Into a modern production workshop, into the eye is not dense workers, but neatly organized
mechanical arm precision assembly, unmanned trucks in the production line between the independent
shuttle, the central control screen real-time jumping on the status of equipment and production
data. This efficient operation of the picture, is the depth of the application of industrial automation
technology is a vivid embodiment. It is not only a simple process of replacing manpower with
machines, but also a profound change in the mode of production, is to support the modern
manufacturing industry efficient, accurate and flexible operation of the intelligent core.
the cornerstone of technology: from a single point of control
to system integration
Industrial automation technology is not a single technology, but a fusion of control theory, computer
technology, electronic technology, mechanical engineering and other multidisciplinary integrated system.
Its development history has experienced an important leap from basic mechanization to digital intelligence.
Early automation relied on simple control loops composed of pneumatics, relays, etc. to realize fixed
repetitive actions. With the emergence of programmable logic controllers (PLC), the production line has
gained “soft” flexibility - by modifying the program can be adapted to different production tasks, laying
the foundation for modern automation. Today, automation technology has evolved into a complex
system of control, monitoring and optimization.
The typical architecture of such a system is divided into three layers:
Equipment layer: as “arms and legs” and “senses”, including sensors, actuators, motors, robots and other
field equipment, directly complete the detection, gripping, processing and other physical operations.
Control layer: as the “nerve center”, with PLC and industrial computer (IPC) as the core, responsible for
processing signals, executing logic control programs, and directing field equipment to work together.
Information layer: as the “brain”, through the monitoring system (SCADA), manufacturing execution system
(MES) and other platforms, to achieve the collection of production data, visualization, analysis and
decision-making support, to open up from the workshop to the management of the digital channel.
The three-layer structure is closely connected through industrial networks (e.g. PROFINET, EtherCAT, etc.),
forming a closed loop of perception, decision-making, and execution to ensure the coherence and efficiency
of the production process.
the composition of key technologies: enabling the pillars of intelligent
manufacturing
The maturity and integration of a number of key technologies jointly promote the continuous improvement
of automation level:
Control technology: PLC and Distributed Control System (DCS) are the core controllers of the automation system;
PLC is better at logic control of discrete processes (e.g., assembly line), while DCS is suitable for continuous process
control (e.g., chemical process), which together guarantee the stability and accuracy of the process.
Transmission and Execution Technology: Servo systems, stepping motors, variable frequency drives and other key
components transform control signals into precise mechanical movements, realizing high-precision control of
speed, position and torque, which is the foundation of high-end precision manufacturing.
Robotics technology: industrial robots have evolved from simple repetitive handling to collaborative work capabilities
with visual recognition and force feedback, capable of replacing or even surpassing manual labor in complex
scenarios such as welding, painting, and testing.
Industrial communication and network technology: fieldbus, industrial Ethernet and other technologies as a
“nervous system” to ensure that the control instructions and status data in thousands of nodes in real-time,
reliable transmission, OPC UA and other unified architecture to solve the “language” between different brands
of equipment. The unified architecture such as OPC UA solves the “language” interoperability problem among
different brands of equipment.
Human-computer interaction technology: touch screen, industrial flat panel and so on constitute an intuitive
operation interface, so that the staff can easily monitor the status of the equipment, set parameters, deal with
alarms, and realize the efficient collaboration between people and machines.
the application value: beyond the efficiency of the overall innovation
The application of industrial automation technology brings multi-dimensional profound value to the manufacturing industry:
Extreme efficiency and quality: automation system can run continuously for 7×24 hours, with stable production
beats, minimizing quality fluctuations caused by human factors, and significantly improving production efficiency
and product consistency.
Significant Cost Advantage: Against the backdrop of rising labor costs, the one-time investment in automation
equipment can bring considerable returns in terms of manpower savings, energy consumption reduction, and scrap
reduction through long-term operation.
Enhanced Safety and Reliability: Freeing employees from dangerous, boring, and high-intensity work environments
significantly reduces the risk of safety accidents. At the same time, the system's self-diagnostic and redundant design
enhances operational reliability.
Data-driven intelligent decision-making: The automation system is the source of factory data. Through in-depth
analysis of production data and equipment data, capacity optimization, predictive maintenance and even process
innovation can be achieved, providing support for refined management.
the future trend: towards a new stage of autonomous intelligence
Currently, industrial automation technology is accelerating its integration with artificial intelligence, Internet of
Things, digital twins and other new technologies to move towards a higher stage of intelligence.
Integration and Intelligence: Controllers are integrating edge computing capabilities, capable of local data analysis
and intelligent decision-making, with faster response. the introduction of AI algorithms makes tasks such as visual
inspection and process parameter optimization more accurate.
Flexible production: market demand is becoming increasingly personalized, requiring production lines to be able to
switch products quickly. Automation systems based on robots, AGVs and other flexible units are becoming the key
to supporting small-lot, multi-variety production.
Deep integration of IT and OT: The deep integration of cloud computing, big data platform and enterprise management
system (ERP) is breaking down the information silos, realizing the transparent management of the whole process from
order to delivery, and constructing a real “smart factory”.
Conclusion
Industrial automation technology has long surpassed the initial stage of “substituting manpower” and developed
into a key technology to enhance the core competitiveness of the national manufacturing industry. It builds an efficient,
flexible and reliable modern manufacturing system through the deep integration of physical production equipment
and digital information technology. For any manufacturing enterprise committed to improving quality, efficiency and
flexibility, an in-depth understanding and application of advanced industrial automation technology is no longer a
choice, but an inevitable path. It will continue to serve as the core driving force to lead the manufacturing industry
towards a smarter future.