Imagine a huge factory's “nerve center”: it always senses the pulse of each piece of equipment,
accurately directs each dance of the robotic arm, calmly schedules the flow of materials, and keenly
captures the slightest fluctuations in production. This maintains the core of efficient, stable, high-quality
production, is the industrial automation control system. It has long surpassed the simple role of equipment
switch, evolved into a complex intelligent system integrating perception, decision-making, execution and
optimization, is an indispensable “operating brain” and “control lifeblood” of the modern
manufacturing industry.
Layered architecture: building a solid skeleton of the control system
A complete set of industrial automation control system, like a sophisticated human nervous system, has a
clear functional layering:
Field Device Layer: The “senses” and “arms and legs” of the system.
Sensing unit (sensor): throughout the production line, real-time collection of temperature, pressure, flow,
position, speed, image, vibration and other key physical quantities (such as thermocouples, pressure
transmitters, encoders, vision sensors).
Execution units (actuators): Receive commands to drive physical actions (e.g. motors/servo drives,
pneumatic/hydraulic valves, relays, contactors).
Basic Components: Pushbuttons, indicators, limit switches, etc., for basic human-machine interaction and
equipment status indication.
Control layer: The “decision-making brain” and “nerve center” of the system.
PLC (Programmable Logic Controller): the cornerstone of industrial control, specializing in high-speed,
deterministic logic control, sequence control and discrete process control. Rugged and reliable, adaptable
to harsh environments.
DCS (Distributed Control System): Designed for large, complex, continuous process industries (chemical,
petrochemical, electric power). Characterized by decentralized control functions (to the field control station)
and centralized operation management (through the operator station). Strong in analog regulation, complex
loop control and large system coordination.
Industrial PC (IPC) / Embedded Controller: Provides powerful computing power and openness for scenarios
requiring complex algorithms (e.g., machine vision processing, advanced motion control) or running advanced
software (e.g., databases, custom applications).
Core controllers:
Specialized controllers: e.g. robot controllers, CNCs, built-in controllers for drives, etc., responsible for precision
motion or process control of specific devices.
Supervisory Layer: The “visualization window” and “operator console” of the system.
SCADA (Data Acquisition and Supervisory Control System): The core tasks are wide-area data acquisition (from
multiple PLC/DCS or remote sites), centralized monitoring, alarm management, historical data storage and basic
control. It is the key bridge between the field and the control room.
HMI (Human Machine Interface): A direct window for operators to interact with the control system. Provide
dynamic display of process flow, parameter setting, equipment start/stop operation, real-time data view, alarm
confirmation and other functions. Various forms (touch screen, operating panel, workstation software).
Information Management System: The system's “intelligent counselor” and “performance optimizer”.
MES (Manufacturing Execution System): The key level from the top to the bottom. It receives the production plan
from ERP, breaks it down, schedules it, and sends it to the automation system for execution; at the same time, it
collects detailed data from the production site (output, quality, equipment status, material consumption, and
manpower and staff time), and carries out process monitoring, OEE, quality traceability, and material tracking,
etc., so as to realize transparency and optimization of the production process.
Historian (real-time database): Specially used for high-speed storage and efficient retrieval of massive time-series
process data, providing data basis for performance analysis and optimization.
Enterprise layer: The “strategic commander” of the system.
ERP (Enterprise Resource Planning), PLM (Product Lifecycle Management), etc.: Responsible for enterprise-level
resource planning, order management, supply chain coordination, and product design data management.
Provide production instructions and basic data for the automation layer.
Core Functions: Underlying Logic for Driving Intelligent Manufacturing
The automation control system realizes its value through the following core functions:
Precise Control: Whether it's simple start/stop logic, complex multi-axis synchronized motion, or precise
temperature and pressure regulation, the system ensures that equipment operates precisely according to
predefined requirements.
Real-Time Response: Millisecond processing speed ensures immediate response to unexpected conditions
(e.g., equipment failure, emergency safety stops) or setpoint changes during production.
Data-driven decision making:
Closed-loop control: Based on real-time feedback data from sensors, dynamically adjusts actuator outputs to
stabilize controlled quantities (e.g., temperature, speed) at setpoints (e.g., PID control).
Process Optimization: Analyze historical and real-time data to find the optimal combination of process
parameters to improve efficiency, quality or reduce energy consumption.
Predictive Maintenance: Based on equipment operating status data (vibration, temperature, current), predict potential
failures and schedule maintenance in advance to reduce unplanned downtime.
Safety: Integration of safety relays, safety PLCs, safety light curtains, emergency stop buttons, etc., constituting
independent or integrated safety circuits to ensure the safety of personnel, equipment and the environment.
Efficient Collaboration: Connect decentralized equipment, controllers, and systems through network communication
(industrial Ethernet, fieldbus) to achieve information sharing, command synchronization, and overall coordinated operation.
Transparency and Traceability: Record complete production process data and operational events to achieve full
product lifecycle traceability (raw material batches, process parameters, quality inspection results) and meet quality
management and regulatory requirements.
Technological evolution: Intelligent wave for the future
Industrial automation control systems are undergoing a profound transformation:
IT/OT convergence: Industrial Ethernet (e.g. Profinet, EtherNet/IP, EtherCAT) is becoming mainstream, the OPC
UA standard is breaking down data barriers, and the boundaries between information technology (IT) and
operational technology (OT) are becoming increasingly blurred.
Rise of Edge Computing: Real-time data analysis, pre-processing and rapid decision-making (e.g., machine
vision inspection, real-time diagnosis of equipment status) on the device side close to the source of the data,
reducing the burden on the cloud and improving response speed.
Software definition and control: The role of software has never been more important. Advanced algorithms
(AI/ML), virtualization technology, and modular software platforms give hardware greater flexibility and intelligence.
Openness and interoperability: Embrace open standards, open source technologies (e.g. Linux, OPC UA), break
vendor lock-in, and realize seamless integration between different systems and devices.
Cloud platform and big data analysis: Control system data on the cloud, combined with big data analysis and AI,
to achieve global optimization, remote monitoring, advanced forecasting and cross-plant collaboration.
Network Security Enhancement: As systems become more interconnected, network security measures such as
industrial firewalls, security gateways, and access control become essential elements of system design.
Building Reliable Systems: Key Considerations
The design, selection and implementation of a successful automation control system requires in-depth consideration:
Matching process requirements: Define the control object (discrete/process), size, complexity, precision, speed,
and safety level requirements. Is the choice of PLC or DCS, what special control functions are needed?
System architecture design: reasonable network topology, controller selection and distribution, redundant
configuration (power supply, controller, network) program to ensure reliability and scalability.
Core component selection: controller performance (processing speed, memory, I/O capacity), I/O modules (type,
accuracy, isolation), network equipment (bandwidth, protocol support, real-time) of the reasonable choice.
Software Platform Capability: Programming development environment (IEC 61131-3 standard), configuration
software function, HMI/SCADA performance, ease of interface with upper layer system (MES/ERP).
Reliability and Maintenance: Component quality, environmental adaptability, MTBF (Mean Time Between Failure),
diagnostic capabilities, availability of spare parts, ease of maintenance.
Supplier ecology and services: technical strength, industry experience, localized service support capabilities
(pre-sales consulting, engineering implementation, training, after-sales response).
Conclusion: the cornerstone of intelligence, the future is promising!
Industrial automation control system is the core engine for efficient, stable and intelligent operation of modern
factories. It builds an interlocking, data-driven intelligent closed loop from the bottom layer of precise control
equipment, to the middle layer of coordinated production line operation, and then to the top layer of driving
management decisions. Understanding its architecture, functions, technology trends and selection points is crucial
for enterprises to enhance automation level and safeguard production competitiveness.
With the advancement of the wave of intelligence, the control system is evolving from “automation” to “autonomy”.
It is not only a tool for execution, but will become the intelligent core for insight into the production process,
optimizing resource allocation and empowering innovative manufacturing. Choosing and building a powerful,
reliable and future-oriented automation control system is to lay the most solid operational cornerstone for the
sustainable development of enterprises in the era of intelligent manufacturing. When the pulse of the factory
beats strongly driven by the intelligent center, the future of efficient, flexible and sustainable manufacturing is
clearly visible.