The structure of industrial automation describes operations at all levels. These include the sensor level, the automatic control level (unit, cell, process control), the supervisory level, and the enterprise level. The pyramid structure shows that, with your guidance, information is broken down as it is aggregated. This means we will find detailed information about specific variables at the bottom. Industrial automation does not mean that all levels are automated in the same way as enterprise automation.
The sensor layer, also known as the processing layer, uses sensors and actuators to continuously or periodically acquire values of process variables. These are the eyes and arms of the industrial process. Some instruments include pneumatic instruments, smart instruments, etc.
The PC//control layer is used for automatic control or general control. PLC industrial control equipment, such as DCS, utilizes various embedded processors and PID algorithms to control the process.
The monitoring or SCADA level system acquires a large amount of channel information and stores the data in a system database. It retrieves data from various control devices and displays it on the HMI (Human Machine Interface). It also sends alarms to indicate the severity levels of process and control variables. To interact with field devices, it uses dedicated software to acquire data and establish communication protocols.
Company-level execution plans, orders and sales, product plans, etc.
Industrial Automation Types
Based on the flexibility and integration of the manufacturing process, automated systems are classified into four basic types. These are described below:
Fixed Automation
This sequence of operations is fixed through equipment configuration. It is used for mass production and specialized equipment. Examples of automated systems are automated assembly lines, distillation processes, and mechanical conveyor lines.
Programmable Automation
Here, the operation sequence can be changed by modifying the program. The operation sequence varies depending on the product configuration. New programs can also be input into the programmable equipment of new products. This system is used for mass production, rolling mills, industrial robots, etc.
Flexible automation
This is an extension of programmable automation. It provides greater flexibility in handling product design differences. If you want to change the sequence of processes, the operator can issue commands in the form of code within the computer program. Lower-level equipment receives these field operation instructions without losing production time. This type of automation is used in the manufacture of multi-functional CNC machine tools, automated guided vehicles, etc.
Integrated Automation
In this type, the entire system is fully automated under computer control. The entire system is fully automated, from the design process to scheduling. Even if the equipment is operated by robots, this is still possible. This system is used in computer-integrated manufacturing systems.
Sensors and actuators
Sensors detect various process variables and convert them into electrical or optical signals. This type of sensor includes actuators for temperature, pressure, speed, and flow, converting electrical signals into mechanical signals for process control. Some sensors and actuators, such as relays, magnets, and servo motors, have the ability to communicate with industrial field communication buses in smart devices.
Sensors detect various process variables and convert them into electrical or optical signals. This type of sensor includes actuators for temperature, pressure, speed, and flow, converting electrical signals into mechanical signals for process control. Some sensors and actuators, such as relays, magnets, and servo motors, have the ability to communicate with industrial field communication buses in smart devices.
Industrial Computer
A Programmable Logic Controller (PLC), also known as an industrial computer, can be programmed to perform control functions. It consists of a CPU or processor, I/O modules (including analog and digital) for connecting various input/output devices, and relay modules. These modules can be fixed modules or integrated modules based on available input expansion modules.
Like PLCs, traditional PCs can control processes online or by changing programs. PLCs have dedicated software to develop control strategies.
Human-computer interface
Human-machine interfaces (HMIs) provide information on computer screens and other monitors, record results in databases, and issue alarm signals. They employ vision-based technologies such as SCADA (Supervisory and Data Acquisition).
Communication system
In industry, many sensors, actuators, control PCs, and other control devices are geographically distributed and interact through multiple data buses. There are three types of buses in industrial automation: factory bus, process bus, and fieldbus.
