What is industrial automation? In layman's terms, industrial automation primarily refers to the process of introducing various mechanical equipment across all stages of production to liberate traditional labor. More importantly, it enables faster and more efficient completion of production tasks, hence the entire process is termed industrial automation development. Currently, across industries such as petroleum, chemical, automotive manufacturing, and defense, improvements in production efficiency are inseparable from advancements in control technology automation. Today, we explore the current state and future trends of industrial automation control.
Current State of Industrial Automation Control
Industrial automation encompasses three components: industrial automation systems, hardware, and software. It is a comprehensive technology that employs instrumentation, control theory, and computer technology to execute predetermined operations according to industrial production requirements, thereby achieving objectives such as increased output, reduced consumption, and improved quality.
Leveraging advancements in electronics and communications, contemporary industrial automation control primarily relies on microcomputer-based systems. Current typical control architectures feature a three-tier structure comprising host computers, industrial controllers, and field actuators. Automation control systems predominantly utilize programmable logic controllers (PLCs), distributed control systems (DCS), industrial PCs, and embedded computers-including PID regulators and controllers-alongside OEM products.
First, programmable controller (PLC) technology represents a new generation of industrial control devices based on computer technology. It is a digital electronic system specifically designed for industrial environments to perform arithmetic operations, sequential control, counting, timing, and logical operations. PLCs effectively manage the entire manufacturing process of products and machinery, maintaining long-term market dominance in industrial automation control.
Second, Distributed Control Systems (DCS) are built upon foundational communication networks and consist of multi-level computer architectures, including process monitoring and control levels. DCS integrates multiple advanced technologies-modern communication, control, display, and computer technologies-making it a product of multi-technology convergence.
Third, with the rise of information technology innovation, industrial PCs have integrated fieldbus and control network technologies, modern network control techniques, and advanced equipment and display technologies. This aligns with the contemporary technological trends toward information, digitalization, and intelligence. Since entering military industrial automation in the early 1990s, industrial PCs have rapidly expanded into commercial and civilian sectors, achieving broader applications.
PLCs Evolve Toward Integration and Networking
The introduction of the Integrated Controller (OCS) has clarified the path toward PLC integration. While evolving from PLCs, OCS is not merely a PLC. It integrates traditional PLCs with HMIs, I/O, and rapidly advancing networking technologies into a unified system, incorporating human-machine interfaces to facilitate industrial automation control operations. Both PLC control programs and HMI programming utilize the programming platform developed by HORNER. Its convenient and efficient operation has made it highly favored by users, making the trend toward PLC integration increasingly evident. Furthermore, innovations in internet technology have driven transformation in process control through the expansion of Ethernet technology. PLC development now relies on internet advancements to evolve toward networking. With high-speed data transmission in communication systems and increased integration of network functions in control terminals, PLCs will continue advancing toward networked solutions.
Development of New Fieldbus Control Systems
Driven by new technologies, computer control systems have evolved through several key stages: base-mounted pneumatic instrumentation control systems, electric unit combination analog instrumentation control systems, centralized digital control systems, and distributed control systems (DCS). Today, they are expanding and extending toward fieldbus control systems (FCS). The future vitality of FCS will grow increasingly robust, primarily because FCS integrates new technologies such as DCS, industrial Ethernet, and advanced control. Industrial Ethernet and fieldbus technologies provide highly reliable, flexible, and convenient data transmission methods, enabling broader application of FCS in industrial settings. New fieldbus control systems will maintain growth in the control field and occupy a more significant market position.
Development of Intelligent Control
The advent of intelligent control has driven transformations across various fields. As an application of information technology, it employs artificial intelligence theory, learning algorithms, and advanced techniques to enable equipment to simulate certain characteristics and functions of human intelligence. Industrial intelligent control, developed from artificial intelligence principles, manifests primarily in the multifunctional automation of mechanical equipment. It realizes open distributed intelligent systems through Ethernet and web technologies, leveraging the universal TCP/IP four-layer protocol suite to deliver highly modular, distributed, and reusable industrial control solutions. For example: New-generation solid-state sensors and smart transmitters are evolving toward miniaturization, high precision, low power consumption, and intelligence. Smart valve positioners, controlled by highly integrated microcontrollers, allow configuration of all control parameters. They enable characteristic correction functions such as linear, split-range control, equal percentage, and quick-opening, while achieving intelligent operation. The embedding of networks makes the realization of intelligence an inevitable trend.