Driven by automation technology, industry is developing towards digitalization, intelligence, networking, and comprehensive integration, with manufacturing plants constantly moving towards a higher degree of integration. Looking ahead, as the means of applying advanced automation technologies become increasingly sophisticated, we can foresee even more possibilities!
I. Intelligentization of Instruments and Meters
Currently, the weakest and most in need of development in my country's intelligent technology field are basic industries such as instruments, meters, and sensors. With the rapid development of science and technology and the continuous improvement of automation, my country's instrumentation industry will also undergo new changes and achieve new development. The high-tech nature of instrumentation products, especially their intelligentization, will become the mainstream of future instrumentation technology and industry development. Intelligent instruments based on intelligent control theory have made progress in the following aspects:
Expert Controller
An expert control system (ECS) is a typical knowledge-based control system. It is a program system with a wealth of specialized knowledge and experience. Using artificial intelligence and computer technology, it reasons and judges based on the knowledge and experience provided by one or more experts in a specific field, simulating the decision-making process of human experts to solve complex problems that would otherwise require human expertise.
Fuzzy controller
Fuzzy controllers (FC-Fuzzy Controller), also known as fuzzy logic controllers (FLC-Fuzzy Logic Controller), are widely used in industrial control because they can handle uncertainty, imprecision, and fuzzy information. They can effectively control processes for which mathematical models cannot be built and solve problems that cannot be solved by conventional control methods.
Neural network controller
The application of neural networks in industrial control systems enhances the system's information processing capabilities and improves its intelligence level. Neural network control, or neural control for short, refers to the use of neural networks to model complex nonlinear objects, act as controllers, perform optimization calculations, conduct reasoning, or diagnose faults.
It is worth noting that in the field of intelligent instrumentation, whether it is neural networks, fuzzy control, or chaotic control, although many articles have been published by Chinese scholars, there are not many rigorous, meticulous, and independently innovative works and achievements. Some high-end instruments still need to be imported from abroad.
II. Networking of Control Systems
The control systems of the 21st century will be systems combining networks and control. Research on Networked Control Systems (NCS) has become one of the cutting-edge topics in the field of automation. With communication networks embedded as a system component in control systems, industrial control technologies and methods have been greatly enriched, leading to significant changes in the architecture, control methods, and human-machine collaboration of automation systems and industrial control systems. At the same time, this has also brought about new problems, such as the coupling of control and communication, time delays, information scheduling methods, distributed control methods, and fault diagnosis. The emergence of these new problems necessitates continuous innovation in control methods and algorithms within a network environment. With the continuous development of computer technology, communication technology, and network technology, the structure of control systems has evolved from the initial CCS (Centralized Control System) to the second-generation DCS (Distributed Control System), and now to the popular FCS (Fieldbus Control System). In today's globalized economy, this networking of industrial control systems and its structural model enables enterprises to adapt to unprecedentedly fierce market competition, helps accelerate new product development, reduce production costs, and improve information services, thus possessing broad development prospects.
III. Industrial Wireless Communication
As wireless technology becomes increasingly prevalent, vendors are offering a range of hardware and software technologies to help add communication capabilities to products. These technologies support communication standards including Bluetooth, Wi-Fi, GPS (Global Positioning System), LTE (Long Term Evolution), and WiMAX (Global Microwave Access Interoperability). However, adding wireless connectivity can be extremely challenging when choosing chips and related software (assuming the chosen implementation functions correctly and meets relevant justification requirements). Even a viable design may fail to achieve market success without optimizing performance, power consumption, cost, and scalability. What's hottest today isn't necessarily the best communication standard or what customers need; therefore, the chosen hardware and software implementation should be designed to avoid requiring a complete overhaul for each new generation of products.
Because wireless technology is still in the research and development stage and constantly being improved, its functionality is ultimately limited. Moreover, in the field of automation technology, there is no universally accepted and proven reliable wireless technology standard for real-time control, which is particularly evident when work cycles are very short. Therefore, the current application of wireless technology is limited to data acquisition and monitoring (SCADA). However, with increased reliability, wireless technology will have a wider range of applications. Wireless communication will grow rapidly in the coming years, but it will not replace wired communication. The stability, reliability, and security of wired communication will not disappear; wireless will only replace wired solutions where wired implementation is inconvenient or costly. If wireless and wired communication are organically combined, leveraging their respective advantages, it will provide new solutions for increasing productivity. Using wired communication where it is suitable and wireless communication where it is suitable, since both wired and wireless communication support the TCP/IP protocol, these two communication methods can be organically combined to leverage their respective strengths and improve production efficiency.
IV. Internet of Things and Automation
Today, the Internet of Things (IoT) is arguably one of the most frequently mentioned terms in the media and closely associated with "intelligence." From the perspective of "management, control, and intelligence," IoT and industrial automation are essentially interconnected. Industrial automation includes data collection, transmission, and computation, while IoT focuses on comprehensive sensing, reliable transmission, and intelligent processing; the two are interrelated. IoT simply emphasizes wireless connectivity, massive data acquisition, and intelligent computing. IoT and automation technology are closely linked. The difference lies in the fact that "traditional automation networks are mostly implemented through wired networks, resulting in a narrow network connection range, while in sensor networks, wireless networks become the primary transmission path, with a much wider connection range." This inherent connection makes it natural for industrial automation manufacturers to seek opportunities in the development of IoT.
Applications of the Internet of Things (IoT) include: IoT technology in logistics, supply chain, and warehousing management systems; IoT technology in industrial product production, tracking, progress monitoring, and quality tracking; IoT technology in the monitoring, tracking, and anti-counterfeiting systems for valuable and hazardous goods; IoT technology in electronic credentials for large conferences, high-level meetings, and important events; electronic tickets for large-scale events, concerts, and scenic spots (e.g., the Shanghai World Expo); IoT technology in traffic toll collection and long-distance automatic identification and management of various types of vehicles; IoT technology in the automatic identification, recording, location, and querying of personnel within a region; IoT technology in the end-to-end traceability of the animal and food industry chains; IoT is used in various fields such as agriculture, disaster relief, and emergency rescue; and IoT technology in the management of valuable and important assets. The Internet of Things (IoT) encompasses various applications, including: the full-process application of IoT technology in branded apparel; the application of IoT technology in the book industry; the application of IoT technology in military firearms management, personnel management, vehicle management, material management, and security and confidentiality; the application of IoT technology in aviation and automotive industries; the application of IoT technology in the retail industry; the application of IoT technology in social security; the application of IoT technology in smart cities; and short-range communication technologies such as Zigbee chips, Zigbee communication modules, Zigbee networks, GPS, RTLS real-time positioning systems, Bluetooth technology, and UWB (Ultra-Wideband) technology and applications; EPC (Electronic Product Code) networks: EPC labeling, EPC middleware, EPC servers, EPC public service platforms, and EPC networks; sensor networks, mobile communication networks, global positioning networks, and related application networks; and business intelligence analysis software systems. The "Internet of Things" overturns the traditional thinking that physical infrastructure and IT infrastructure are completely separate, effectively connecting physical facilities such as roads and buildings with personal computers, mobile phones, home appliances, transportation facilities, and IT facilities, enabling comprehensive interconnection and interoperability in government management, manufacturing, social management, and people's personal lives.
V. Cloud Computing and Automation
Cloud computing is the development of distributed processing, parallel processing, and grid computing, or more precisely, the commercial realization of these computer science concepts. Its core is the storage and computation of massive amounts of data, with a particular emphasis on the application of virtualization technology. In short, cloud computing is a supercomputing model relying on the internet, connecting vast resources to provide users with various IT services.
For example, cloud computing will bring about a huge transformation in the automation software industry. The main aspects include:
(i) The architecture of automated systems will be more flexible, and distributed architectures will be extended to a wider range.
In modern large-scale industrial automation and information projects, systems are becoming increasingly large and complex, and existing network and system architectures are no longer able to adequately meet these challenges. The revolutionary concept of cloud computing has completely broken down the rigid architecture of automation systems. In cloud computing systems, automation and information systems do not simply run on a fixed computer, but rather on an entire network, including the Internet, allocating system resources and implementing various functions based on the entire network.
(ii) The analysis and processing of massive amounts of information will become a standard function of automation software.
In modern large-scale automation projects, the volume of automated and informational data is increasing dramatically, to the point that the term "massive" is not an exaggeration. Therefore, current automation software technologies, including database types, data storage models, and data retrieval methods, are all focused on the accurate and timely processing of these massive amounts of data. The processing of massive amounts of information has become one of the bottlenecks restricting the development of automation software. However, in the era of cloud computing, users can leverage the computing power of different hardware platforms and networks at different levels. They can easily utilize cloud services (SaaS), platforms (PaaS), and computing hardware and network resources (IaaS), fully integrating the computing power of public networks. This makes the analysis and processing of massive amounts of automated and informational information a reality, meeting the needs of large-scale application systems and enabling the control of complex automated and informational systems.
(iii) Completely change the engineering development model.
In the era of cloud computing, the development of engineering projects will no longer be limited to a single computer. The SaaS model allows users to develop directly using software on the servers of automated software vendors via the Internet. The development process takes place in a cloud computing network, and once the development is completed, an engineering project that can be run directly is generated.
(iv) Transform the service model of software vendors to reduce maintenance costs.
The cloud computing model will also reduce the service costs for software vendors. In the past, software vendors needed to provide technical support and maintenance for automated software running in various hardware and software environments. In the cloud computing era, they only need to maintain one set of software on their own server.
(v) Reduce the hardware requirements of automation systems and enhance the industry status of software.
Whether it's a private cloud based on an enterprise's internal network or a hybrid cloud with some connection to the external network, the goal is to dynamically allocate system computing power. This allows for smoother and more stable system operations, significantly reducing the enterprise's hardware requirements without compromising operational efficiency. It's well known that in current automation systems, software occupies a crucial position, yet its value is relatively low, accounting for only 5%-10%. In the era of cloud computing, system hardware requirements are decreasing, while software requirements are increasing. Therefore, the value and importance of software in the automation industry will greatly increase.
(vi) New technologies and new product concepts will become the core of competition.
Undoubtedly, cloud computing will bring about a massive transformation in the automation software industry. How to grasp the trends of IT development? How to develop next-generation automation software based on cloud computing? How to make older automation software versions compatible with cloud platforms? How to upgrade traditional automation engineering systems to cloud systems? These will become primary concerns for companies in the industry. It is believed that with the increasing maturity of cloud computing technology and the efforts of the automation community, the development of automation systems utilizing cloud computing in my country will advance rapidly. This is also an issue that the Chinese automation industry should pay attention to.
VI. Automation of Low-Carbon Economy
Automation in the low-carbon economy is a broad and important topic. We will use the process industry as an example. The process industry refers to the dominant sectors in my country's national economy, such as petrochemicals, oil refining, chemicals, metallurgy, pharmaceuticals, building materials, light industry, papermaking, mining, environmental protection, and power. The annual output value of my country's process industry enterprises accounts for 66% of the total annual output value of all industrial enterprises in China. The development of the process industry directly affects the country's economic foundation. The process industry is a very large industry, occupying an important position in the industrial sector. It is a crucial pillar industry for national economic development and an important component of the manufacturing industry. Its characteristics include primarily handling continuous or intermittent material and energy flows, with products mainly produced in large quantities.
The production and processing methods in process industries mainly include chemical reactions, separation, and mixing. In the 21st century, the era of the knowledge economy, process industries, as traditional industries, will remain an important pillar of economic development. Process industries are both producers and major consumers of energy and various raw materials, making energy conservation, emission reduction, and cost reduction crucial. These industries generally suffer from high energy consumption, severe pollution, poor product quality, outdated production processes, low levels of automation, low management levels, low information integration, and weak overall competitiveness. Industry is the largest sector of my country's economy and also the largest consumer of energy and resources, generating the most environmental pollution. Process industries have become the primary targets, especially in the six major sectors of petroleum processing, chemicals, steel, power, non-ferrous metals, and building materials, where energy consumption accounts for nearly 70% of the nation's industrial energy consumption. Vigorously promoting the development of a "low-carbon economy" will inevitably allow us to seize innovative opportunities in scientific research projects and market development! Currently, the world economy is accelerating its transformation towards a "low-carbon economy," which has spawned many new economic growth points and will be the key to future national and corporate competitiveness. Smart companies are adept at seizing opportunities, transforming production methods, and staying ahead of the curve, turning passivity into initiative. They leverage changes in social development concepts as a driving force for accelerated growth. They strive to gain a leading position in the "low-carbon economy." When considering their development strategies, companies should also consider how to formulate a "low-carbon strategy" and strive to grow in sync with the nation's sustainable development trends.
VII. Automation of Safe Production
Automation in safe production has become a frequently mentioned term in recent years. This is due to the increasing number of safety accidents and the growing demand for automation technology in safe production. How to efficiently utilize automation and information technology to improve the level of safe production has become a top priority. Therefore, the country has proposed the "Science and Technology for Safety" strategy. The development of safety is also inseparable from automation. Safety in manufacturing can be divided into mechanical safety and process safety. Mechanical safety primarily protects personnel and has received high attention. Safety switches, safety buttons, safety doors, and safety mats have become increasingly popular in factories, along with safety sensors, safety PLCs, safety buses, and safety Ethernet products. Process safety ensures the safety of the production process. Today, many automation suppliers are considering providing safety solutions. A true safety solution is not just about providing one or a few safety products, but more about improving the safety of user equipment. How to embed safety functions into user machinery and equipment to improve safety without affecting the production process still requires further development.
Automation refers to the process by which machines or devices operate or are controlled automatically according to prescribed procedures or instructions without human intervention. The adoption of automation technology not only liberates people from heavy physical labor, some mental labor, and harsh or dangerous working environments, but also expands human organ functions, greatly improves labor productivity, and enhances humanity's ability to understand and transform the world. Therefore, machines, equipment, systems, or processes (production and management processes) achieve expected goals through automatic detection, information processing, analysis, judgment, and control, according to human requirements, with little or no direct human involvement. Safety automation is a general term for using automation technology to implement the "science and technology for safety" strategy and achieve safe production. Specific applications of safety automation vary across different industries, such as: coal mine safety production automation, petrochemical safety production automation, chemical safety production automation, metallurgical safety production automation, transportation safety production automation, intelligent building safety production automation, and safety production automation in other industries, etc.
8. Energy Conservation, Consumption Reduction, and Automation
In recent years, "energy conservation and emission reduction" has become one of the most discussed terms in the development of automation technology in my country, and its significance is profound. "Energy conservation and emission reduction, and scientific development" has become the strategic guiding ideology for my country's economic development.
As a carrier and medium for technology transformation, the equipment manufacturing industry is a fundamental "means-based" industry. Its products are production equipment for various industries, forming the foundation of the foundation. Its characteristics include: wide scope, numerous categories, high technological content, and strong correlation with other industries. After years of development, my country's equipment manufacturing industry has formed a complete, large-scale industrial system with a certain level of technology, making it an important pillar industry of the national economy. Conserving energy and improving energy efficiency are not only long-term strategies for ensuring normal production and operation and achieving healthy and sustainable development for enterprises, but also inevitable choices for enterprises to adapt to market needs, reduce costs, increase efficiency, improve the environment, and enhance competitiveness. For enterprises to achieve long-term development, implementing energy conservation and emission reduction is imperative. For example, motor energy saving, process optimization, waste-to-resource conversion, waste heat utilization, enterprise transformation, and new energy utilization are all closely related to the adoption of automation technology.
IX. Development of Industrial Control Software
The development of industrial control software is also a crucial aspect of automation technology development. Since the 1990s, IBM has acquired a series of middleware vendors, making middleware the core of enterprise IT architecture and gradually highlighting the importance and central role of software. Subsequently, IBM acquired several well-known software companies, such as Lotus and DB2. Software began to advance in tandem with hardware. In 2004, IBM further sold its PC business to Lenovo, an event that signaled the end of the hardware era and the arrival of a software boom. In the field of industrial control, hardware-to-software integration is a development trend, exemplified by the emergence of embedded soft PLCs. Currently, the latest version of CoDeSys V3.4 software (an embedded system soft PLC based on the CoDeSys platform) is the leading software on the market from the German company 3S Software . It advocates an "open and reconfigurable automation" concept based on "reusability." This software uses the IEC61131 development environment and supports several languages of the automatic control industry standard, including ladder diagrams, flowcharts, block diagrams, and high-level ST languages.
Software reuse is a method and theory in computer software engineering, essentially a solution to avoid repetitive work in software development. It is an effective way to improve software development productivity and software product quality. Software reuse involves using existing software and its effective components to construct new software or systems, thereby reducing software development time and maintenance costs . Software reuse is an important technology for improving software productivity and quality. The key factors (technical and non-technical factors) for achieving software reuse mainly include: software component technology, software architecture, domain engineering, software re-engineering, open system processes, CASE (Computer-Aided Software Engineering) technology, and various non-technical factors. The benefits of software reuse are: (1) higher productivity (and the resulting cost reduction); (2) higher software quality (errors can be corrected more quickly); (3) proper use of software reuse can improve system maintainability.
10. Universalization of Simulation
Networked modeling and simulation technology is currently a research hotspot in the modeling and simulation field. The technical connotations and application models of networked modeling and simulation are constantly expanding and enriching with the development of network technology. The rapid development of network and computing technologies will lead us into the era of ubiquitous computing. Ubiquitous computing aims to establish an intelligent space by integrating an information space composed of computing and communication with the physical space of people's lives. In this intelligent space, people can transparently access computing and information services anytime, anywhere. Networked modeling and simulation technology will develop towards ubiquity. "Ubiquitous simulation technology," which integrates ubiquitous computing technology, realizes the combination of information space and physical space, and will propel modern modeling and simulation research, development, and application into a new era.
For the complex, heterogeneous, and dynamic ubiquitous computing environment of the future, ubiquitous simulation systems have the following basic characteristics:
(1) Ubiquitous and widespread: Simulation resources are everywhere. With the help of grid technology, simulation mesh has realized the service-oriented provision of various software and hardware simulation resources in people's lives, shielding users from complex and heterogeneous ubiquitous computing environments, making simulation resources ubiquitous and solving the problem of "widespread accessibility".
(2) Anytime, anywhere: People can access simulation services at their work or home locations without having to sit in front of a dedicated computer. Grid technology extends simulation applications to every corner of the network, completely freeing them from the constraints of time and space. People can access simulation resources and services in the grid environment using any networked device, fulfilling the need for "anytime, anywhere".
(3) Adaptive: The simulation information space can provide a consistent simulation service that adapts to changes in the computing environment in a way that suits the user.
(4) Transparency: Users do not need to spend much attention when accessing simulation services. The way simulation services are accessed is very natural and even imperceptible to the user, which is the so-called implied interaction.
Introducing ubiquitous computing concepts and technologies into simulation meshes can effectively meet the evolving demands of ubiquitous simulation environments for mobility, adaptability, intelligence, and application modes. This allows the simulation information space to provide adaptable simulation environments and coherent simulation services in a user-friendly manner. Ubiquitous simulation mesh technology, which integrates mesh technology and ubiquitous computing, will become a new focus of research and application in networked modeling and simulation.
In summary, the current top ten trends in automation technology development can be summarized by several key words: integration, communication, collaboration, energy saving, security, and standards and openness. This has also given rise to many new products and concepts. For many years, new automation has been the most direct force driving the rapid development of the manufacturing industry, and this force, inevitably fueled by the driving force of "innovation," will become even stronger in the context of "Intelligent Manufacturing in China"!
Driven by automation technology, industry is developing towards digitalization, intelligence, networking, and comprehensive integration, with manufacturing plants constantly moving towards a higher degree of integration. Looking ahead, as the means of applying advanced automation technologies become increasingly sophisticated, we can foresee even more possibilities!
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