Industrial automation

Author:

Mohsen Shamsi

Category:

Articles

Study time: 15 minutes

Industrial automation refers to the process of using technologies and automatic systems to control and manage production and industrial processes. The main goal of industrial automation is to increase productivity, reduce costs, improve product quality, and reduce the need for human intervention in various stages of production.

In industrial automation, various equipment and systems are used, such as PLC (programmable logic controllers), robots, sensors, automatic controllers, process control software, and data management and monitoring systems. These systems can completely or partially replace human resources in performing repetitive and complex tasks.

Industrial automation is used in many industries including automotive, oil and gas, food and beverage, electronics, and pharmaceutical industries. This process not only helps to improve production performance and efficiency, but can also lead to increased safety in work environments.

Industrial automation equipment

Industrial automation uses various equipment and systems to control, monitor and optimize production processes. These equipments are generally divided into different categories, each of which has an important role in the implementation of automation processes. In the following, we will review the key equipment in industrial automation:

PLC (Programmable Logic Controllers)

PLC is one of the most important and widely used equipment in industrial automation. These devices act as the brain of automation systems and are able to receive inputs from sensors and other equipment, make decisions based on the program written in them, and send appropriate outputs to operators. PLCs are used in various industries due to their high programmability, stability and flexibility.

HMI (Human Machine Interface)

HMIs are displays that allow operators to interact with automation systems. Through HMIs, operators can monitor production processes, view data, and adjust control parameters as needed.

Sensors

Sensors are devices that detect physical or chemical changes in the environment and convert them into electrical signals. Different types of sensors are used in industrial automation:

Temperature sensors: to measure and control temperature.
Pressure sensors: to measure and control the pressure of gases and liquids.
Optical sensors: to detect the presence or absence of objects or to measure distance.
Motion sensors: to detect movement or speed.

Drives

Drives are devices used to control the speed and torque of electric motors. Drives can precisely adjust the speed of the motor and are therefore very useful in applications that require precise speed control. VFD (Variable Frequency Drives) is one of the most common types of drives.

Robots

Robots are used in various industries to perform repetitive, complex and dangerous tasks. Robots can perform tasks such as welding, packaging, material handling, assembly and even quality control. Industrial robots usually have mechanical arms with high degrees of freedom that allow them to perform complex movements.

Industrial Networks

Industrial networks are used to communicate and transfer data between different devices in an automation system. Protocols such as Profibus, Modbus, Ethernet/IP and CANopen are used to connect and communicate equipment in industrial environments.

SCADA (supervision, control and data acquisition)

SCADA are systems used to monitor and control large-scale industrial processes. These systems collect data from sensors and PLCs and transmit them to a control center. Through SCADA, operators can monitor processes in real time, receive necessary alerts and take control actions.

PID controllers

PID (proportional, integral, derivative) controllers are used to control processes that require precise and continuous regulation. These controllers work based on three components (proportional, integral and derivative) to minimize process errors and keep the system at the set point.

Safety Systems

Safety systems include equipment used to protect operators and equipment from potential hazards. These equipments include emergency switches (E-Stop), safety rails, safety sensors and safety controllers, which are designed to prevent accidents and create safety in industrial environments.

Weighing and measuring systems

These systems include equipment used to accurately measure weight, volume, flow and other parameters related to materials and products in production lines. Load cells and flowmeters are examples of these equipments.

Actuators

Actuators are devices that perform mechanical or movement action by receiving control signals. Actuators can operate electrically, hydraulically or pneumatically and are used, for example, to open and close valves, move robots or adjust the position of mechanical parts.

These equipments work together to make production processes automatic and with high efficiency. Industrial automation plays a vital role in improving product quality, increasing productivity, and reducing costs and human errors.

The performance of industrial automation in automotive industries:

Industrial automation plays a very important and extensive role in the automotive industry. The use of automatic equipment and systems in this industry not only increases productivity and reduces costs, but also improves production quality and safety. In the following, we will examine the performance and role of industrial automation in various sectors of the automotive industry:

Production and assembly lines:

Industrial robots are widely used in car production and assembly lines. These robots are able to perform complex and repetitive tasks such as welding, painting, assembling parts, and installing components with high accuracy and speed. Using robots reduces production time and improves assembly quality.
Automated Conveyor Systems are also used to move parts and cars between different production stations. These systems automatically move parts along the production line, resulting in increased efficiency and reduced labor requirements.

Quality control:

Machine vision systems and sensors are used to automatically inspect parts and products during the production process. These systems can quickly and accurately detect manufacturing defects and send information to control systems to take necessary actions.

SCADA systems are also used to monitor the performance of devices and collect data related to production quality. These systems allow production managers to be informed of the production status and quality of products at any moment and make the necessary adjustments if needed.

Production management and planning:

Manufacturing Execution Systems (MES) are used to plan and manage production processes. These systems allow companies to optimize production scheduling, materials and parts management, and resource allocation.

Together with ERP (enterprise resource planning), these systems collect and analyze data from different parts of the factory and help optimize the entire production process.

Process control and settings:

PLCs and PID controllers are used for precise and continuous control of manufacturing processes such as injection molding, welding, pressing, and painting. These controllers adjust and control various production parameters so that the final product is produced with the desired quality.

Variable frequency drives (VFDs) are used to control electric motors that are critical in processes such as conveyors, ventilation systems, and pumps. These drives optimize the speed and torque of the motors.

Safety and risk reduction:

Automatic safety systems such as safety sensors, emergency switches, and safety controllers are installed in automotive industrial environments to protect workers and prevent accidents. These systems can automatically stop production processes if any danger is detected.

Collaborative robots, also known as cobots, are used in environments where humans and robots work simultaneously. These robots are equipped with advanced sensors that can detect human movements and prevent accidents.

Energy management and sustainability:

Industrial automation in the automotive industry also helps to optimize energy consumption. Energy management systems help reduce energy costs and improve efficiency by monitoring energy consumption in different parts of the factory.

In addition, robots and equipment with optimal energy consumption are used, which reduces the consumption of electricity and consumables.

Painting and coating:

Automotive painting and coating processes have also been heavily influenced by industrial automation. Painting robots can paint cars with high precision and in the shortest possible time. These robots can also control the coating thickness and uniformity to ensure high final quality.

Storage and handling of materials:

Automated Storage and Retrieval Systems (AS/RS) are used to manage and move materials and parts in warehouses and production lines. These systems automatically store, move and retrieve materials, reducing human error and improving productivity.

In general, industrial automation in the automotive industry helps to improve quality, increase production speed, reduce costs and increase safety. These technologies allow automotive companies to be more competitive by producing higher quality products and to respond to market needs more quickly and flexibly.

Advantages of industrial automation:

Industrial automation has many advantages in various industries. These benefits have made many companies and factories turn to automation to significantly improve their performance and efficiency. In the following, we mention some of the most important advantages of industrial automation

Increasing productivity and efficiency:

Industrial automation makes production processes more speedy and accurate. Machines and robots can work continuously without interruption, which leads to increased production and reduced production time.

Product quality improvement:

By using automated and accurate systems, human errors in production processes are minimized. Machine vision systems, sensors, and controllers can continuously monitor the quality of products and prevent the production of defective products. This leads to an increase in the overall quality of the products.

Cost reduction:

Industrial automation can reduce production costs by reducing the need for human labor, reducing material waste, and optimizing energy consumption. In addition, automated systems require less maintenance and repairs than manual systems, which also helps reduce operating costs.

Increased safety:

The use of robots and automatic equipment instead of human labor in performing dangerous or repetitive tasks can significantly reduce work risks and accidents. Also, automatic safety systems such as sensors and emergency switches can prevent accidents.

High flexibility:

Industrial automation systems, especially robots and PLCs, are reprogrammable and can be quickly adjusted to produce different products. This flexibility allows companies to quickly respond to changes in market demand or customer needs.

Better control and monitoring:

Industrial automation allows factory managers to monitor production processes more precisely and in real-time. SCADA and MES systems collect and analyze data on equipment performance, product quality, and energy consumption, which leads to more efficient decision-making and better management.

Downtime reduction:

By using advanced monitoring systems and preventive maintenance, sudden equipment failures can be avoided. This helps reduce production downtime and increase productivity.

Optimal use of resources:

Industrial automation can help to optimize the consumption of materials and energy. Accurate control systems can minimize material consumption and prevent waste of resources. This is especially important in industries with expensive raw materials or limited resources.

Improving data and information management:

Industrial automation systems allow accurate collection and analysis of production data. This data can be used to improve processes, increase quality, and reduce costs. In addition, this data can help improve internal communication in the factory as well as with suppliers and customers.

Sustainability and reduction of environmental effects:

By reducing energy and material consumption, industrial automation helps reduce environmental impacts. Optimizing processes and reducing waste is not only economically beneficial, but also leads to improved sustainability and reduced pollution.

Increasing the speed of entering the market:

Industrial automation helps companies run manufacturing processes faster and more efficiently, which can reduce time to market for new products. This advantage is especially important in the automotive industry where there are rapid changes in technology and market needs.

Improving customer satisfaction:

Higher quality, shorter delivery times, and more flexibility in custom-made products lead to increased customer satisfaction. Industrial automation enables companies to respond to their customers' needs more accurately and quickly.

Collectively, industrial automation brings about significant improvements in the performance, quality, and efficiency of the automotive industry, enabling companies to operate more successfully in competitive global markets.

Conclusion:

Industrial automation, by using advanced technologies, has played a key role in the transformation of industries, especially the automotive industry. This development has increased productivity, improved product quality, reduced costs and increased safety. Also, industrial automation allows companies to quickly respond to changing market and customer needs with greater flexibility and more precise control.

Considering the wide range of benefits that industrial automation offers, including improved resource management, reduced environmental impact, and increased speed to market, we can conclude that this technology not only contributes to increasing the competitiveness of companies, but also to the sustainable and long-term development of the industry. leads to

As a result, the adoption and expansion of industrial automation in various industries, especially automobile manufacturing, is necessary and unavoidable to maintain and improve the position of companies in the global market.