Modern automated production systems are characterized by their complexity, as they integrate a vast array of technologies to optimize efficiency, precision, and flexibility in manufacturing processes. These systems are composed of interconnected machines, robots, sensors, actuators, and software, all working together seamlessly. The coordination of these components requires sophisticated control systems like PLCs that manage everything from individual machine operations to entire production lines. Automation often involves the use of advanced algorithms, real-time data analysis, and artificial intelligence to adjust processes dynamically, making decisions faster and more accurately than human operators. This high level of integration and automation, while improving productivity and reducing human error, also introduces significant complexity in design, implementation, and maintenance.
At the heart of these systems is the industrial communication network, which serves as the backbone for transmitting data and enabling communication between various devices across the factory floor. Constructing such networks involves careful planning to ensure reliability, speed, and scalability. Industrial fieldbus, real-time Ethernet or IIoT protocols like EtherCAT, PROFIBUS, PROFINET, EtherNet/IP, Modbus, and OPC UA must be selected based on the specific needs of the application, considering factors like data volume, security requirements, the existing network infrastructure and the need for real-time communication. The network infrastructure must also be robust enough to handle the harsh conditions often present in industrial environments, such as electromagnetic interference, temperature extremes, and physical stress.
The development of communication interfaces for field devices, like SoCs, embedded modules or PC cards is crucial for ensuring that sensors, actuators, and other equipment can communicate effectively with the central control system. These interfaces must be designed to handle diverse protocols and ensure seamless integration between different manufacturers’ devices. As automation systems become more complex and interconnected, the challenge of designing these interfaces grows, requiring innovative solutions to ensure interoperability and maintain high levels of system performance. The successful integration of these components leads to more efficient, adaptive, and reliable manufacturing systems.
The high complexity of these interfaces and the extremely high level of expertise required for this is not or not sufficiently available in many development departments of automation companies. And even if the know-how is available, the specialist personnel also need the free resources to be able to implement development projects. In times of lack of specialists and the battle for talents, this is an important factor in many organizations. For reasons of cost efficiency and a fast time-to-market, it is therefore often advisable to rely on the experience of specialized development partners.
