Walking into a modernized production workshop, what comes into your eyes is no longer just a roaring
machine, but an organic life form operated by countless precision parts. Driving the efficient, precise and
safe operation of this living body is a wide range of industrial automation products, each in its own way.
They are like the factory's “senses”, “nerves”, ‘brain’ and “muscles”, and together they weave the neural
network and execution framework of intelligent manufacturing. They are like the “senses”, “nerves”, ‘brain’
and “muscles” of a factory, weaving together the neural network and execution framework of intelligent
manufacturing. Understanding these core products and their roles is a key step towards industrial intelligence.
the “senses” to perceive the world: sensors and identification
equipment
Core mission: Transform the state of the physical world (position, speed, temperature, pressure, flow, color, size,
presence, etc.) into electronic signals that can be understood by the control system.
Key Types & Scenarios:
Position/Displacement Sensors: Optical switches (to detect passage of objects), Proximity switches (to sense
metallic/non-metallic objects), Encoders (to accurately measure angle of rotation or linear displacement for
servo positioning).
Vision Sensors/Machine Vision Systems: Industrial Cameras + Lenses + Light Sources + Processing Software for
complex localization, precise measurement, defect detection, character recognition (OCR/OCV), guided robot gripping.
Process Variable Sensors: Temperature sensors (thermocouples, RTDs), pressure sensors/transmitters, flow meters,
level meters, analytical instrumentation (pH, concentration, etc.), the basis for process control.
Force/Torque Sensors: Used in robots for precision assembly, grinding and polishing to achieve “tactile” feedback.
RFID readers and tags: non-contact identification of materials, carriers, work-in-progress, logistics tracking and information binding.
Selection points: accuracy, range, response speed, environmental adaptability (temperature, humidity, dust, corrosion,
EMC anti-interference), protection level (IP), the type of output signal (analog 4-20mA/0-10V, digital PNP/NPN, bus communication).
the command action of the “nerve” and “brain”: controller and control system
Core mission: receive sensor signals, according to preset logic or algorithms for computing, decision-making, and send precise
control instructions to the actuator.
Core product:
The “conductor” of precision movements: specializing in controlling servo motors and stepper motors to achieve multi-axis,
high-precision, high-speed coordinated movements (pointing, interpolation, electronic cams, etc.).
Forms: stand-alone controller cards/modules, motion control modules integrated in PLC/PAC, IPC-based soft motion control cards.
The “brain” of complex computing and data processing: based on PC architecture, with powerful computing capabilities, mass
storage, rich interfaces.
Applications: machine vision processing, complex motion control (such as CNC), data acquisition and monitoring system (SCADA)
server, advanced process optimization algorithms running platform, human-machine interface (HMI) host.
The “central nervous system” of the process industry: designed for large-scale, continuous, complex process industries (chemical,
petrochemical, electric power, pharmaceutical).
Features: decentralized control (field control station), centralized management (operator station, engineer station), highly reliable
redundant design, powerful analog loop control, historical data recording and alarm management capabilities.
The “mainstay” of industrial control: high reliability, strong real-time, excellent anti-interference capability. It is good at handling
switching logic, sequence control, timing and counting.
Components: CPU module (computing core), I/O module (connecting sensors and actuators), power supply module,
communication module, backplane/rail.
Applications: Widely used in the discrete manufacturing industry for production line control, stand-alone equipment control.
Programmable Logic Controller (PLC):
Distributed Control System (DCS):
Industrial Computers (IPC) and Embedded Controllers:
Motion controllers:
Selection points: processing power (I / O points, program capacity, scanning cycle), real-time requirements, the complexity of
the control task (logic / motion / process), communication capabilities, redundancy requirements, environmental adaptability,
ease of use of the development environment.
drive the world's “muscle”: actuators and drive systems
Core mission: to convert the instructions issued by the controller into actual physical action or energy output, drive
equipment operation.
Key products:
Basic power source: AC asynchronous motor (most commonly used), DC motor, stepping motor (open-loop control). Combined
with contactors, soft starters, protection relays, etc., they form the basic drive circuit.
Power and speed of the “reliable partner”: cylinders / hydraulic cylinders (linear motion), pneumatic / hydraulic motors (rotary
motion), control valves (direction, flow, pressure), auxiliary components (filters, pressure reducing valves, oil mist).
Features: simple structure, easy maintenance, low cost (especially pneumatic), high output (hydraulic). Suitable for scenarios
requiring fast reciprocation, medium accuracy, and cost sensitivity.
Motor speed control and energy saving “experts”: by changing the frequency and voltage of the AC motor power supply to
control its speed and torque.
Core values: energy saving (fans, pumps), smooth start/stop, process speed requirements.
The “golden combination” of precise positioning and speed control: servo drive + servo motor + feedback device (encoder).
Provides motion control with high accuracy, high response speed, and high overload capability.
Applications: precision machining equipment (CNC), robot joint drive, high-precision positioning platform, flying shear, chase shear.
Versatile “robotic arms”: Articulated robots (flexible), SCARA robots (high-speed flat work), Delta robots (ultra-high-speed sorting),
collaborative robots (human-machine collaboration), mobile robots (AGV/AMR) (intelligent logistics).
Applications: Handling, loading and unloading, welding, painting, assembly, testing, packaging, palletizing.
Industrial robots:
Servo system:
Frequency inverters:
Pneumatic/hydraulic components:
Motors and starters:
Selection points: load type and size, motion requirements (speed, accuracy, travel), control mode (position/speed/torque),
environmental adaptability, power/torque requirements, response speed, cost.
the interconnection of the “pulse”: industrial networks and communications
Core mission: to realize the controller, sensors, actuators, HMI, the upper levels of the system between fast, reliable, safe data exchange.
Mainstream technology:
Representative technologies: Wi-Fi (industrial grade), Bluetooth (low power), Zigbee, LoRaWAN, private 5G/4G LTE.
Representative protocols: Profibus DP/PA, Modbus RTU, CANopen, DeviceNet, CC-Link.
Protocols represented: EtherNet/IP (CIP), Profinet, EtherCAT, Powerlink, Modbus TCP/IP, CC-Link IE.
Advantages: High bandwidth, good integration with IT networks, wide range of applications.
Industrial Ethernet: Has become mainstream, based on the standard Ethernet physical layer, enhanced real-time, certainty, reliability.
Fieldbus: Widely used in traditional applications, relatively low cost, suitable for small and medium-sized systems.
Wireless technology: For mobile equipment (AGV/AMR), rotating parts, difficult wiring areas.
OPC UA: platform-independent, service-oriented architecture to achieve cross-system, cross-supplier security data
interoperability, is the key bridge for IT/OT integration.
Selection points: real-time requirements, bandwidth requirements, transmission distance, number of nodes, topology
(star, ring, bus), anti-jamming ability, security requirements, cost, existing system compatibility.
Interaction and insight “window”: human-machine interface and software
Core mission: Provide operators with an interface to monitor equipment status, intervene in the production process,
and enter parameters; provide engineers with tools to configure the system, develop programs, and analyze data.
Key Product:
Domain-specific “smart engines”: e.g. Advanced Process Control (APC) software, digital twins, predictive maintenance
analytics, energy management systems (EMS).
Engineer's “toolbox”: for PLC/DCS/Robotics/Motion Controller programming (Ladder Diagram LD, Function Block
Diagram FBD, Structured Text ST, Sequential Function Chart SFC, etc.), HMI/SCADA configuration, simulation debugging.
Production management “baton”: connects the upper ERP and the lower automation system, manages work order
execution, material tracking, quality management, equipment efficiency (OEE) analysis, personnel scheduling and so on.
Factory-level “monitoring center”: used for large-scale, distributed process or equipment monitoring, data collection,
alarm management, historical data storage, report generation. Usually based on PC platform.
Operator's “console”: touch screen, text display, operation panel. Displays real-time data, alarm information, process
screen, and receives operating instructions.
Human Machine Interface (HMI):
Data acquisition and monitoring system (SCADA):
Manufacturing Execution System (MES):
Engineering development software:
Industry-specific software:
Selection points: functional requirements (monitoring/control/management), data capacity and processing
capabilities, user roles and ease of use, system integration capabilities (interfaces, protocols), scalability,
security, supplier support and service.
the safe operation of the “guardian”: industrial safety products
Core mission: to protect people, equipment, the environment from the potential dangers of automation systems.
Key categories:
Safety input devices: emergency stop buttons, safety door locks, safety light grids / light curtains, two-handed
operation devices, safety carpet, safety rope switch.
Safety control logic: safety relays, safety PLCs (IEC 61508/62061 SIL/PLe rated).
Safety output devices: safety contactors, safety valves.
Mechanical protection: fixed guards, interlocking guards, safety fences.
Core concept: Based on risk assessment (RA), adopt safety design in accordance with relevant standards (e.g. ISO
13849, IEC 62061) to realize the reliable realization of safety functions (no loss of safety functions even if a single
point of failure occurs).
Selection and Application: Matching Needs, Building Optimal Solutions
In the face of a wide range of automation products, the key to selection lies in the in-depth understanding of their
own process requirements and technical pain points:
Define the goal: what specific problem to solve? (Improve efficiency? Ensure quality? Ensure safety? Reduce energy consumption?)
Analyze the scenario: What is the environment (temperature, humidity, cleanliness, interference)? Process precision
requirements? Rhythmicity requirements? Maintenance convenience requirements?
System thinking: Consider the compatibility between products, communication protocol matching, future scalability.
Avoid the “headache, foot”.
Reliability Priority: In harsh industrial environments, long-term stable operation is more important than short-term
performance parameters. Pay attention to the average MTBF (MTBF), protection level (IP), brand reputation and service
support.
Openness and standards: Prioritize products that support mainstream open standards and protocols to reduce the
difficulty of integration and the risk of being locked into a single vendor in the future.
Total Cost of Ownership (TCO): In addition to the purchase cost, it is more important to consider the installation and
commissioning, maintenance, energy consumption, training, upgrading and other long-term costs.
Conclusion:
Industrial automation products are not a pile of cold parts, they are the figurative expression of modern industrial
wisdom and power. From sensing subtle changes in the sensor, to high-speed computing controller, to accurate and
powerful actuators, as well as the network to connect them closely and give them the “soul” of the software, each type
of product in the grand movement of the smart factory plays an irreplaceable role. In-depth understanding of their
principles, characteristics and selection of the way, in order to accurately build their own needs to meet the skeleton
of the automation system, so that the real flow of data, so that efficient collaboration of the machine, and ultimately
drive the manufacturing enterprise towards intelligent, flexible, sustainable development of the future. The process of
selecting and applying these products is itself a practice of industrial art of excellence.