Industrial Automation: A Complete Guide — Optimize Your Production Process

IndustLabs prepares your company for the future

Industrial automation plays an essential part in modernizing your industrial capability. Modernizing your automation equipment can improve product quality, reduce errors and improve efficiency. The following steps will help your business stay competitive in a world where more services are undergoing a transition into Industry 4.0. IndustLabs can assist you with upgrading your facilities.

Industrial automation processes can handle manual tasks, control the tools handling distinct steps, and more. Upgrading your facility with programmable automation will reduce costs and give you better insight into your company's expenses, manufacturing processes, and production rates.

Industrial Automation — All You Need to Know

Industrial automation is more than just robotics—it's a comprehensive system upgrade that gives your equipment the ability to handle tasks by itself. Your facility itself becomes smarter so your company can benefit from greater control, lower operating costs, improved quality, increase efficiency, and faster production times. Instead of adopting one smarter process or an isolated improvement, integrating flexible automation tools and sensors into your whole operations can result in exponential improvements. 

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WHAT IS INDUSTRIAL AUTOMATION?

Industrial automation is the use of control technology to eliminate or reduce manual labor in a manufacturing or process. For example, if you are a food manufacturing company you might want to automate the packaging of your product without the need of human operations. In addition, Industrial automation streamlines industrial systems by integrating computers and smart tools into multiple operations. Using smart technologies and automatic control devices, computers control production or manufacturing processes with minimal human intervention beyond initial programming.

Integrated technologies can perform mechanized tasks that were previously manual or had to be controlled by an operator. Industrial automation improves overall performance by increasing standardization, speed, and adherence to design specifications. It also reduces daily operating costs and the risk of human error. 

Industrial automation includes the use of devices such as programmable automation controllers (PACs), PCs, and programmable logic controllers (PLCs).

What are the types of industrial automation?

Industrial automation is the use of control systems, such as computers or robots, and information technologies to assist in the production and servicing of products. Typically this involves using sensors and software to coordinate efficient operations within a manufacturing environment at minimal cost to the manufacturer. Such automation ensures consistency and quality within an assembly line, as well as improved productivity.

What are the 4 types of automation?

Direct automation, Programmable Logic Controller (PLC) automation, Process control system, Human Machine Interface (HMI).

What is Direct Automation?

Direct automation requires no intermediary device to send its instructions—one motor may open or close a series of valves using an electric signal generated by its armature. The other types of automation have a need to communicate their instructions from one device to another.

What is PLC?

A Programmable Logic Controller (a programmable controller) is an industrial digital computer, distributed control system (DCS), or embedded controller that is used for automating electromechanical processes.

Allen-Bradley Programmable Controller

It is a type of industrial computer that provides automation of the control production system.

What is PLC Automation?

PLCs are programmed for specific tasks through a user interface that may either be a human-machine interface or several types of interfacing protocols such as Ethernet, Profibus, and Foundation Fieldbus H1/HSE. PLCs have a large range of applicability to different industries. PLCs are programmed to send logical programming commands to your machinery or factory line.

What is Process Control System?

A process control system (PCS) is an example of "closed-loop" automation. The PCS's code monitors the results from its sensors and sends signals to its actuators as needed, such that any change in its inputs will result in a corresponding change in its outputs. The process is maintained at the desired set point. PCSs are typically found online, meaning that they continuously monitor their respective processes and make incremental adjustments to the process control variables as required.

What is Human-Machine Interface?

In an industrial implementation, human-machine interfaces (HMIs) are typically programmable logic controllers (PLC) devices. HMIs are sometimes referred to as "supervisory control and data acquisition" systems, although many HMI devices no longer collect or process data through an acquisition subsystem.

Human Operator Interface (HMI)

What are the difference between PLC, PCS, and HMIs Interface?

A programmable logical controller (PLC) is a digital computer used for the automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures. A PLC is an example of a hard real-time system since output results must be produced in response to input conditions within a limited time and with no missing data.

A process control system (PCS) is an example of "closed-loop" automation. The PCS's code monitors the results from its sensors and sends signals to its actuators as needed, such that any change in its inputs will result in a corresponding change in its outputs.

An HMI is an interface between a human (the operator) and an industrial process, machine tool, or other application. HMIs are employed in most modern production facilities as well as in office environments. The term HMI is often used interchangeably with Human-Computer Interface (HCI) since it is the preferred control method for computer-based equipment such as process control systems and office automation equipment. HMIs are typically based on a personal computer running an industry-specific software package, although increasing integration of PLCs into the system is giving rise to hard real-time HMI functionality.

What are the different types of automation tools available in the industry?

There are several automation tools used in a variety of industries today.

For Manufacturing: PLCs, PCS, robots, programmable automation controllers (PAC), human-machine interface - HMI.

For Process Automation: Cloud-based technology, SCADA system.

For Oil and Gas: Field instruments, DCS systems.

What is automation in the industry?

With increased pressure to cut costs and improve productivity, automation in industry is becoming more widespread. Advances in technology mean that a manufacturing process can now be monitored and controlled remotely – making it easier for manufacturers and oil and gas companies to reduce manual labor and improve safety.

What are process control and automation?

Automation is a method or system in which the operation and control of equipment are made automatically using mechanical, electronic, computer systems. The term has become widespread in industrial applications as well as in commercial operations such as transportation and distribution.

How is automation used in the industry?

Today, we benefit from automation systems in several ways: increased safety, convenience, and productivity. Some of the most common examples include:

o  Industrial manufacturing: an automated production line can reduce errors, provide consistent quality products and meet customer demands for speedier delivery.

o  Oil and gas: remote monitoring systems allow operators to closely monitor data at oil rigs and production plants around the world. This enables them to avoid dangerous situations such as fire or chemical leaks. Automation also allows increased accuracy in gauging well levels and reduced time in identifying potential harvesting opportunities.

o  Robotics: robots can perform an array of manual tasks that would otherwise be extremely dangerous to humans, such as handling hazardous materials or inspecting equipment within a radioactive environment.

o  Supply chain management: data-linked backpacks enable employees to collect information on the move, such as measurements and product readings. Combine this with real-time updates of inventory lists and you have a powerful means for improving efficiency and reducing the risk of stock shortages.

What is process control in the industry?

Process control is the use of automation to maintain material properties, such as temperature or pressure. There are various types of process control – including feedback and feedforward – all of which provide different functions:

Positive Feedback: Positive feedback exists when a system's output influences input. For example: if a thermostat detects that the temperature in your room is a few degrees too high, the system will switch on your heater to reduce the temperature. The lower temperature then results in higher output from the thermostat – which turns on your heater even more. In this way, the excess warmth feeds back as input and triggers an increase in output.

Negative Feedback: Negative feedback exists when a system's output counteracts its input. For example, your heating system uses a thermostat to determine the temperature of a room and switches on or off depending on whether it is too hot or too cold. If, however, the heat isn't needed then the thermostat will detect that the temperature is just right – and switch off your heater. In this way, the system's output cancels out its input – preventing it from changing the temperature any further.

Feedforward: Feedforward is a control system in which a feed-forward controller calculates the required future action before receiving feedback from the controlled system. Feedforward controllers aim to predict how a system will respond and preemptively adjust the system to achieve the desired output.

Why is automation good for the industry?

Industrial processes are often dangerous and difficult to monitor, particularly if it requires traveling long distances or entering hazardous environments. Due to this, companies are increasingly turning to automated solutions to improve safety, efficiency, and productivity.

How important automatic control systems are in industrial processes?

There are many benefits to automated control systems in the industry, including the following:

o  Increased safety: Remote monitoring allows companies to closely monitor data at oil rigs and production plants. This enables operators to avoid dangerous situations such as fire or chemical leaks, which can lead to serious injuries. Automation also reduces accidents that would otherwise be the result of manually handling hazardous materials or inspecting equipment within a radioactive environment.

o  Reduced risk of stock shortages: Data-linked backpacks enable employees to collect information on the move, such as measurements and product readings, which are then automatically uploaded into inventory lists. This improves efficiency by minimizing the time needed for manual updates that can lead to stock shortages.

o  Easier process control: By monitoring their various production processes, companies can maintain material properties such as temperature or pressure by using processes such as positive feedback, negative feedback, or feedforward. Process control can help with a range of issues, from ensuring they meet customer specifications to reducing the risk of equipment failure and/or environmental damage.

o  Increased productivity: Automated solutions increase the speed and accuracy of actions, which means that companies can produce higher volumes at a faster rate. This, in turn, reduces costs and increases profit margins. The ability to communicate with multiple locations simultaneously via central control terminals also enables companies to respond more quickly to issues as they arise.

o  Increased efficiency: Automation can help companies make their workforce more efficient by reducing the number of errors made during everyday tasks, such as reading gauges and labeling containers. In some cases, automated systems within a production line enable workers to focus on high-level duties or management activities – allowing them to oversee multiple processes instead of taking part in individual tasks.

o  Higher-quality products: Data logging and trending can also help companies improve product quality by enabling them to spot any defects before they occur and take the necessary action to prevent these issues from recurring. In the case of food production, for example, this could include setting threshold limits on temperature or pressure to prevent spoilage.

o  Increased flexibility: Many companies are increasing the number of products they offer, which can lead to greater diversity in production methods and increased complexity in logistics. This makes it difficult for employees to keep track of data while simultaneously ensuring that a production line remains flexible enough to meet changing demands. Automation ensures that all information relating to a particular product is collected together and easily accessible, so employees can adapt workflows as needed.

o  Faster disaster recovery: In the event of a disaster, automated monitoring allows companies to quickly identify where equipment has been damaged or production processes have been disrupted – meaning they can focus on shifting resources from unaffected areas to the affected areas to get everything running smoothly again.

o  Improved safety standards: Lowering safety risks, reducing environmental impact, and meeting regulatory requirements are all important factors that influence investment decisions in manufacturing automation. Over time, these trends led to stricter legislation on health and safety issues, which has resulted in more manufacturers using automation with built-in safety features to keep people out of harm's way.

o  Increased plant efficiency: Automation technologies allow companies to improve their equipment utilization rates by using an automated procedure, which can increase profitability. They also enable them to work for longer periods without compromising production quality or inputting incorrect data into the system – resulting in more consistent finished products.

o  Higher quality raw materials: Using automated devices to monitor the production process allows companies to keep a closer eye on their input materials. If they notice that certain ingredients are becoming less effective, for example, they can adjust their blending ratios or switch to different source materials as needed.   

What is the role of automation in the industry?

Industrial automation is increasingly popular—and often necessary—for modern industrial facilities. Some of the advantages of increasing industrial automation include:

Analytics collection

• Computerized and smart devices can collect more data about your facility and the details of production. This allows facility managers to learn about error rates, production rates, energy usage, and other factors that will help devise efficiency plans.

Improved product quality

• When the fabrication process is automated, each unit of production becomes more standardized. Automated processes better adhere to design specifications within tight tolerances and offer superior repeatability from part to part.

Increased safety

• In automated processes, humans shift to the role of a supervisor rather than an operator. This reduces the risk of injury on the production floor because employees have less exposure to potentially toxic materials or dangerous processes.

More flexibility and capacity

• Automated production facilities can run 24/7 or adopt more dynamic schedules to meet demand.

More productivity with Manufacturing Automation

• Automated processes are typically faster than human capabilities or more simply mechanized processes. Automated machinery operates faster with a reduced rate of error. Smarter facilities can also quickly transition materials through different stages of production for overall faster performance all at the same time reducing waste.

Reduced operational costs

• Smart devices and automated machinery run self-diagnostics and alert human operators about potential malfunctions, streamlining maintenance and repair. The resulting preventative maintenance and faster breakdown response times make maintaining the machinery less expensive.

PRODUCTION PROCESS/LINE EFFICIENCY

Each of these advantageous compounds provides greater overall efficiency in the production process. Industrial automation can be included during every step of the line, from initial mixing or production of raw components, to fabrication and machining, to final packaging.

Increasingly smart systems improve line efficiency by taking on specific tasks and alerting human workers when there are signs of a developing problem. This allows employees to spend more time troubleshooting developing problems, creating more efficient processes, and other tasks that require a more creative approach that only a human can offer.

INDUSTRIAL AUTOMATION TOOLS

Every industrial automation system can be custom-crafted to match the facility and the production process at hand. Industrial automation relies upon the different control systems used for integrating the devices or equipment in each process into the larger system. These tools include:

Artificial Neural Network (ANN)

• A computer system that can analyze complex factors and processes to make decisions.

Distributed Control System (DCS)

• A monitoring control that allows different tools and parts of the industrial process to communicate.

Human Machine Interface (HMI)

• The interface allows the automated systems to speak to the human operator and vice versa.

Programmable Logic Controller (PLC)

• A control system that carries out predetermined steps in a task, but can also change its operations based on input from sensors and other machines.

Robotics

• The mechanical or physical equipment that the smart tools operate and control.

Supervisory Control and Data Acquisition (SCADA)

• A system for data acquisition and analyzing real-time data to make decisions.

• Different combinations of these parts allow customized industrial automation systems that match specific operational needs.

ROBOTICS & DATA ANALYTICS — SYSTEM INTEGRATION

System integration is one of the most critical aspects of industrial automation. With a supervisory control (SCADA )system, machine learning, artificial intelligence, and other technological advances that collect and act on information, the manufacturing systems become more efficient and self-corrective.

The machines can work together to correct earlier errors or stay informed about developments on the production floor. Integrated systems can also better sense developing malfunctions before they slow down production time or cause unscheduled downtime.

THE FUTURE OF INDUSTRIAL AUTOMATION

With a shortage in human labor, industries are moving towards a greater focus on manufacturing automation and integrated systems because they improve overall efficiency. It's important to invest in smart tools now to keep up with demand and provide the high-quality performance consumers expect. Industrial automation is quickly developing into Industry 4.0, the complete automation of production facilities through cyber-physical systems and the Internet of Things (IoT).

HOW TO BECOME PART OF INDUSTRY 4.0?

With current technology, the first step to becoming part of Industry 4.0 is to automate individual manufacturing facilities. When the machinery can communicate with other in-house systems, the output becomes higher-quality and more efficient. The facility itself can also benefit from improved quality, better energy and maintenance management. The next step is to widen automation across all company facilities and offices for complete virtual communication and control.

Industrial Automation Solutions

Industrial Automation is already part of existing industrial facility designs. Far from being a novelty or a facet of design only for advanced facilities, smart tools and industrial automation are quickly becoming standard practice in heavy industrial facilities and plants that face extreme or demanding conditions. 

INDUSTRIAL APPLICATIONS

IndustLabs has retrofitted and designed industrial automation solutions for facilities across multiple industries. Some examples of our work include:

Oil & Gas

• IndustLabs can integrate SCADA systems and control panels with pre-existing systems to provide more data and control. We assisted one flare stack manufacturing company by integrating our systems with an oil dehydration product at a third-party site for immediate results.

Food & Beverage

• IndustLabs implemented a temperature control system to reduce coffee ground waste by 90% for Quality Cup Systems.

Semiconductor Temperature Control

• A thermoelectric module manufacturer needed to update its automation and temperature control systems. The new tools needed to provide precise temperature control ranging from 0–1500° C. IndustLabs designed and implemented a software system to automatically monitor and control eight industrial ovens. This allowed for complete remote control and oversight of the ovens.

IndustLabs can help get to the core of your facility's automation needs and devise a custom solution that allows for automated performance, remote monitoring, and simple controls.

Preparing Your Company for the Future with IndustLabs

Industrial automation is a crucial part of modernizing your facility's industrial capabilities. Upgrading your system with industrial robots, PLCs, and overarching software systems can increase production quality, reduce errors, and make your facility more cost-efficient. Taking these actions now will help drive your company to remain competitive as more providers transition to Industry 4.0.

IndustLabs can help upgrade your facility. Our six key service areas are:

• Automation Systems

• Safety and standards

• Complete turnkey services, including hardware development, custom software creation, and automation field services

• Consultation services on how to increase productivity throughout automate production processes

• High-quality solutions in manufacturing automation from experienced professionals

• Industrial Robots

Industrial Automation Project in Mind?

Contact IndustLabs to learn more about how we can increase productivity, reduce labor costs, improve quality and solve your facility's unique challenges, or to request a quote for automating your industrial processes today. You can also subscribe to our newsletter below for the latest industry trends in automation.

What is a VFD Drive and Why You Need One?

A VFD (variable frequency drive) is a electrical device that controls the speed of an electric motor by varying its input voltage. VFDs are used to control pumps, fans, conveyor belts and other types of machinery in industrial plants.

What is a VFD Drive?

The VFD (variable frequency drive) is a type of motor control that converts direct current (dc) into variable-frequency alternating current (ac). These VFD's not only convert the power, but also boost and regulate it before sending it to the ac motor. The VFD does this by varying the field on the stator and rotating its angle.

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Image Source: https://americas.fujielectric.com/products/vfd-inverters-ac-drives/frenic-mega/

VFD drive working principle

The VFD drives are usually provided with the three-phase voltage supply to power the motor. The VFD drive consist of three main parts, namely VFD controller, inverter and feedback device.

3-level VFD controller

The VFD controller works according to the desired rpm value that is being given by the computer. First VFD controller is received by the computer and VFD controller's feedback device detects it. The VFD then works on this information to control the speed of the motor.

The vfc (variable frequency controller) converts low voltage dc input into corresponding output for v/f conversion, amplifies the magnitude of ac power according to output, then feeds to v/f converter.

VFD inverter configuration

The VFD inverter is used to convert input power into three phase output ac. This VFD inverter consists of six IGBTs (integrated gate bipolar transistors) in the case of 6-pulse v/f configuration and twelve pulse v/f configuration VFD inverter.

The VFD inverter has three main components: input, output and control terminals. There are three power devices in VFD inverter, namely IGBTs (insulated-gate bipolar transistors), thyristors and SCRs (silicon controlled rectifiers). These IGBTs and thyristors are connected in the case VFD inverter as per three-phase v/f configuration.

The VFD inverter is designed such that it converts low voltage dc input into corresponding ac output with v/f conversion and amplifies the magnitude of ac power according to v/f setting. If we want to increase the speed of a motor, then we have to increase the v/f ratio.

5 VFD drive operation

There are five VFD drive operations namely, VFD fault finding calculation, VFD start up procedure, VFD positioning control, VFD speed control and VFD troubleshooting tips.

VFD Fault-finding calculation

VFD faulty components can be easily calculated by VFD fault calculation formula. VFD drive v/f magnitude will be proportional to v/f ratio of the VFD drive. We can find v/f relation at any speed by this calculation formula. Let X = input voltage, Y = output voltage and Z = load current.

VFD Wiring

VFD Startup Procedure

To start v/f VFD drive, VFD start up procedure should be followed. VFD controller sends switching sequence from VFD inverter to VFD motor. Switching sequences vary according to v/f ratio of the VFD drive.

VFD Speed Control

V/f control is a type of VFD speed control system in which voltage and frequency are controlled by VFD controller and VFD inverter respectively. It is a feedback control system in which v/f controller calculates the error and then corrects it according to VFD start up procedure.

VFD Troubleshooting Tips

If v/f VFD drive is not working properly, v/f VFD drive fault will be shown on VFD v/f controller's display. v/f VFD drive fault can be found using VFD fault finding calculation formula. v/f VFD drive also has some VFD controls like VFD speed control, VFD positioning control and v/f VFD drive troubleshooting tips.

Examples of VFD applications

They are used in many types of industries, mostly the mechanical and electrical industry where they are found in servo systems, VFD-based control systems, VFD-fed inverters for traction applications (like trains), VFD's that regulate frequency for power plants, VFD's that run compressors or pumps at their best efficiency, VFD's that run the spindle on CNC machine tools for improved precision, VFD-fed inverters for welding power supplies (one of the biggest VFD applications), VFD-fed control systems that provide better speed regulation, VFD-fed welding machines and VFD's in robotics where they provide torque and speed control.

VFD manufacturers

Some VFD manufacturers are:

ABB, Fuji Frenic, Emerson, Siemens, Allen Bradley and Mitsubishi

When should you install a VFD?

You should consider installing VFD's when you want to get the most out of your ac motor. For example, VFD's are often used on older ac motors because they get better performance from VFD's than they did with original equipment. VFDs are also installed when it is necessary to automate an ac process or improve its speed regulation.

In industry VFD's are installed for a variety of reasons. VFDs allow users to choose the speed that they want their motors to run at, and VFD's also allow process manufacturers to improve energy efficiency because VFD's can match the motor speed with an optimum electrical frequency.

Along with all this, VFD's maintain the same ac frequency as the power supply, which means it does not have to be converted from 50 or 60 Hertz frequency to a VFD's output frequency through an inverter. Therefore, VFD's reduce power consumption and help process manufacturers improve energy efficiency.

Some VFD's can also isolate electrical networks so that if one network has an issue, VFD's can disconnect it from the other networks and protect them. By doing this VFD manufacturers also help manufacturers increase safety.

Can a VFD be installed on any motor?

The VFD is a variable speed drive and it can be used on most ac motors. However, there are certain types of ac motors that VFD's cannot be used on. VFDs cannot be used on motors that need high starting torques. VFD's also cannot be used to run induction motors or ac induction motors because the VFD produces a variable frequency output which does not vary smoothly. The VFD can only control synchronous ac motors, and VFD's should never be used on dc motors.

Can I use a VFD on a single-phase motor?

Most VFD manufacturers recommend VFD's to be used on three-phase motors. VFDs can also be used on single-phase motors, but VFD's are not the best choice when it comes to speed control of single-phase ac motor. VFDs can work with single-phase supplies if they are protected properly.

Does a VFD replace a motor starter?

Most VFD manufacturers recommend VFDs to be installed near the motor in order to get improved control. VFDs are often used when it is necessary to isolate ac motor starters so that if one starter fails, VFDf will not affect all other motors on the same power distribution system.

Where do you mount a VFD?

VFDs should be mounted vertically with their cover on the top so that VFD fans or filters can easily access them for maintenance purposes.

How do VFDs work?

VFD's are used to control ac motors. The VFD's input voltage (ac power supply) is reduced by the VFD transformer, rectified and filtered into dc voltage. The VFD then converts the dc voltage into adjustable frequency ac output voltage that matches the speed of the motor to be controlled. Proportional speed control is achieved by varying the VFD output frequency. VFDs can produce up to 1000 pulses per revolution of the ac motor's rotor, and VFD's provide much smoother speed regulation compared to v/f control where a v/f converter is used to regulate the voltage going into an ac motor so that its torque matches load requirements. VFD's also allow the v/f converter to be bypassed so that it can protect motors from overload conditions, v/f converters do not provide this capability.

What are VFD advantages?

VFDs have many advantages over v/f control motor speed regulation, benefits of vfd include: smoother motor speed regulation, less weight, lower cost and better safety. VFDs also have additional advantages which include: VFDs can be used on more kinds of ac motors, VFD's can track a load step faster than v/f control systems, VFDs do not produce any harmonics that may cause problems with downstream equipment, VFD's have built-in overload protection, VFD's can be connected to a security system for remote start and VFDs do not require an external v/f converter.

What are VFD disadvantages?

VFDs have a few disadvantages compared to v/f control systems. The first disadvantage is that VFDs cannot provide very high starting torques because the VFD's maximum torque is limited to what the VFD motor can produce. v/f control systems are still better at high torques because v/f converters use a variable frequency square wave voltage output, but VFDs do not have this drawback because v/f conversion circuitry can be used in parallel with VFD's simple variable frequency ac output. VFD's also cannot provide v/f conversion when there is no high frequency ac supply available. V/f control systems are better in these cases because v/f converters run on dc power. Motor starting torque can be increased by adding v/f converters to v/f control systems, but the v/f converter's dc power input must match the VFD's v/f converter.

Proper VFD installation

When VFD's are being installed, it is important to take safety precautions. According to IndustLabs, a VFD control system company, VFDs should only be installed by qualified VFD field technicians who have obtained the correct license. Before installation, it is recommended that you consult your VFD manufacturer for specific safety guidelines regarding VFD installation and maintenance.

AUTHOR’S BIO:

Uziel Salgado is a co-founder at IndustLabs. He loves learning new things, researching and curating valuable content to save you time and help you achieve your goals.

I have been building and integrating Industrial Automation solutions for many industries for over 15 years. I have worked with Food & Beverage, Oil & Gas, Automotive Manufacturers, and just about any other industry you can think of.

Beyond services and automation I can provide quality Electrical Control Panels. I specialize in keeping lead times low and providing UL quality control panels even if the certification is not needed.

Also, I do not stop at just providing a box or an automated manufacturing process, I go beyond by integrating ours or your systems into our highly salable Internet of Things (IoT) platform so you can turn data into business insights. I also partner with the leading Industrial Artificial Intelligence company to provide greater insights into the data with anomaly detection and predicting machine failures.

What is Industrial 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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The Importance of Automation in the Oil & Gas Industry

The oil and gas industry is growing every day—but it can be difficult to keep up with this increase in demand without automation. Various automated systems, such as SCADA and PLC technology, are incredibly useful in catching and preventing errors, increasing productivity, and reducing safety risks.

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Automation in the Oil & Gas Industry

The market for oil and gas is rapidly growing, and the use of automation in this industry is expanding right along with it. Demand for an increased oil and gas supply is particularly prevalent in developing regions due partially to population increases in these areas. 

While transmitting, extracting, and refining oil and gas can be incredibly complex, automation helps to simplify the process. By incorporating automative practices, companies can increase productivity, decrease costs, and provide greater safety and convenience for personnel. Automation is particularly beneficial due to the fact that oil and gas wells are frequently located in remote locations that are difficult and dangerous for people to work in.

SCADA Systems

One common type of automation in the oil and gas industry is supervisory control and data acquisition (SCADA). SCADA systems collect information and data at remote oil and gas locations, therefore reducing the need for supervisors and personnel to make trips to the sites. This saves time and money, and aids in personnel safety. Additionally, managing the incredibly high volumes of data put out by oil sites is an immense challenge; SCADA systems make this data collection significantly more manageable. 

Use of SCADA in the Upstream Sector

Most frequently, SCADA systems in the upstream sector are used to remotely gather data and transmit it back to headquarters. In this scenario, SCADA systems allow personnel to quickly respond to critical situations, preventing blowouts and increasing safety. 

Use of SCADA in the Midstream Sector

As oil and gas moves downstream, it must traverse thousands of miles of pipe systems, often moving through harsh conditions. SCADA systems in this midstream sector monitor the flow of oil, ensuring that the pipeline’s pressure remains optimal. SCADA systems can also detect leaks, resolving issues before they escalate.

Use of SCADA in the Downstream Sector

This segment of the oil and gas industry consists of plants that specialize in processing and refining oil. SCADA systems are used here to make sure that the plants are prepared for the appropriate amount of product inflow. These systems also increase personnel safety by detecting and mitigating errors.

PLC Technology

While SCADA systems are largely used to remotely collect data, a programmable logic controller (PLC) connects with field devices to control various automated processes. PLC technology utilizes communication protocols to regulate processes within plants.

The Industrial Internet of Things

The industrial Internet of Things (IIoT) enables various machinery and systems to communicate with each other without human intervention. In the gas and oil industry, IIoT is used to increase security, manage industrial and customer data, and provide preventative maintenance to machinery. IIoT has numerous benefits, including:

• Decreasing environmental impact

• Providing real-time data

• Increasing efficiency and profits

• Reducing risks

IndustLabs Automation Solutions for the Oil & Gas Industry

For more than 10 years, IndustLabs has provided high quality automation solutions for use in a wide range of industries. We offer Web HMI that easily integrates with your preexisting SCADA system, making automation even more streamlined. 

Additionally, we develop, program, and configure PLC technology. This is useful in a variety of applications; for example, we have successfully tested our PLC technology for use in automating flare stack operations. Our PLC technology can determine gas and pressure buildup within an oil well by evaluating Key Performance Indicators (KPIs). The PLC can then ignite flare stacks and alert personnel to ignition failures, leading to an increase in productivity and profits. 

IndustLabs specializes in providing effective and streamlined automation solutions. To learn more about how we can help your business, contact us or request a quote today. Also, subscribe to our newsletter below to stay up to date on the latest trends in the Industry.