What is Industrial Automation?
The world of industrial automation may sound complex, but it is simply how technology is used to enable the automatic operation of industrial processes and machinery in environments such as factories. It includes the use of robotics, machines and control systems to take on tasks that would have been performed by human operators, streamlining business operations and saving significant time and labour costs.
Here, we’ll take a look at how industrial automation works, discussing the benefits of automation for our industries. Making effective use of automation means increasing the efficiency of your operations and bringing your business into line with industry leaders who already benefit from this technology. If you are not sure what industrial automation can do for you, we’ll take a look at the latest developments in this exciting area and show you how it could transform your business.
How does Industrial Automation work?
Historically, industrial processes have been controlled manually by human operators. The introduction of industrial automation standardises these processes, controlling them through the use of computers and robotics so that they are carried out automatically. Automation has undergone rapid development in recent years as technology has advanced quickly.
Industrial automation uses a combination of software, which controls the processes, and hardware, which is automated by the software.
The process of industrial automation works as follows:
• Industrial automation systems rely on sensors, cameras and input devices, which detect changes in the environment and record data to protect or manage the workplace and complete the assigned tasks.
• The data collected by the sensors, cameras or input devices is transmitted to a controller, which is the hub of industrial automation, often seen as the ‘intelligent’ component. This is where the data is analysed and interpreted, and the necessary commands are then sent to the output devices that form part of the automation system. This controller, or ‘thinking’ part of the system, is commonly a PLC, or Programmable Logic Controller, or a DCS, or Distributed Control System.
• Once the data has been analysed and actioned by the controller, the part of the system known as an actuator or output device carries out the commands given by the controller. This might be a motor, a valve or a robotic arm, for instance, that carries out necessary operations.
• All industrial automation systems will have a Human-Machine Interface (an HMI) that will allow operators to monitor and interact with the system using a single compact unit, panel or dashboard that is programmable to handle the whole process.
As industrial automation systems become more advanced, the processes that have been automated become faster, safer and more efficient, so industrial automation improves the reliability, consistency and speed of your operations.
Why do we use Industrial Automation?
Industrial automation can save time and energy on the routine tasks that your business depends upon, taking care of the processes that can be managed by machine so that human energy can be re-directed more efficiently. For instance, processes such as portion weighing and packaging can be automated for convenience and standardisation, and printing processes can be automated to improve quality and avoid waste.
Taking into account wages, training costs and overheads, as well as the costs of maintaining working hours and conditions, employing people to carry out the processes that can be automated may be the largest outlay for your business. Labour costs are high, and automation is a great way to reduce them. Although training in managing the automated system is essential, this can streamline your workforce and optimise your budget.
Different Types of Industrial Automation
There are 4 types of Industrial Automation, and the type you choose will be determined by the type of products you produce and the level of variety your system is required to accommodate. The four different types of industrial automation are known as:
1. Fixed automation. If you need your machines permanently set up to carry out one specific task, a fixed automation system may be the best solution for you. This involves a single task being performed by your machine, which is then reset and repeated. This is common in production lines with conveyor belt systems, especially in the food industry.
2. Programmable automation. A programmable automation system is set up to enable a machine to be programmed with several different tasks, which can enable a factory to produce a more extensive range of products and is more complex to manage. This is useful when several product lines are made using the same machines or to cater for variety between batches.
3. Flexible automation. Many production lines use flexible automation systems, especially in factories or industries where the product lines vary. Flexible automation allows machines to perform a range of tasks and to vary the way these tasks are carried out, which means that production lines can be altered with ease.
4. Integrated automation. An integrated automation system is designed to allow all elements of the production process to be controlled from a single interface in one location that all machines are connected to. This type of system is used in industries where small quantities of products are made and where it is necessary to make quick, simple changes to the production line.
Finding the right industrial automation system for your business means working with the experts to identify exactly what you need and making it happen. There will be installation, implementation and training considerations to fully automate your business, so it is important that the systems you choose are the right options for your industry and your unique business profile.
Industrial Automation in Action
Leading businesses in many industries are optimising their performance and profits by making the move to industrial automation. For instance, in Greece, the olive industry has been transformed by the introduction of a fully automated weighing system that streamlines the essential process of weighing olives. The system includes Horner X2 PLC Controllers, which ensure precision weighing, material monitoring and automatic bin detection.
The efficiency that can be achieved with industrial automation in an industry such as this is impressive, reducing labour costs significantly and eliminating human error in the filling and tracking of bins. Businesses using these systems report excellent results in terms of efficiency and reliability, effectively streamlining their operations. These systems incorporate a compact controller that can also provide essential feedback so that managers can further improve processes and ensure accuracy and flexibility going forward.
Identifying the best options for your industry and the type of business you manage will enable you to make significant improvements to your practice and your outcomes.
Industry Leaders at Horner Automation
At Horner Automation, we are the industry-leading provider of all-in-one controllers, and we can help you find the most effective solutions for your business. We offer all-in-one control solutions for OEMs, integrators, and end-users. We will take the time to understand your requirements and deliver the high-quality automation you need. With Horner Automation, your business is in safe hands.
