Technology today is advancing by leaps and bounds to make people’s lives more convenient, and industry is no exception. Factories are adopting automation systems to support and improve the efficiency of their processes.
If you want to bring automation into your factory, you should first understand what an automation system is, how it can support factory processes, and which types of products in the automation control systems business group suit your needs, so your factory can get the most effective results from automation.
Table of Contents
- What Is an Automation Control System?
- Types of Automation Control Systems
- Benefits of Automation Control Systems
- Disadvantages of Automation Control Systems
- Examples of Automation Control Products Available Today
- Frequently Asked Questions About Automation Control Systems
- Summary: Automation Control Systems
What Is an Automation Control System?
An automation system uses technology from electronic devices or software to control the operation of machinery or equipment in a factory, so processes can continue automatically according to commands entered by people.
The purpose of automation is to reduce the amount of labor and time each process requires. Some production steps are dangerous for people, require very high precision, or are highly repetitive. Applying automation in factories helps these processes run more smoothly and quickly.
For these reasons, automation control systems are used in many industries, such as power generation, steel smelting, assembly work, highly detailed and complex work, and computer systems or electronic equipment.
Types of Automation Control Systems
- Hard Automation
Hard automation, also known as fixed automation, is used for highly specific production tasks. It can produce large volumes of products safely, accurately, and quickly, while greatly reducing production costs. Its limitation is that it can produce only one type of product.
- Programmable Automation
Programmable automation is a system in which a set of program instructions is entered to be read, interpreted, and executed for production. This type of system can be reconfigured to produce other products, but doing so takes time and is complex. It is therefore suited to batch production, which is non-continuous and low-volume.
- Process Automation
Process automation is a system for keeping business operations aligned, using applications or software to improve efficiency within the organization. It can also provide in-depth insights and recommend appropriate solutions to problems that arise.
- AI Automation
AI automation applies artificial intelligence that can learn to perform repetitive tasks with clearly defined rules. The system analyzes the data it receives and makes decisions according to those rules.
Benefits of Automation Control Systems
Industrial control systems are becoming increasingly widespread. Automation systems benefit factories in the following ways:
- Increased production capacity
Automation helps machines maintain a consistent production speed, allowing factories to run production for longer, which increases the volume of products that can be made each time.
- Higher product quality
Automation greatly improves the quality of the products made, because automation systems are highly accurate and can handle production work with a level of detail beyond human capability. This reduces the chance of defects (NG) in products.
- Greater production safety
Some production steps involve equipment or materials that are dangerous to the human body, such as heat from furnaces or hazardous chemicals. Implementing automation in a factory reduces the chance of accidents and the harm the body may suffer from chemicals. It also helps control various industrial measuring instruments so they operate correctly, accurately, and safely.
- Reduced costs
Implementing automation requires a large initial investment, but in the long term, automation significantly reduces labor costs for repetitive processes. It also reduces costs arising from workplace accidents.
Disadvantages of Automation Control Systems
Although automation is highly beneficial for industrial plants, it still has some disadvantages:
- High investment
When developing an automation system, a factory needs a large budget, as the initial stage involves costs such as research and improving and developing the system until it is stable. After the system has been in use for a while, maintenance costs are added as well.
- System failures
Today’s automation systems operate over internet connections. If the internet is unstable or drops out, the system may fail, halting processes and affecting operations.
- Limited flexibility
Although some automation systems are flexible, they are still less flexible than human workers, whether in terms of the time each process takes or certain workpiece positions that require skilled workers to avoid damage. Some processes therefore still need human labor to keep production running smoothly.
Examples of Automation Control Products Available Today
Graphic Terminals (HMI)
Graphic terminals, or HMIs, are devices that display data from interactions between people and machines, computers, or automation systems. They receive commands from input devices such as keyboards, mice, or touchscreens, and can display both current and historical data. These devices are commonly used in industries such as energy, food, beverages, transportation, and many more.
One such product is the PanelView 800 Graphic Terminals , a 4–10 inch panel-mounted display that accepts input from keypads or touchscreens for local and remote control via Virtual Network Computing. With a powerful processor and large memory, it is ideal for use with small PLCs such as the Micro800.
Programmable Logic Controllers (PLC)
A Programmable Logic Controller, or PLC, is a device for controlling the operation of machinery and processes in a factory. Its brain (microprocessor) directs the connected inputs and outputs, for example by receiving signals (input) from sensors or switches and sending signals (output) to control equipment and machinery.
PLCs are often used together with HMIs: the PLC acts as the controller, while the HMI handles communication between people and the display. They are commonly used in industries that rely on automation, such as packaging, agriculture, plastics, wastewater treatment, and more.
There are two types of PLCs:
- Compact PLCs are small and suitable for installation in limited spaces or for small applications.
- Modular PLCs allow the system to be reconfigured and inputs and outputs to be expanded easily.
For those looking to use PLCs in their factory, one example we recommend is the MicroLogix 1400 Programmable Logic Controller Systems, a PLC that connects via EtherNet/IP and has an LED backlit display for checking I/O and controller status. It supports expansion of up to 7 modules, making it ideal for small-scale control applications.
Software for Data Collection and Analysis
Software is a program or set of instructions written to make a computer carry out the commands entered. Software for data collection and analysis is used to store and analyze raw data so it can be put to effective practical use.
There are many data collection and analysis software products used with automation systems today. One we recommend is FactoryTalk Historian Site Edition (SE) , software that quickly collects large volumes of time-series data, so important data can be stored at all times. It also converts raw data into an easy-to-understand form.
Power Supply
A power supply is a device that supplies electrical current to the components of a computer so they can operate. It converts alternating current into direct current before sending it to the computer. Because the power supply affects the computer’s overall performance, it is considered one of the most important components.
A power supply is an essential device for anyone implementing automation in a factory. One device that can be used with other equipment in the factory is the Essential Switched Mode Power Supplies, compact power converters that convert high-voltage alternating current to low voltage with high efficiency and good heat dissipation.
In addition to the automation control equipment above, there are many other devices that can be applied in industrial plants. If you’re interested in high-quality equipment for factory automation, you can find more information here:
Click here: Automation Systems Product Catalog
Frequently Asked Questions About Automation Control Systems
What Is an ICS and How Does It Support Automation?
An ICS (Industrial Control System) is an automated system that gathers useful data to control processes within a factory, covering both systems and machinery, in order to improve production efficiency, for example by saving the energy and resources used in production, reducing costs, and reducing errors in the production process.
What Is RPA Automation?
RPA (Robotic Process Automation) is a type of automation in which people design software robots that mimic human behavior. Decision-making steps are built in so the robots can perform repetitive tasks efficiently, while also reducing the chance of human error.
Summary: Automation Control Systems
An automation control system automatically controls the operation of machinery in a factory using programmed commands, making each step of the process efficient.
Applying factory automation in industrial plants brings many business benefits, such as reducing factory costs, lowering the risk of worker accidents, improving production efficiency, and increasing production capacity and volume, so every step of production runs smoothly.
However, implementing automation in a factory requires proper system design and high-quality equipment, as these affect the factory’s overall operation. If you’re looking for equipment to use with automation systems, contact or order from PICO, a supplier of high-quality, high-performance automation equipment, using the details below:
Petro-Instruments Co., Ltd. (Head Office)
Address: 7/409 Soi Vibhavadi Rangsit 36, Vibhavadi Rangsit Road, Chatuchak Subdistrict, Chatuchak District, Bangkok 10900, Thailand
Business Hours: Monday–Friday, 8:30 AM–5:30 PM (closed weekends and public holidays)
Tel: (+66)2-939-5711 (12 lines), (+66)2-513-2333 (12 lines)
Email: marketing@pico.co.th
Facebook: https://www.facebook.com/Petro.Instruments/
Reference
Industrial Quick Search. Automation System: What Is It? How Is It Used? Advantages.
https://www.iqsdirectory.com/articles/automation-equipment/automation-system.html#:~:text=An%20automation%20system%20is%20an,%2C%20electrical%2C%20and%20electronic%20systems.
Mikell P. Groover. (1999). Automation | Technology, Types, Rise, History, & Examples | Britannica.
https://www.britannica.com/technology/automation