Walking into a modern factory, you may not see too many busy workers, instead of rows of
robotic arms accurately assembling parts, automatic guided vehicles quietly shuttle in the
workshop, the central control room screen real-time jumping the entire production line of data.
This scene, it is industrial automation technology to bring about profound changes. So, what
exactly is the field of industrial automation? How has it reshaped the face of modern manufacturing?
First, the core definition: from mechanization to the leap
of intelligence
Industrial automation, in short, refers to the use of control systems (such as PLC, DCS), information
technology and electromechanical equipment, so that the industrial production process can be in the
least human intervention in the automatic operation, measurement, inspection and control of the collection
of technologies. It is not just about freeing workers from repetitive, heavy or hazardous labor, it is also
about revolutionizing the paradigm of industrial production by improving accuracy, efficiency and
consistency of production.
The evolution of this field is clear: from the initial “rigid automation” driven by relays and pneumatic
pressure, to “flexible automation” realized by programmable controllers, to today's “smart automation”
incorporating the Internet of Things (IoT), big data and artificial intelligence. “Intelligent automation”.
Each advancement marks a leap in industrial productivity.
Second, the hierarchical structure of the system: an “industrial pyramid”.
To understand industrial automation, think of it as a pyramid structure:
1. Field equipment layer (tower base): This is the automation system's “senses” and “hands and feet”, in direct
contact with the production process. Including various types of sensors (such as temperature, pressure sensors),
actuators (such as motors, valves), switchgear and so on. They are responsible for collecting field data and
executing control instructions.
2. Control layer (tower): This is the “nerve center” of the system, the core is programmable logic controller
and distributed control system. They receive data from the field equipment, operate according to the preset
program logic, and then send control commands to the actuator to command the equipment to run. This
layer ensures the stability and continuity of the production process.
3. Monitoring Layer (Tower Neck): This layer provides a visualized monitoring window for the operator through
the data acquisition and monitoring system and the human-machine interface. Staff can check the production
status, adjust process parameters, handle alarms, and realize efficient interaction between human and the
production system.
4. Information Management System (Tip of the Tower): This is the top layer integrated with enterprise
management, which usually consists of the Manufacturing Execution System (MES) and the Enterprise
Resource Planning (ERP) system. It is responsible for integrating production data, production scheduling,
quality analysis, equipment management and resource optimization, and directly connecting the production
site with the enterprise's business decision-making to achieve truly intelligent management.
This four-layer structure together constitute a complete closed loop of information gathering from bottom
to top and instructions executing from top to bottom, making the whole factory an organic synergistic whole.
Third, the key technologies and core components
The field of industrial automation covers a series of key technologies and components:
Control technology: represented by PLC and DCS, is the “brain” of the automation system, responsible for
logic control and process control.
Transmission technology: including servo systems, variable frequency drives, etc., is responsible for the precise
control of the position, speed and torque of the motor, is the guarantee of precision manufacturing.
Robotics: Industrial robots have become the main force in automated production lines, engaged in welding,
painting, handling, assembly and other complex work.
Industrial communication networks: such as PROFIBUS, PROFINET, EtherCAT and other fieldbus technologies,
as a “neural network”, to ensure that the data in the device, controller and the system between high-speed,
reliable transmission.
Machine vision: Giving machines “eyes” for precise positioning, quality inspection and identification,
significantly improving the level of production intelligence and quality consistency.
Four, far-reaching impact and core value
The value of industrial automation is far more than “machine for man”, which brings profound changes
reflected in a number of dimensions:
Production efficiency and quality of the leap: automated systems can run 24 hours a day, the production of a
stable beat, almost completely eliminating human error, thus enhancing the output at the same time, greatly
ensuring the consistency of product quality.
Effective control of production costs: Although the initial investment is large, in the long run, automation
significantly reduces labor costs, reduces material and energy waste, improves equipment utilization, and thus
reduces the total cost per unit of product.
Improved safety and reliability: It frees employees from hot, dusty, toxic or hazardous environments, dramatically
reducing the risk of workplace injuries. At the same time, the system's own diagnostic and fault-tolerance capabilities
improve production reliability.
Data-driven Decision Optimization: The huge amount of data generated by the automation system provides the
possibility to analyze the status of the equipment, optimize the process parameters, and realize predictive maintenance,
which makes the management decision more scientific and precise.
Future Trends: Toward a Smarter Industry 4.0
At present, industrial automation and a new generation of information technology is the deep fusion, towards the
“Industry 4.0” and “intelligent manufacturing” as the symbol of the new stage. Cloud computing, big data, artificial
intelligence and digital twins and other technologies are being deeply applied, the future automation system will
be more predictive, adaptive and self-optimizing capabilities, to achieve large-scale personalized production.
Conclusion
The field of industrial automation is the cornerstone and soul of modern industry. It builds a modern production
system that is efficient, precise and reliable by deeply integrating control technology, mechanical engineering and
information technology. Understanding industrial automation is not only about understanding a range of
technologies and systems, but also about understanding the fundamental ways in which modern industrial civilization
continues to break through productivity boundaries and shape our future world through intelligent means. It is
no longer an optional, but a mandatory way for all system modeling companies to move into the future.