Factory Automation

Factory automation ensures that more and more previously manual processes are taken over by machines. This has many advantages, such as increased operational efficiency and reduced production costs. It has its roots in the first Industrial Revolution in the 18th century, where mechanization replaced human labour with mechanical power. The second industrial revolution took place in the 19th century with the discovery of electricity and assembly line production. And finally, factory automation, as we understand it today, began in the 20th century as part of the third industrial revolution, with the use of computers and programmable logic controllers (PLCs). Since then, it has been possible to conduct complete work processes automatically, i.e. without human intervention. Examples of this are robots that carry out programmed processes. A key development that made factory automation possible in the first place was the networking of a wide variety of machines and components that can exchange data via industrial communication technologies and thus interact with each other.

The impact of factory automation extends beyond mere cost savings and safety improvements. It also leads to higher customer satisfaction due to the ability of automated systems to produce products with higher precision and accuracy. Furthermore, the integration of information technologies such as the Internet of Things (IoT) enables real-time monitoring and analysis of production processes, allowing manufacturers to quickly identify and address issues, thereby optimizing operational efficiency. This development, i.e. the networking of factories (operational technologies) with IT systems, is known as the fourth industrial revolution or Industry 4.0.

The key hardware components of automated factories are integral to the efficiency and productivity of modern manufacturing processes. The core of every factory automation system includes: 

• Programmable Logic Controllers (PLCs) 

  PLCs or other control systems like DCS (distributed control systems). They act as the brain, executing control instructions based on programmed logic as well as managing input and output through I/O modules and interfacing with controlled machinery.

• Human-Machine Interfaces (HMIs)

  HMIs provide user interfaces connecting operators to machines and centralize data, displaying information in graphs or dashboards, optimizing processes.

• Sensors and actuators

  Sensors measure parameters, converting physical signals for real-time feedback while actuators convert energy into mechanical motion, controlling systems with precision.

• Industrial Communication networks

  Essential for seamless operation, enabling real-time data exchange. This includes specialized networks like PROFINET, EtherCAT,EtherNet/IP, Foundation Fieldbus, PROFIBUS, and Modbus, etc.

• Industrial robots 

  Industrial robots are advanced applications integrating PLCs, HMIs, sensors, actuators, and networks. They are programmed for complex tasks, improving productivity, reducing errors, and handling hazardous environments.

Furthermore, the importance of automation system types in factory automation is multifaceted, with each type offering specific technical advantages that contribute to the overall efficiency and productivity of manufacturing processes. Factory automation systems can be categorized into three major types:

• Fixed automation

  Also known as "hard automation”, configured for specific tasks, ideal for high-volume, repetitive production. Examples: automated assembly machines, machining transfer lines, and material handling conveyor systems.

• Programmable automation

  Offers more flexibility compared to fixed automation by producing different products in batch quantities and requires reprogramming for each new batch. Examples: numerical-control machine tools and industrial robots.

• Flexible automation

  An extension of programmable automation with greater adaptability, which involves advanced robotics and computer controls, allowing reconfiguration for new tasks. Higher initial costs but leads to long-term savings, suitable for industries with frequent product variations and customization. Examples: Robotic cells in electronics assembly.

The modern industry 4.0 operates on a sophisticated hierarchy of factory automation, designed to streamline production, and integrate various levels of operation and management. This structure is often visualized as an automation pyramid which serves as a structured model for categorizing the various levels of automation within industrial settings. At the apex of this pyramid is the Management Level, which is integral to the overarching control and visibility of operations within a company. This level is characterized using Enterprise Resource Planning (ERP) systems, which provide top management with the ability to oversee and manage their operations comprehensively. Beneath the Management Level is the Planning Level, known for its utilization of Manufacturing Execution Systems (MES). These systems are pivotal in monitoring the entire manufacturing process, from raw materials to the finished product, ensuring that production is executed efficiently and effectively.

The Supervisory Level, identified as Layer 3 within the pyramid, is responsible for the monitoring and control of the Control Layer below it. It employs SCADA (Supervisory Control and Data Acquisition) systems and Human-Machine Interfaces (HMIs), which enable operators to keep a close watch on the automation system and make necessary adjustments. Further down the hierarchy is the Control Level, where the actual process control takes place. This level includes all types of control units, such as PLCs or DCS, that execute the control tasks based on sensor inputs. At the base of the pyramid lies the Field Level, which is the production floor itself. Here, physical work and monitoring occur, involving sensors and actuators, like electric motors, hydraulic and pneumatic actuators, proximity switches, and photoelectric switches, all of which play a role in the direct manipulation and detection of materials within the manufacturing environment.

The key components of factory automation are important because they enable manufacturers to achieve higher productivity, better quality control, enhanced workplace safety, and reduced costs. By leveraging these automation technologies, businesses can maintain competitiveness in the global marketplace and respond effectively to customer demands. 

Essential for factory automation are industrial communication technologies that enable secure and reliable data exchange between the various automation components. Specifically, this refers to communication controllers that act as an interface in PLCs, sensors or actuators and communicate with each other via standardised fieldbus systems with the respective communication protocols. Traditionally, these were the classic fieldbuses such as:

• PROFIBUS DP 

  Profibus DP operates on a controller-device model, where a controller communicates with various devices in a network. This cycle ensures synchronized operations across the factory floor by sending outputs and receiving inputs from connected devices. In factory automation, PROFIBUS DP is crucial for high-speed data transmission, supporting up to 126 devices per segment, making it ideal for time-critical applications. It plays a pivotal role in enabling the operation of sensors and actuators through a centralized controller, ensuring seamless integration and efficient operations within a production line.

• CC-Link 

  CC-Link involves a high-capacity controller network, designed to facilitate communication between various automation devices. The standard CC-Link operates at a high communication speed of 10 Mbps and can handle both control and information data simultaneously. This network can connect to 64 stations with a maximum transmission distance of 100 meters. The application of CC-Link in factory automation is the facilitation for the overall control and automation of processes such as mixing, blending, and reaction. 

• CANopen 

  CANopen utilizes a controller-device model and orchestrates various device devices in manufacturing environments for streamlined operations. The standardized communication objects specified by CANopen, such as Process Data Objects (PDOs), Service Data Objects (SDOs), and network management data, ensure seamless interaction between different devices, even if they are from various manufacturers. PDOs transfer real-time process data, while SDOs handle configuration and diagnostics. CANopen, utilizes synchronization and emergency objects, manages configuration and process data in both broadcast and unicast modes. In factory automation, CANopen-based embedded control systems, like those in injection moulding equipment, enable precise control and monitoring, ensuring efficient and reliable production processes.

Over time, however, there was a growing desire to enable standardized communication across all levels of the automation pyramid. This was achieved by adding real-time data transmission capability to the standard Ethernet. Real-time Ethernet or Industrial Ethernet was born. Within this framework, there are a number of IP-based Industrial Ethernet protocols:

• Ethernet/IP

  Ethernet/IP, a robust industrial communication protocol based on Common Industrial Protocol (CIP) over standard Ethernet with TCP/IP, facilitates multi-layered communication from sensor bus to enterprise level. Employing a producer/consumer model for I/O data transfer, Ethernet/IP treats each device as an object, simplifying data exchange. With CIP over TCP/IP, it ensures reliable and ordered data packet delivery, crucial for precise industrial applications. Widely adopted in industry, Ethernet/IP supports real-time communication and high-speed data transfer, enhancing operational efficiency in manufacturing by connecting PLCs, HMIs, sensors, and automation equipment. This results in reduced downtime and enables quick responses to changes through seamless data transfer.

• PROFINET

  Industrial Ethernet standard designed for data communication in industrial systems. PROFINET operates through three channels: Standard TCP/IP for non-deterministic functions, Real Time (RT) for deterministic automation, and Isochronous Real Time (IRT) for precise synchronization in motion control. These channels can function simultaneously, with bandwidth sharing to ensure at least 50% availability for TCP/IP communications. PROFINET is widely used in diverse industrial applications, facilitating communication between PLCs, DCSs, PACs, and devices like I/O blocks, drives, and process instruments. 

• Modbus

  Facilitates information transmission over serial lines in industrial settings. Data is conveyed as binary bits represented by voltages. It operates over various mediums, including serial lines, Ethernet, and wireless methods. Supporting ASCII, RTU, and TCP data encapsulation, with RTU and TCP being common, Modbus is integral in factory automation, where it is embedded into equipment without the need for royalty payments, making it a cost-effective solution for connecting a wide array of industrial electronic devices. Its role in facilitating data exchange between smart devices, sensors, and instruments is pivotal for monitoring field devices through Desktop PCs and HMIs.

• EtherCAT

  It employs a controller-device model where the EtherCAT controller sends a telegram that passes through each node. Each device processes the data addressed to it "on the fly" and inserts its response into the frame as it moves downstream. This innovative approach allows for extremely high bandwidth utilization and ensures that cycle times are deterministic, making EtherCAT suitable for hard real-time requirements. EtherCAT's role in factory automation can be seen even in the most critical and time-sensitive applications, such as emergency shutdowns or high-speed robotic operations, ensuring that the system remains robust and responsive.

In view of the great heterogeneity and incompatibility in the field of proprietary fieldbus and RTE protocols, the networking of comprehensive production systems with a wide range of machines often involves a great deal of effort for commissioning and maintenance. To avoid this in the context of even more extensive IIoT networking, two open standards in particular are emerging for industrial communication in the IIoT:

• MQTT

  MQTT employs a broker-based architecture where a central broker connects clients, acting as an intermediary for message distribution. Messages from publishers are categorized based on hierarchical topics, facilitating organized distribution to subscribers. In factory automation, MQTT is pivotal for data exchange between Manufacturing Execution Systems (MES) and Supervisory Control and Data Acquisition (SCADA) systems. This integration spans various automation levels, from factory floor equipment to cloud-based IT services. MQTT enables efficient bidirectional communication between PLCs and sensors with limited resources, enhancing Overall Equipment Effectiveness (OEE) by improving availability, production quality, and machine performance.

• Open Platform Communications Unified Architecture (OPC UA)

  OPC UA is based on a client-server model, facilitating flexible data access for operations like read, write, subscribe, and call. Its service-oriented architecture (SOA) with protocol-independent method descriptions ensures scalability and extensibility in industrial communication. In factory automation, OPC UA's application spans various operating systems, making it ideal for integrating machine data into enterprise resource planning (ERP) systems. This accelerates processes, reducing manual labour and errors by eliminating traditional hierarchical information flow structures.

Factory automation stands as a transformative force in modern industry 4.0, offering a multitude of benefits that significantly enhance production capabilities. There are many advantages for factory automation, such as: 

• Increased efficiency

  Factory Automation enables faster production cycles and minimizes downtime, as machines can operate continuously and at speeds beyond human capability. This not only accelerates the rate of production but also allows for more efficient use of resources, leading to higher throughput and better utilization of materials.

• Quality improvement

  Automated technology systems are designed to execute tasks with high precision and consistency, reducing the likelihood of errors that can occur with manual labour. 

• Cost reduction

  By reducing the reliance on manual labour, automated technology lowers labour costs and mitigates the risks associated with human error. 

• Scalability and flexibility

  It is one of the crucial aspects of factory automation, as automated technology systems can be easily reconfigured or expanded to accommodate changing production demands. 

In conclusion, the implementation of factory automation brings forth a synergy of increased efficiency, improved quality, cost reduction, and advanced industrial communication culminates in a robust and dynamic production environment capable of meeting the challenges of modern industry 4.0.

The landscape of factory automation is being shaped by the integration of advanced interfaces for industrial communication, which are becoming increasingly efficient and at the same time more functional. One of the most significant trends in this domain is the use of System-on-Chip (SoC) technologies, which consolidate multiple processors and interfaces on a single chip, optimizing performance and efficiency for high-challenging industrial applications.

The SoCs developed in-house by Hilscher, a leading global provider of industrial communication solutions, utilize the company's own netX technology. The multi-protocol capable netX 90 SoC can be integrated into all common industrial fieldbus and RTE networks by simply reloading the protocol stack firmware and is ready for modern Industry 4.0 applications thanks to their MQTT and OPC UA capability. Hilscher's netX chips form the basis of all the company's communication interfaces. In addition to the pure SoC, Hilscher also offers embedded modules and PC cards in many different form factors, which are characterized by lower integration costs and faster time-to-market.

The comprehensive portfolio also includes gateways and switches, IO-Link controllers and devices for network and communication diagnostics. In addition, Hilscher's Managed Industrial IoT offering helps companies to benefit quickly and easily from the possibilities of IIoT. With the netFIELD edge management platform, consisting of edge gateways with integrated Docker container management, an edge OS runtime running on it, centralized edge management via the netFIELD cloud portal and ready-to-use container apps, Hilscher offers a turnkey solution for the aggregation and use of extensive machine data via the Internet and the remote management of industrial components. Thanks to open technologies and interfaces, this system can be customized quickly and easily and adapted to your own requirements.