W H AT I S I N D U S T R I A L

A U T O M AT I O N ?
Industrial Automation, Automation

What is Industrial Automation?

INDUSTRIAL AUTOMATION
Industrial automation is the use of robotics, machines and control systems to perform tasks that were traditionally
carried out by human workers. Automation can improve productivity, quality and safety in manufacturing and
other industrial applications.

Automation technology includes a wide range of tools and technologies, such as robots, numerical control (NC)
machine tools, programmable logic controllers (PLCs), computer numerical control (CNC) systems and
industrial sensors. Automation systems can be integrated into existing production lines or stand-alone and can be
used to collect data for preventative maintenance of the equipment.
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Industrial automation offers a number of benefits over traditional manual labor. Automated facilities can work
faster and more accurately than human workers, and they can operate around the clock without tiring and can
collect data for monitoring the health status of the equipment and reduce waste. Automation can also help to
improve safety in hazardous environments.

In recent years, industrial automation has been adopted by a number of industries, including automotive
manufacturing, food and beverage processing, pharmaceuticals and electronics assembly. The trend is expected
to continue as companies look for ways to improve efficiency and competitiveness.

Industrial automation can make production lines safe and uses logic-based programs to operate machinery and
other industrial equipment technologies. The machine makes decisions without any human input based on its
programming to unlock the efficiency of your work.

Though this may seem complicated at first glance, let us look at what Industrial Automation is through the lens
of a small example.

WHAT ARE INDUSTRIAL AUTOMATION & TYPES OF

INDUSTRIAL AUTOMATION SOLUTIONS!
In modern factories and warehouses, the industry has always been automated. Industry automated systems
employ controls such as computers, software, and robotic devices to perform traditionally manual work.

This advanced technology automatically manages industrial building equipment, significantly reducing operator
participation. Automation systems generally comprise feedback loops and sensor software that can manually
change operations to reach an optimal value if real-time data trigger them.

An industrial production process usually starts with raw materials from one machine, then gets processed by the
next in a sequence of many.

Today, industrial automation is involved in the production line of many industries. Any given machine can be an
electromechanical device such as motors or drills. Still, they can also be chemical machines like ovens and dryers
- whatever it takes to produce the desired final product. However, thinking about an industry without a control
system can be challenging.
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WHAT IS INDUSTRIAL AUTOMATION, THEIR TYPES, AND

WHAT HIERARCHY OF AN INDUSTRIAL AUTOMATION
SYSTEM?
The rapidly increasing competition in the industry requires quality products at a competitive price. Currently, the
most influential way to solve this issue is industrial automation.

Industrial automation improves product quality and reduces production and design costs by integrating
innovative technologies with services. Various sectors are considering different products to address their
challenges with automated devices.

WHAT IS AN EXAMPLE OF INDUSTRIAL AUTOMATION?

Advanced robotics can make crucial decisions in manufacturing operations. Robotic and CNC machines are
excellent examples of today's modern automation equipment. Automated devices can control events in a variety
of ways and increase efficiency by monitoring data which leads the production line to reduce waste.

Consider this example where a human hand would take control of what had to be done manually. Let us say we
have an oven that needs a certain amount of heat but cannot go over it. Someone has been tasked with reaching
the right temperature and then maintaining it for 30 minutes.

To ensure they do not miss anything, they check on the oven periodically while monitoring how much fuel is
needed to go into the oven at any given time - all through trial and error. With industrial automation, though,
everything takes care of itself.

Engines use valves to control systems for fuel supply to different engine parts. A computer also controls this
valve so that it will open if a certain temperature threshold is met. As time passes and the optimum temperature
has been reached, it closes again so that no excess gas is being fed into the engine, which would generate too
much heat - this could damage other parts such as cylinders or pistons.
When 30 minutes have elapsed (indicated by an alarm from the computer), another set of commands takes over
automatically until all tasks have been completed successfully; at this point, there is no need for human
intervention whatsoever!

INCREASE QUALITY AND FLEXIBILITY IN YOUR

MANUFACTURING PROCESS
In the past, automated systems were intended to enhance productivity and save costs associated with manual
operations. Nevertheless, automation is moving away from increasing quality and flexibility in manufacturing.
The piston fittings for cars were manually installed in the engine with a rate of 1-1.5% in some cases. Automated
machines carry out this task, averaging around 0.000-11% errors per hour.

MOTIVATION FOR INDUSTRIAL AUTOMATION!

The term 'Automation' was first coined by an engineer from Ford Motor Company, who pioneered industrial
automation and manufacturing assembly lines. At the start of the Industrial Revolution, production was reliant on
the human hand. Yet now, it relies solely on automated machines programmed to complete specific tasks without
error when given instructions.

This type of automation is geared toward optimizing efficiency; for instance, if one device needs certain
materials to finish its job and another machine requires a different material - instead of relying on what is being
delivered at that moment which might cause setbacks due to miscommunications.

Each will send out requests for what they need through signals known as triggers so other sources can deliver
them efficiently. With the start of the Industrial Revolution, industry and business strategy changes began to take
effect.

The goals of Industrial Automation are:

 Increase productivity
 Reduce costs solutions (especially for human-based labor)
 Improve quality
 Use resources efficiently
 Generate greater profit

WHAT ARE THE 4 TYPES OF AUTOMATION?

Several automations has been identified in manufacturing, including (1) Fixed automation, (2) Programmed
automation, (3) flexible automation, and (4) Integrated automation.

1. FIXED AUTOMATED SYSTEM!

Now that we have seen a little about the basic layout of an industrial automation system let us continue
exploring how Fixed Automation Systems work. Unlike Variable Automation Systems, which allow for
manual modifications, Fixed Automations Systems operate at the same rate all day long with no change
from one shift to another. These systems are typically found in manufacturing or food service industries,
where high-volume production is key to success and productivity.
2. PROGRAMMABLE AUTOMATION SYSTEM!
In a Programmable Automation System, the sequence of operations, as well as the configuration of the
machinery, can be changed using electronic controls. This system typically takes significant time and effort
to reprogram the machines and is most often used in batch process production to improve productivity.
3. FLEXIBLE AUTOMATION SOLUTIONS!
 A Flexible Automation System is usually always controlled by computers and is often implemented where
the product varies frequently. Based on the code given by an operator to a computer, it acquires the
necessary tools or equipment needed to produce different effects- just like how there could be countless
versions of one car model depending on its year or trim level. CNC machines are one of the best examples
of this system.
4. INTEGRATED AUTOMATION SYSTEM!
An Integrated Automation System is a set of independent equipment, processes, and data, all working
synchronously under the command of control systems to implement an automation system for production. In
other words, it is when you use CAD software or computer-controlled equipment such as robots or
computers to do your work instead of relying on people.

INDUSTRIAL AUTOMATION PROCESS!

There are many different ways to depict what an Industrial Automation Process entails. Still, this simple
hierarchy of three-stage representation of a typical Industrial Automation Application is the easiest way.

1. SUPERVISOR LEVEL
At the pinnacle of all hierarchies, supervisors are responsible for overseeing processes until they run
smoothly. This position typically entails having multiple Industrial PCs, often available as Desktop Panel or
Rack-mounted Computers.
These computers run on standard Operating Systems with a particular software package from the
supplier that provides them with industrial process control capabilities. The primary purpose is
process visualization and parameterization. A unique industrial Ethernet is used for communication,
which can be gigabit LAN or any wieless topology (WLAN).
2. CONTROL LEVEL!
A Programmable Logic Controller is a device that executes automation-related processes. PLCs are usually
microprocessor-based and often use 16-bit or 32-bit microprocessors; they manage these processes because
they provide real-time computing capability. A PLC can interface with multiple input/output equipment -
such as sensors, lights, and motors - and communicates with other systems through different types of
wireless communications protocols - like CAN.
3. FIELD LEVEL!
Various devices in the field (such as sensors and actuators) are field-level equipment in the manufacturing
process. Sensors like temperature, optical, pressure, etc., and actuators like motors, valves, switches, etc.,
are interfaced to a PLC through a field bus. Point-to-point connections allow for communication between
these devices and their corresponding PLCs. Wired or wireless networks may be used here depending on
factors such as cost and mobility, enabling diagnostics of the various components connected throughout the
installation of machines.

MORE ABOUT INDUSTRIAL AUTOMATION SOLUTIONS !

In addition, an industrial automation solutions system also requires two significant systems. These are

 Industrial Power Supply

 Security and Protection

Power requirements of different systems at different levels of the hierarchy can be significantly different - for
example, PLCs usually run on 24V DC. In contrast, heavy motors are either powered by one of three phases of
AC. Therefore, various proper input power supplies are needed to function without any trouble.
ADVANTAGES OF INDUSTRIAL AUTOMATION
Let's have a look at the advantages of industrial automation:

 Reduced operating costs: Industrial automation reduces healthcare and employee pay time. Industrial
automation is also not dependent upon other workers' benefits like pension protections, bonus programs, etc.
 Even if this initial expense is highly significant, it saves wages and thus leads to substantial savings for the
company.
 Maintenance costs associated with machines for industrial automation are lower because they rarely fail.
 When this fails, only technicians and computer technicians must do it.
 Human operators doing tedious jobs can be replaced with automated equipment.
 This eliminates the need for human operators to do tasks in hazardous environments involving extreme
temperatures, pollution, intoxicating elements, or radioactive substances.
 Tasks typically challenging for a person may seem easy to control system.
 These include lifting heavy and large loads, working with highly tiny objects, etc.
 Production goes much faster and less costly when the operator is automated.
 Automation also provides quality control checks for consistency and uniformity.
 The economy will improve significantly, positively impacting the standard of living across society.

NOW, LET'S HAVE A LOOK AT THE DISADVANTAGES:

 Jobs are being lost due to the increasing popularity of machines and automation.
 With most tasks involving manual labor, it is not easy to automate everything with today's technology.
 Some things cannot be automated—for example, goods with irregular shapes or varying dimensions.
 Machines may only work well for large-scale production runs, repetitive processes, or items where
consistency is key.
 Automation systems require lots of time and money up front; they also need people skilled in service and
maintenance.
 What is the use of industrial automation?
 Industrial Automation Technology provides companies with enhanced security and a reduced cost while
increasing product development quality. Having these advantages helps companies increase profits and
productivity.

WHAT IS THE USE OF INDUSTRIAL AUTOMATION?

Industrial Automation Technology provides companies with enhanced security and a reduced cost while
increasing product development quality. Having these advantages helps companies increase profits and
productivity in the production line.

WHAT CAN WE BUILD FOR YOU?

Regardless of your industry or industrial automation needs, IndustLabs has the experience and manufacturing
facilities to design and build your automation equipment. We have an experienced engineering and quality
control team dedicated to providing the best solution to your automation needs..

Our manufacturing facility in Dallas, TX is staffed with experienced engineer technicians, ensuring your
automation equipment meets safety and performance criteria. At IndustLabs, we feature a variety of automation
solutions. If you have questions regarding any of our products, their function or applicability to your project, give
us a call, +1(877)945-2272 or contact us for information without obligation.
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