” and “skin” of the
machine, capturing changes in the physical world (e.g., part position, equipment vibration, material flow, product
quality) in real time.
The machine vision system acts as a “quality control expert”, identifying defects, measuring dimensions and
reading characters in milliseconds.
Decision center (control core):
PLC (Programmable Logic Controller): The “Field Commander” of the production line, based on preset logic,
processes sensor signals at high speed, and accurately controls the actuators (e.g., opening and closing of valves,
starting and stopping of motors). Anti-interference, high reliability is the soul of industrial grade.
DCS (Distributed Control System): The “intelligent brain” of large-scale process industries (chemical industry, electric
power), coordinates and controls complex circuits throughout the plant to ensure that parameters such as temperature,
pressure, flow rate and so on are stabilized at the optimal value.
Industrial Computer (IPC) and Edge Computing: Provide stronger computing power to support advanced algorithms
(e.g., machine vision analysis, predictive maintenance models) running in real time at the edge of the equipment.
Actuators (drive and operation):
Servo motors and stepper motors provide precise power and position control.
Pneumatic/hydraulic cylinders for reliable and powerful pushing and positioning.
Industrial Robots: From heavy-duty handling to precision welding, from high-speed sorting to flexible assembly, robotic
arms are the “all-around performers” on the automation stage. Collaborative robots (Cobot) have created a new paradigm
for safe human-robot collaboration.
Information networks (connectivity):
Industrial Ethernet, field buses (e.g. PROFINET, EtherCAT) form a high-speed “information superhighway”, ensuring
millisecond transmission of control signals and data.
Industrial Internet of Things (IIoT) platform: Open up equipment silos, realize the fusion of massive equipment data (OT data)
and production management information (IT data), and lay the foundation for intelligentization.
Human Machine Interface (HMI/SCADA):
Touch screen, monitor screen is the operator's “console”, providing equipment status visualization, parameter setting, alarm management.
SCADA (Data Acquisition and Monitoring System): Widely distributed plant or pipe network “air command tower”, to achieve
remote monitoring, data aggregation and key control.
Application scenario: from “point” to “surface” of the efficiency revolution
Cell-level automation: Single equipment or small workstations (e.g., CNC machine tools for automatic machining, robotic welding cells).
Line-level automation: Collaboration of the entire assembly line (e.g., automotive assembly line, SMT electronic placement line),
automatic flow of materials (AGV/RGV), seamless integration of processes.
Workshop-level automation: scheduling coordination of multiple production lines (MES system), intelligent distribution of materials
(WMS + automated warehouse), centralized control of energy.
Factory-level automation: cross-plant resource optimization, plant-wide data aggregation and analysis, simulation and
decision-making based on digital twin.
Core Value: Reinventing Manufacturing Competitiveness
Efficiency leap: 7x24 hours continuous production, breaking through the limit of manpower; precise beat compression of production
cycle; maximize the overall efficiency of equipment (OEE).
Excellence in Quality: Eliminate human fluctuations, process parameters are not even close to the same; 100% online inspection,
defects have no place to hide; quality data-driven continuous improvement.
Cost Control: Optimize manpower structure (release high-value manpower); precise material management to reduce wastage;
dynamic optimization of energy consumption; reduce rework and scrap.
Safety: Replacement of high-risk environment (high temperature, toxic, heavy load); intrinsically safe design (interlock, emergency
stop); collaborative robots to ensure human-machine safety.
Flexibility: Rapid production changeover (SMED conceptualization and practice); flexible response to small-lot, multi-variety
demand; improved supply chain resilience.
Data-driven: Transparency in the production process; predictable equipment status (predictive maintenance); decision-making
based on real-time insights rather than experience; fuel for continuous innovation.
The evolutionary path: moving deeper into “smart” manufacturing
Industrial automation is not the end of the road, but the cornerstone of smart manufacturing. It is now evolving into a more advanced form:
Deep Interconnection (IT/OT Convergence): Breaking down data barriers and realizing vertical integration from the equipment level to
the enterprise management level.
Intelligent analysis (AI-enabled): using machine learning to optimize process parameters, predict equipment failure, and improve
visual inspection accuracy.
Flexible and Adaptive: The production line is capable of self-awareness, self-decision-making and self-adjustment to cope with
high uncertainty.
Human-machine symbiosis: Humans focus on innovation, optimization, and decision-making, while machines are responsible for
precise execution and dangerous tasks, creating greater value through collaboration.
Conclusion: Embrace the invisible engine, drive the manufacturing future!
Industrial automation is an indispensable “invisible engine” of modern industrial civilization. It is not only the integration
of technology, but also the innovation of production concepts - from relying on “manpower” to relying on “systems”, from
the pursuit of ‘scale’ to the pursuit of “scale”. From the pursuit of “scale” to the pursuit of ‘efficiency’ and “intelligence”. A deep
understanding of its connotation, components and value, enterprises can accurately plan the automation upgrade path, the
cold equipment into a drive efficiency leap, quality peaks, cost control, safety and reliability of the core kinetic energy. In the
flood of the era of intelligent manufacturing, those who master the automation engine will be able to win the future. Is your
factory ready to start this powerful engine?