In the roaring factory, equipment running efficiently, material flow accurately, quality stable as one - behind
this modern industrial picture, there is a vital “invisible commander” in silent operation: industrial automation
control system. It is far from a simple collection of switches, but the depth of the integration of control
technology, real-time computing, network communications and data analysis of complex systems, is to drive
the intelligent manufacturing of efficient, accurate and reliable operation of the core pivot and neural network.
Understanding and optimizing this system has become a key step for manufacturing enterprises to enhance
their competitiveness and move towards high-quality development.
More than control: the core value of automation control system
The core mission of the Industrial Automation Control System (IACS) is to monitor, control and optimize
production processes. It obtains real-time data through sensors (“sensory nerves”) throughout the
production line, transmits it via high-speed networks, and carries out logical operations and decision-making
in the controller (“decision-making brain”), which ultimately drives the actuators (“action muscles”) to
complete precise actions. The controller (“decision-making brain”) makes logical calculations and decisions,
and finally drives the actuator (“action muscle”) to complete precise actions. Its value goes far beyond
replacing manual operations:
Precise execution, not a hair out of place:
Stable reproduction of complex processes (e.g., precision painting, high-speed filling, micron-level cutting)
ensures product quality consistency far beyond that of manual labor.
High-speed motion control (e.g., robot trajectory, servo positioning) realizes sub-millimeter precision,
improving production efficiency and yield.
Strict timing control ensures seamless multi-equipment co-operation (e.g. assembly line beat synchronization)
and avoids wasteful waiting.
Real-time response and control:
Millisecond data collection and command issuance, instant response to unexpected conditions (such as
emergency stop, parameter overrun), to protect the safety of personnel and equipment.
Real-time monitoring of equipment status (running/stopped/faulty), process parameters (temperature/
pressure/flow), energy consumption data, production status at a glance.
Quickly respond to changes in production plans or order insertion, and realize flexible switching of
production lines through system adjustment.
Data-driven, optimized decision-making:
Automatic collection and storage of massive production process data (equipment OEE, energy consumption,
yield rate, beat) lays the foundation for analysis and optimization.
Identify production bottlenecks (e.g., long waiting time at a station) and energy efficiency pockets (e.g., high
no-load energy consumption of a piece of equipment), and provide precise directions for improvement.
Integrate with upper management system (MES/ERP) to realize the coherence of planning, production,
logistics and quality data.
Safety and security, stable and reliable:
Strict safety logic (safety PLC, safety relay, safety light curtain) guarantees the safety of man-machine collaboration
in hazardous areas and complies with international safety standards (e.g. ISO 13849).
Redundant design (controller, power supply, network) ensures continuous operation of critical processes and
minimizes losses from unplanned downtime.
Reliable industrial-grade hardware and software, adapt to harsh environments (high temperature, high humidity,
dust, vibration), to ensure long-term stability of the system.
Core Architecture: Building the “Four Pillars” of the Control System
Modern industrial automation control systems usually present a layered architecture, each in its own way, operating in concert:
Field layer: sensing and execution
Sensors: like “eyes” and “ears”, real-time collection of temperature, pressure, flow, position, speed, image, vibration and
other physical signals (such as thermocouples, encoders, vision sensors).
Actuators: Like “arms” and “fingers”, they receive control commands and execute actions (e.g. motors, valves, cylinders,
servo drives, relays).
Fieldbus/Industrial Ethernet: High-speed and reliable “nerve fibers” connecting field devices to the control layer (e.g.
PROFINET, EtherNet/IP, Modbus TCP, CC-Link IE).
Control layer: Calculations and decisions
Programmable Logic Controller: The “core brain” of the system (PLC). It is responsible for performing tasks such as logic
control, sequence control, timing, counting, arithmetic operations, processing field level data and issuing control commands.
With its high reliability, strong anti-interference, modular expansion of industrial control cornerstone.
Distributed Control System: Widely used in process industries (e.g. chemical, electric power) (DCS). More focused on
complex process loop control, advanced algorithms (such as PID optimization), centralized monitoring and management
of large-scale systems. Usually consists of multiple controller nodes working together.
Industrial Computer/IPC: Used in scenarios requiring complex computation (e.g., machine vision processing,
advanced motion planning), data logging, or HMI functionality.
Monitoring Layer: Visualization and Management
Data acquisition and monitoring system: The “cockpit” of the system (SCADA). Provides a graphical Human Machine
Interface (HMI) that displays process flow, equipment status, alarm information, and historical trends in real time.
Supports remote monitoring, data logging, report generation and some control operations. It is the main window
for the operator to interact with the control system.
Manufacturing Execution System: The “scheduling center” (MES). Focuses on workshop-level production management,
receives ERP plans, schedules production resources, manages work orders, materials, quality, equipment maintenance,
and collects production results for feedback to ERP. SCADA provides key real-time production data for MES.
Information Layer: Analysis and Optimization
Enterprise Resource Planning: The “command center” of the enterprise (ERP). Responsible for macro-level resource
planning, supply chain management, finance, sales, and so on.
Data Lake/Analytics Platform: Aggregates data from control systems, MES, ERP, etc., and uses big data analytics and
artificial intelligence (AI) technology to conduct deep mining and realize advanced applications such as predictive
maintenance, quality prediction, energy efficiency optimization, and process improvement.
Key Technologies and Evolutionary Trends
Automation control systems continue to evolve, incorporating cutting-edge technologies to meet higher challenges:
Openness and interoperability: OPC UA (Unified Architecture) has become a key standard for breaking down “information
silos” and realizing secure and reliable data exchange between systems of different brands and tiers.
Deep IT/OT Convergence: Industrial Ethernet has become popular, and 5G and TSN (Time Sensitive Networking) are helping
to realize wireless/wired communications with lower latency and higher certainty. Edge Computing is close to the source of
data for real-time processing and analysis, reducing the burden on the cloud and improving response speed.
Software Definition and Control: Increased use of PC-based soft PLCs and virtualization technologies to improve system
flexibility and scalability. High-level programming languages (e.g., structured text ST, C/C++) support more complex algorithms.
Enhanced Cybersecurity: As systems become more interconnected, it is critical to deploy defense-in-depth strategies
(firewalls, access control, encryption, auditing) to protect control systems from cyberattacks in compliance with standards
such as IEC 62443.
Artificial Intelligence: AI algorithms (machine learning, deep learning) are applied to control systems to enable more accurate
predictive maintenance (e.g., predicting bearing life based on vibration analysis), adaptive control (e.g., dynamically adjusting
process parameters based on raw material characteristics), and intelligent optimization (e.g., energy management).
Building Reliable Systems: Selection and Implementation Essentials
Successful deployment of industrial automation control systems requires comprehensive consideration:
Clarify requirements and pinpointing: In-depth analysis of process characteristics (discrete/process), control scale, accuracy
requirements, security level, communication needs, scalability expectations and budget. Should you choose a PLC as the
core, a DCS, or a hybrid architecture?
Choosing a reliable core component: The reliability, processing power, I/O capacity, and communication interface of the
controller (PLC/DCS) are key. Focus on compliance with industry standards, a rich feature library, and good technical support.
Focus on network architecture: Design robust, high-speed, secure industrial networks (wired/wireless). Select appropriate
fieldbus and industrial Ethernet protocols, considering bandwidth, real-time, topology and redundancy requirements.
Human-computer interaction design: HMI/SCADA interface should be intuitive, easy to use, clear information, alarm
management needs to be standardized and effective, so that operators can quickly grasp the situation and respond.
Safety and protection: From hardware selection (safe PLC, safe I/O) to software programming (safe logic), to network
protection (regional isolation, access control), to build a comprehensive functional safety and network security system.
Integration and data communication: Ensure that the control system can realize seamless data interaction (using standards
such as OPC UA) with upper-level systems such as MES and ERP, as well as various types of intelligent equipment
(e.g., robots, smart meters).
Professional implementation and continuous maintenance: Rely on experienced system integrators for design, programming,
and commissioning. Establish a comprehensive documentation system (drawings, programs, manuals). Develop preventive
maintenance programs and spare parts strategies.
Conclusion: Control the core, intelligent future
Industrial automation control system is the cornerstone of modern manufacturing efficient, intelligent and safe operation.
It is like the “intelligent brain” and “precise nerve” of the factory, which silently coordinates the actions of thousands of
equipments, guarantees the quality of each product, and drives the continuous improvement of efficiency and cost
optimization. In the era of intelligent manufacturing, in-depth understanding, careful construction and continuous
optimization of this core system is an inevitable choice and the key to victory for enterprises to enhance their core
competitiveness and achieve sustainable development. Let the stable and reliable control system become the powerful
engine of your intelligent manufacturing upgrade, accurately control every production link, and move towards
a more efficient and better quality future!