Early in the morning, you pick up a toothbrush and start washing. How does this toothbrush transform
from a pile of plastic particles and nylon bristles to the final product with precision? Behind this, there is
a powerful nervous system in command of the operation - it is the industrial automation system.
Industrial automation system is not a single device, but a highly integrated technology network. It is through
automation control technology, computer technology, communication technology, alternative or auxiliary
artificial, to realize the entire production process of accurate perception, intelligent decision-making, efficient
implementation and comprehensive management. Its core mission is to equip machines with the ability to
complete complex tasks autonomously, so that factories can operate continuously, stably and efficiently.
The core architecture of industrial automation system: sensing,
thinking and executing.
"Sensory layer: sensing the state of the equipment and the environment
Sensors: the “nerve endings” of the production line. They collect key data in real time: machine speed, temperature,
pressure, material position, product dimensions, environmental parameters (e.g. humidity, dust concentration) and
even image information (visual inspection systems).
Instrumentation: Provides more precise measurement and monitoring, such as flow meters, analyzers, etc., to ensure
the accuracy of process parameters.
The "brain" layer: information processing and decision-making center
Programmable controller: The core decision-making unit of the automation system. It receives signals from sensors,
carries out high-speed calculations and judgments according to program logic pre-written by engineers (e.g., shutting
down heaters when the temperature exceeds the threshold, starting the assembly arm when the part is in place), and
then sends precise control commands to the lower level of the actuator.
Distributed Control System: Provides more powerful centralized monitoring and decentralized control capabilities for
large, complex continuous production processes (e.g., chemical, oil refining).
Industrial computers: running advanced monitoring software, data processing and analysis platforms, human-computer
interfaces, more complex calculations, data storage, visualization and system management.
Motion Controller: Specialized in precision control of motors, servo drives, etc., to achieve high-speed, high-precision
position, speed and trajectory control, is the core of the robot, CNC machine tools and other equipment.
"Hand and Foot" Layer: Execution and Drive
Actuator: Receives instructions from the controller and converts electrical signals into physical actions. The most
common is a variety of motors (servo motors, stepper motors) to drive robotic arms, conveyor belts, valves, pumps
and so on.
Robot: highly flexible, multi-functional automation execution unit, can replace the manual completion of welding,
painting, handling, assembly, testing and other complex tasks.
Industrial valves, pumps, inverters, etc.: Precise regulation of process parameters such as flow, pressure, speed, etc.
The "neural network" layer: interconnected information
Industrial communication networks: like the “nervous system” of a factory, connecting sensors, controllers, actuators,
computers and other equipment. Common protocols include fieldbus, industrial Ethernet, etc., to ensure high-speed
and reliable transmission of control commands and data within milliseconds.
"Interactive Window" Layer: Human-machine communication bridge
Human-computer interface: The operator monitors the running status of the equipment, process parameters and alarm
information through the touch screen and display, and can set parameters and start/stop operations. It is the window
of human interaction with the automation system.
The power of industrial automation systems: reshaping the production landscape
Efficiency leap: 7x24 hours uninterrupted operation, the speed far exceeds the manual, greatly improving the utilization
rate of equipment and production capacity.
Quality Assurance: Eliminate the volatility of manual operation, ensure a high degree of consistency and accuracy in the
processing, assembly and testing processes, and significantly improve the yield rate.
Safety: Replace manual operation in dangerous and harsh environments (high temperature, toxic, dusty, high altitude),
effectively guaranteeing personnel safety.
Cost optimization: In the long run, significantly reduce labor costs, reduce scrap loss, reduce energy consumption.
Flexible production: Combined with advanced software, the automation system can switch product lines faster and adapt to
the needs of multi-species and small batch production.
Data-driven: Real-time collection of massive production data provides a solid foundation for process optimization, predictive
maintenance, and scientific decision-making.
Ubiquitous application: driving modern industry
Industrial automation systems have long permeated almost all manufacturing areas:
Automotive manufacturing: from body welding, painting to engine assembly, assembly line, automation is everywhere.
Electronics: Precision circuit board assembly, chip packaging and testing rely on high-precision automation equipment.
Food & Beverage: Aseptic filling, high-speed packaging, and batch control ensure safety and efficiency.
Pharmaceutical industry: Strict process control, aseptic production environments, precise dosing and mixing.
Chemical industry: safe, stable and optimized operation of large-scale continuous processes.
Machining: CNC machine tools, automated production lines to achieve efficient and precise processing of complex parts.
Warehousing and logistics: automated three-dimensional warehouse, intelligent sorting system, AGV handling.
Looking to the future: from automation to intelligence
With the deep integration of industrial Internet of Things, artificial intelligence, big data, 5G and other technologies,
industrial automation systems are accelerating to intelligent evolution:
Intelligent perception: more complex and accurate sensors and machine vision.
Intelligent decision-making: AI algorithms optimize control strategies to achieve predictive maintenance, self-learning
and self-adaptation.
Flexible Collaboration: Human-machine collaborative robots, more flexible line reconfiguration capabilities.
Comprehensive interconnection: Deep interconnection between equipment, products, systems and enterprises.
Industrial automation system, as the cornerstone of modern industry and the nerve center of intelligent manufacturing, is
continuing to evolve. It has not only profoundly changed the production mode of factories, but also played an irreplaceable
core role in continuously improving product quality, safeguarding personnel safety, reducing operating costs and enhancing
enterprise competitiveness. Understanding “what is industrial automation system” is a key step in grasping the pulse of future
industry. From the toothbrush in your hand to the speeding car, automation systems are quietly connecting the start and
end of the product, driving manufacturing towards a more efficient and intelligent future.