Process Automation

Process automation is a term that is initially ambiguous. A distinction must be made between: 

Process automation in the sense of streamlining tasks and workflows in various industries

It involves the use of software, hardware, and other tools to automate repetitive and manual processes, thereby improving efficiency, reducing errors, and saving time and resources. It encompasses the systems, protocols, and technologies that enable machines, devices, and systems to exchange information and coordinate actions. 

Process automation in the sense of the automation of procedural processes 

This field, also called process engineering, deals with the production of raw materials through the use of physical, chemical and biological processes. 

Since the first definition in the industrial environment is closely related to the general definition of automation technology, for which we have a separate knowledge page, the following article deals with the challenges of automating process engineering processes and how these can be overcome with the help of industrial communication technologies in line with the second definition. 

In the digital age, the automation of process engineering processes and systems has become pivotal in enhancing industrial efficiency and innovation. This field involves employing advanced technologies such as robotics, artificial intelligence (AI), machine learning (ML), and sophisticated software to streamline complex workflows, reduce human intervention, and boost productivity. Automation facilitates precision and consistency in processes, ultimately fostering a more adaptive and intelligent industrial landscape. 

Need for reliability

Process plants often carry out critical processes, both in relation to the operating companies and in the context of society. For example, the oil and gas industry supply important products for industrial companies and private households and other companies in the process industry produce basic materials for pharmaceuticals and food. Integrity and reliability therefore play a central role in process automation. 

Complexity of integration

 One of the biggest challenges is the complexity of integrating automation systems into existing processes. Outdated systems are often incompatible with new technologies and require extensive customization and upgrades, which can be both time-consuming and costly. 

Cybersecurity risks

As automation increases, so does the risk of cyber threats. Automated systems within modern Industry 4.0 concepts are vulnerable to hacking and other cyberattacks, requiring robust cybersecurity measures to protect sensitive data and maintain operational integrity. 

Skills gap

There is a significant skills gap in the workforce as employees need to be trained to manage and operate new automated systems. This requires significant investment in new skilled staff as well as training and ongoing education to keep pace with technological advances. 

High initial investment

The initial cost of introducing automation is often high. The purchase of advanced machinery, software and systems involves significant investment costs, which can be a barrier for small and medium-sized enterprises (SMEs). 

Change management

Effective change management is crucial for successful automation. Companies need to address employee resistance to change and ensure that all stakeholders are aligned with the vision and benefits of automation. Building a culture that encourages innovation and continuous improvement is essential for sustainable success on this transformative journey. 

By addressing these challenges, the automation of process engineering continues to redefine the industrial landscape, paving the way for smarter, more efficient, and resilient systems. a

Industrial communication serves as the backbone of process automation and enables the smooth exchange of data between different systems at field level, such as sensors, actuators or controllers. This interconnected network works with fieldbus or Real Time Ethernet protocols and standards such as Ethernet/IP, PROFINET, Modbus and PROFIBUS and ensures that different devices and software platforms can work together seamlessly. A significant development in the context of increasing digitalization is the Industrial Internet of Things (IIoT), which bridges the gap between physical devices and the digital world using standards like OPC UA or MQTT. 

In process engineering automation, real-time data exchange facilitated by industrial communication is crucial for optimizing performance and improving efficiency. For instance, sensors embedded within manufacturing equipment can monitor critical parameters such as temperature and pressure. This data is then transmitted to centralized control systems, which can make instantaneous adjustments to maintain optimal conditions, thereby ensuring consistent product quality and reducing waste. 

Predictive maintenance is a significant advantage of industrial communication in the sense of IIoT. By continuously collecting and analyzing machinery data, communication systems can detect patterns indicative of potential failures. This predictive capability allows for preemptive maintenance, reducing unplanned downtime and extending equipment lifespan, ultimately saving costs and enhancing productivity. 

Safety, a central aspect of process engineering, is greatly enhanced through robust industrial communication networks. Automated systems rely on these networks to operate within predefined safety parameters. Any deviations or emergency situations trigger immediate alerts or automatic shutdowns, protecting both personnel and equipment from harm. 

The industrial communication is vital for the successful automation of process engineering. It ensures real-time data exchange, predictive maintenance, enhanced safety, and the integration of cutting-edge technologies, thereby driving greater efficiency, reliability, and innovation in industrial operations. 

As a leading company in the field of industrial communication, Hilscher offers a broad portfolio of technologies and solutions for networking industrial environments. 

This includes a wide range of interface solutions for connecting sensors, actuators and controllers to industrial communication networks. The communication controllers of the netX family form the basis for this. The multi-protocol-capable SoCs can be integrated into automation components as required and their extensive chip peripherals enable powerful, efficient and flexible solutions. A protocol change is achieved by simply reloading Hilscher's own netX firmware. Building on this, the company also offers embedded modules and PC cards in all form factors in order to realize the netX communication interface with less integration effort. 

Hilscher also offers a comprehensive managed industrial IoT range under the netFIELD brand. This ranges from edge gateways as an application-oriented computer platform with integrated container management and the Edge OS Runtime running on it to the central cloud portal, via which the docker containers are deployed to the edge devices, through to turnkey containers for communication applications. 

Gateways and switches, devices for network diagnostics as well as masters and bridges for the wireless connection of IO-Link sensors round off the automation portfolio.