With the emergence of modern industrial automation technologies, the way industries used to operate has drastically transformed over recent years. Whether it’s a small unit or a large enterprise, industrial automation has become more of a necessity than choice, and its scope is only increasing. According to Statista, the industrial automation market is projected to grow at a CAGR of around 8% from 183 billion dollars in 2020 to approximately 300 billion dollars in 2026. Apart from this, the disruption in operations due to Covid-19 led industries to rethink use of automation systems for enhancing the scalability and flexibility of operations. Industries looked up to automation and robotics solutions for achieving greater resilience to unprecedented circumstances and maintaining production efficiency.

To help businesses understand, evaluate, and implement industrial automation systems for transforming their facility into smart manufacturing units, we have compiled everything that businesses need to know!

What is Industrial Automation

Industrial automation comprises control systems and smart devices like computers, robots, etc., along with information technologies and computer software to automate industrial processes, eliminating the need for human intervention. For automating the industrial processes, a wide range of industrial communication, control, and networking devices are used, like PLCs, PACs, SCADA, DCS, Supervisory Control PCs, HMI devices, etc. Automating industrial processes helps achieve operational accuracy, financial benefits, enhance production capabilities, eliminate labor costs, etc.

Hierarchy of Industrial Automation Systems

The industrial automation systems are complex and include a plethora of high-tech devices that work in synchronization to achieve the desired result. Hence, for successful implementation of industrial automation in a business model, it’s inevitable to understand the hierarchical structure. For the convenience of understanding, the structure is presented in four levels consisting of devices, systems, and software used at each level.

Fig. Hierarchy of Industrial Automation System (Source)

1. Field level: This is the bottom level from where all the required data for further manufacturing processes are transferred to the control level by use of sensors and actuators. Sensors transform real-time parameters like flow, pressure, temperature, etc. into electrical signals for controllers to interpret and carry out the further process. Similarly, actuators convert electrical signals to form mechanical movements for the processes.
2. Control level: This is the automation execution level where process parameters received from sensors are acquired by automation devices like PLCs and CNC machines. The obtained information is then directed to actuators for programming specific operations.
3. Supervisor and monitoring level: At this level, supervisory and monitoring devices like HMI, DCS, and SCADA controls the overall automation process. From setting machine start to shutdown time, specifying product targets, historical archiving, controlling product parameters etc. is facilitated at this level.
4. Managerial or information level: This is the topmost level which deals with the entire automation system. It includes fewer technical aspects and focuses more on commercial requirements like production planning, market analysis, order tracking, sales, etc. Various communication networks like ethernet, field buses, serial communication systems, etc. are installed for the transfer and exchange of data throughout the hierarchical structure. Gathering data and deriving valuable insights from it is the most crucial step for the management of enterprise and making informed decisions.

Types of Industrial Automation

Industrial automation systems do not follow a one-size-fits-all approach, they defer according to the requirements of manufacturing processes. Therefore, it’s important to know various types of automation systems, to identify the most suitable type for your enterprise. On basis of integration level, and operational flexibility, following are the four main types of industrial automation.

1. Fixed (hard) automation
2. Programmable automation
3. Flexible (soft) automation
4. Integrated automation

For instance, an automotive industry will require flexible automation that can be easily integrated with infrastructure whenever introducing new models. Similarly, each type will cater to the diverse and unique requirements of various industrial units.

Industrial Automation Tools

For efficient management and control of industrial processes, an extensive range of automation tools is incorporated into the system. Industrial automation tools combine process, people, and technology to obtain desired results. Following are some of the key industrial automation tools used,

1. Programmable Logic Controller (PLC)
2. Supervisory Control and Data Acquisition (SCADA)
3. Human Machine Interface (HMI)
4. Artificial Neural Network (ANN)
5. Distributed Control System (DCS)
6. Robotics

Industrial Applications

Manufacturing, automobile, steel, shipbuilding, pharma, oil and gas, paper mills, packaging, etc. various industries can be benefitted from automation systems. With help of automation tools and employing reliable strategies various industrial processes like, packaging, material handling, welding, painting, metal fabrication, quality control, and inspection, inventory management, production planning, etc. can be automated.

Benefits of Industrial Automation

The advantages of industrial automation are not only restricted to businesses but also benefit customers, employees, and everyone involved with the business. From improved safety, reliability, better productivity, enhanced quality, lower operational costs, to reduction in machine downtime, etc. industrial automation has plenty of benefits.

1. Higher return on investment:

If implemented strategically automation systems can remarkably increase the profitability of businesses. Once past the initial implementation stage, automation provides innumerable benefits in terms of costs, ease of operation, etc. But it can only be achieved if the automation system installed is in sync with your process requirements. We at ENWPS, strategically design and implement automation strategies catering to diverse requirements of various industrial sectors. Check out our website for more information.

2. Elimination of error:

Since the entire process is automated, there are minimum possibilities for error as automation systems can detect errors at an initial level of production. Automated systems are also capable of self-diagnostics and quality control checks.

Be Future-Ready with our End-to-End Industrial Automation Solutions

Industrial automation has become an invaluable asset for companies around the world. With ever-growing significance and its potential to cater to custom consumer demands, the scope of automation is only going to fuel over time. It would be wise for businesses to rethink, renovate, and plan industrial automation implementation strategies for their facilities to stay relevant and competitive in the market.

ENWPS is an industrial automation solutions company located in Pune, Maharashtra (India). Our team designs, tests, validates, plans, implements, and takes care of all the operations involved for the successful installation of automation systems. Our team directly coordinates with industry personnel and provides necessary industrial automation training alongside installation and commissioning. For more information, contact us at: rfq@enwps.com. We look forward to helping your business achieve its organizational goals.

Among applications that would benefit from early adoption of industrial 5G are obviously related to implementation of Industry 4.0 in manufacturing.

By now everyone is familiar with the term 5G from the mobile users’ perspective – an upgrade over 4G that will offer better cell phone services and browsing experience. But when it comes to Industrial 5G, it more than a generational shift, since 5G has a very strong focus on the industrial requirements of machine-to-machine communication and the Industrial Internet of Things (IIoT). Industrial 5G will revolutionise the IIoT experience with higher bandwidth and the kind of reliability never experienced before. It also provides a much higher device density and ultra-low latencies. So far, this kind of bandwidth and reliability came only with cable connections. With 5G, it becomes wireless, making it easy to connect the numerous devices without cables, ideal for the smart factory ecosystem. In short, industrial 5G will unleash the true potential of IIoT with a bandwidth to support massive data transfers required for artificial intelligence and machine learning applications in the journey of digital transformation.

Benefits of Industrial 5G

So far much of the talk about the smart factory was in the realm of theory, though the equipment as well as support systems – machines, robots, autonomous guided vehicles (AGVs), AR/VR/XR – were available. However the key element was missing – high speed data transmission in real time that makes the hardware operate to the full potential. With industrial 5G roll out within a striking distance, the fourth industrial revolution is now ready to take off. Consider these facts:

• At 20 Gbps, the peak data transfer rate of 5G is 20 times faster than 4G. 5G also has extremely low latency, which makes it as good as using cables for data transfer; and a high reliability of up to 99.99 per cent.
• There is no limit on the number of devices connected with 5G. If 4G can connect a maximum of 2000 devices in a given area, 5G can support up to 1 million devices in the same area, making it ideal for a smart factory where everything is connected.
• Of the smart factory, it is said only the structure of the plant – walls, floor and ceiling – is fixed and everything else could be moveable or reconfigurable for flexible production. Only 5G can support this kind of flexibility.
• Tailor made local networks under 5G communication standards can easily assure of data safety and security, with controlled access to authorised persons only.

Industrial 5G Roll Out

According to a study published recently by GSMA Intelligence, as of March 2021, 157 mobile operators have launched commercial 5G services in 62 countries. 5G is available in some locations in USA and Canada for about two years now with ATT and Verizon as service providers. So is the case in Germany, with Deutsche Telekom providing 5G services in cities like Berlin, Darmstadt, Munich, Bonn and Cologne by late 2019. Even UK and France have rolled out services in select cities from 2019 and 2020 respectively. In China, 5G services were rolled out at a few locations in 2019 by China Unicom.

After many missed deadlines and much delay, 5G trials have begun in India with the Department of Telecommunications granting permission to Bharti Airtel, Reliance Jio and Vodafone, as well as MTNL to conduct 5G technology trials recently. With that the trials have begun, the validity period being 6 months. The spectrum allocation will be done in days to come.

Major automation companies like Siemens, Bosch and ABB, among others have already commenced their own trials and have the hardware ready for the eventual roll out.

Applications to Benefit with Early Adoption

Among applications that would benefit from early adoption of industrial 5G are obviously related to implementation of Industry 4.0 in manufacturing, for more and more autonomous systems in factories. Other major application areas include the various services for smart cities including HD cameras to monitor safety; smart energy, such as smart grid control; smart buildings and connected offices, including sensor-based building management; and healthcare services including emergency services

In India, Capgemini in collaboration with Ericsson has set up a 5G Lab in Mumbai to accelerate the deployment of 5G solutions for industry to enable innovation, experimentation and deployment of 5G and Edge technologies for clients across industries. This is expected to bring a step-change in connectivity, services automation, autonomous devices and various applications. However, early adoption in India is expected to be in segments like energy and utilities, manufacturing and health care.

How ENWPS Can Help?

With over two decades of experience in executing several automation and robotics projects and providing various services, ENWPS is eminently qualified to handle industrial 5G projects. As of now 5G technology is still not widely implemented in industry and is a work in progress. But the need for such high reliability and low latency wireless services has long been felt. The technology is expensive and not every project needs it at the moment. The experts at ENWPS understand the nuances and can prioritize projects for implementation based on global use cases.

Talk to us today! Reach us on rfq@enwps.com

The modern PLC can be used to put in place a robust preventive maintenance programme.

What is a PLC?

A Programmable Logic Controller (PLC) is a type of computer used for machine control and is like the brain of a machine and holds the key for troubleshooting in case of any problem. PLC programming is done for specific tasks, so reviewing the steps in the program can lead to fault diagnoses and rectification. The PLC receives inputs from various sensors, switches, barcodes and other data fed by the operator, and gives output in the form of signals for the operation of motors, solenoids, indicators and alarms, etc., in a given sequence. Any change in the operation is effected through a PLC. Similarly any malfunction can be detected by reviewing the PLC actions. Now this is typical reactive maintenance once a fault occurs. Contemporary technologies go beyond that and in conjunction with IIoT devices and data analysis, a PLC can be used for predictive maintenance by anticipating faults and problem before they occur, analysing data patterns for anomalies and oddities.

How Data Acquisition Works in PLCs

For predictive maintenance, the PLC needs to use data, which is collected in course of the plant operation – data of parameters like vibration, temperature, electrical current, voltage, sound frequencies, pressure, etc., is collected by various sensors and dated, labelled and stored appropriately. While this data is good enough for regular troubleshooting, it is not enough for applications like preventive maintenance or other IIoT projects. The PLCs normally are programmed to measure parameters to indicate OK or Not OK, but not to monitor variations within those limits. This is because the primary role of a PLC is to control the machine operations and not data collection which is incidental. If any change has to be made in PLC operation, it needs a skilled programmer who may not be available and any attempt to do so without the expertise could actually have negative consequences. There are other methods of data acquisition but even those are not perfect.

So how can the data requirements for predictive maintenance be adequately addressed when it comes to PLCs? The answer here is provided by advances in technology, especially the IoT and Edge Computing devices that are now available for use with modern PLCs. These facilitate data collection from all the equipment (OT data) besides having the capability to process it further to provide structured data for storage in the cloud, also matching it with the requirements of the IT systems, offering transparency as well as greater control with better security through IT and OT collaboration. Modern PLCs also work with cloud platforms like Microsoft Azure or Amazon Web Services that make data collection and storage easier and provide tools to customise predictive maintenance operations as required.

Role of PLCs in Process Control & Monitoring

Plants exist to manufacture products, but the primary purpose of a plant is to make profit, which can be done only if the plant operates with optimum efficiency and minimum or no downtime. Any disruption in plant operation results in losses so process control and monitoring is extremely important, which brings the ball back to the PLC court. PLC, as mentioned earlier, is the brain of the machines and equipment, and is programmed to automatically control the operating conditions of the plant in which products are manufactured. Any deviation from process, in the absence of effective control, is likely to cause stoppage or worse, damage. Given the fact that most manufacturing processes are operating in harsh and hazardous environments, especially the chemicals or petrochemicals sectors, the smallest errors in reading of can cause significant safety problems and may even result in extensive damage to equipment or even loss of life. The role of a PLC in process control is thus central to safe plant operation with a predictive maintenance schedule in place.

Conclusion – How PLCs Ensure Smooth Plant Operation

A PLC is programmed to operate in a sequence and repeat the same in cycles. It can detect the status of each equipment operated with the output, and also monitor all input devices like sensors and switches in real time. It applies the user-created logic, and then executes it based on the input status, thereby controlling the devices like motors and valves, either turning them on or off. During these steps, the PLC also does a safety check by communicating with internal diagnostics and programming terminals, to ensure that everything is within normal operating conditions. Equipped with IIoT enabled data acquisition and analytics, the PLC acts quickly when a discrepancy occurs by alerting the operator, based on the built-in troubleshooting tools, initiating remedial measures. The modern PLC can be used to put in place a robust preventive maintenance program, avoiding costly downtime due to equipment failure.

ENWPS has been in business for 20 years and we specialize in Automation and Robotics. We provide innovative automated systems coupled with technology expertise. Our team of engineers, technicians and programmers design and develop customized solutions for a variety of end-user industries, including: Petrochemical, Manufacturing, Food and Beverage, and Pharmaceutical. Talk to us today! Reach us on rfq@enwps.com.

The need for IWLAN in today’s automotive industry is already established and the technology used by leading manufacturers in their connected plants.

The digital revolution sweeping across the world is powered by data which is generated by connectivity and facilitated by state-of-the-art communications technology. What started in the pre-internet area with networking of machines or local area network (LAN) became wireless (WLAN), first with radio communication and later Wifi as the internet became widely available leading to a proliferation of digital devices. While Wifi is widely used and hugely popular in general applications, the requirements of industry in terms of capacity and reliability are different, which led to the creation of dedicated Industrial Wireless LAN or IWLAN. Simply put, Wifi neither has the bandwidth, nor reliability for critical requirements of industrial plants or factory environment for manufacturing operations. IWLAN is one of the best options for industrial wireless communication. As for the advantages of IWLAN, there are many, the foremost being elimination of the need for extensive cabling between different devices.

IWLAN in the Automotive Industry

While IWLAN is important for industry, it is even more of a critical requirement for the Automotive Industry, which is one of the most visible and profitable industries, besides being the most automated. Every process in automotive manufacturing, the assembly in particular – the body shop, paint shop and trim and chassis shop – is automated. PLCs play an important role in automation as they communicate, monitor and control automated processes like assembly lines, machine functions, or robotic devices. The movements are either through conveyors of various types and overhead monorails, controlled by PLCs, the programming of PLCs done as per the role and function of the relevant system or cell. Most of these operations are performed with high end robots operating in tandem based on real-time communication between different assembly stages synchronised for continuous operation, with some form of human collaboration. IWLAN plays an important role in this environment in facilitating a safe and reliable operation with low latency, high bandwidth network for modern production concepts. The safety factor, including the plant as well as human safety, is extremely important with the protocols for safe shutdown in place for emergency use, with effective communications. Depending on the requirements and vendor services, various devices and systems of IWLAN are available, adhering to the relevant industry standards and compatible with different automaton protocols.

Changing Requirements

The automotive industry is also in its most disruptive phase of transformation ever. Over the last few years, facing the pressure from various quarters, mainly environmental and safety concerns, cars have become lighter, more fuel efficient and equipped with more and more active and passive safety features, with increased use of electronics and composite materials. Being one of the most R&D invested industry, there are rapid changes in the way which cars are built and assembled, with more models and variants, and ever increasing customisation demands, keeping with the Industry 4.0 promise of batch size 1. Amidst all these changes, automation is making way for digitalisation, which calls for state-of-the-art communications technology. The answer is IWLAN, which conforms to the most recent industry standard relevant to this technology. Manufacturers thus need to upgrade their facilities that do not require expensive infrastructure, just IWLAN compliant components with minimal outlay for the transition to fast and reliable connectivity, even in harsh environments and remote locations.

The Future of Automotive Manufacturing

According to an insight published by McKinsey & Company in late 2020, disruptions will result in billions of dollars lost, and only the manufacturers that reimagine their operations will survive. With labour and skills both in short supply in the developed world, digital factories are the way forward. More automation optimising asset deployment and building a resilient supply chain are among the prescribed changes, reinforced by the learnings from the Covid pandemic. Emerging technologies like 3D printing or additive manufacturing are part of the automobile assembly lines as are software technologies like augmented reality and virtual reality in automotive design and rapid prototyping. With the evolution of the smart factory and the expected future transition to lights-out manufacturing, the role of IWLAN will become critical to the emerging manufacturing ecosystem, also coordinating the logistics and materials movement, in conjunction with the Automatic Guided Vehicles (AGVs), forklifts and crane applications, both spanning the hardware in equipment as well as the software component in networking.

Conclusion

The need for IWLAN in today’s automotive industry is already established and the technology used by leading manufacturers in their connected plants. As the automotive assembly gets digitalised, there will be the cascading effect for technology adoption on the suppliers and vendors, to align them with the new manufacturing ecosystem. The demand for IWLAN compatible products and system integrators would also shoot up. Going forward, it is the autonomous car where IWLAN will be playing a much big role. The autonomous car is a connected car with vehicle-to-vehicle and vehicle-to-supporting infrastructure communication, and these features would be unimaginable without IWLAN. Autonomous cars would also be getting regular software upgrades, reinforcing the importance of IWLAN.
Talk to us today! Reach us on rfq@enwps.com.

There is no silver bullet of a solution in the form of an off-the-shelf industrial wireless communication system for a given requirement.

What is Industrial Wireless Communication?

Industrial wireless communication means machines and devices communicating with each other as well as with human operators without physical connections by cables. Imagine there was no wireless in industry. Consider the typical shop floor with all the machines, control panels and automation paraphernalia like relays, sensors, etc., all needing cables to connect with each other to send the signals for operation and the resultant jumble of wires. The concept of industrial wireless communication is not new. It has been around for over 3 decades now in various forms beginning with radio connection initially, and later the Wi-Fi. However, by wireless what is implied is data communication and cables are still needed for electricity supply and also hydraulic/pneumatic pipelines where the machines and equipment need these. But in general, wireless technology cuts the clutter and problems that occur due to damaged cables and connections.

The Challenges of Industrial Wireless Communication

Data communication is a vital part of the Industry 4.0 ecosystem that aims to create smart factories by networking all the machines with embedded devices. Though the idea of industrial wireless communication sounds simple, especially in view of the proliferation of Wi-Fi devices in day-to-day life, there are many challenges when it comes to implementation in the industrial environment. First and foremost, with all the machines and metallic equipment running on electricity, there is a lot of electromagnetic interference (EMI) or the disturbance caused by an electromagnetic field, which adversely affects the performance of wireless communication with the ‘noise’ it generates. The other major issue is bandwidth and frequency related, which affects the performance by causing system faults due to overcrowding of devices. The third significant factor is the harsh environment of a manufacturing plant with all the heat and dust, and in case of process industries, the corrosive environment due to the presences of vapours and chemicals. Finally, there is the matter of standards and protocols, and the interoperability of products from different suppliers, that need to be matched for compatibility of devices as well as address the cybersecurity concerns. All these challenges call for careful consideration and professional expertise for implementation of industrial wireless communication solutions.

Industrial Wireless Communication Solutions for the Smart Factory

One of the most common mistakes that occurs is when enterprises approach industrial wireless communications networks from the IT perspective. Unlike the IT environment where regular modems and routers can perform satisfactorily, the conditions in OT are different and call for specialised devices to meet all operational requirements in varying conditions. Personnel and equipment safety, reliability of the devices, and productivity are the top priorities here. The concept of smart factory or digital factory essentially evolved thanks to the advances in communications technologies which enabled connected machines and devices for highly flexible and customised manufacturing. This needs precision and accuracy with no room for error. A second of lost communication can cause not just a disruption in the process, but also damage the equipment, and worse, compromise the safety of personnel and equipment. Since technology is in continuous evolution mode, where there are problems, solutions are also available; and so is the expertise in the form of experienced professionals to implement them.

Conclusion

Today there are solution providers galore catering to a burgeoning post-pandemic market where digitalisation has become a priority. But there is no silver bullet of a solution in the form of an off-the-shelf industrial wireless communication system for a given requirement. The ideal solution is a carefully crafted one, devised by taking into consideration actual requirements, existing machinery and equipment with room for expansion, the selection of devices and compatibility, and so on. A solution that seems perfect for a warehouse may not suit discrete manufacturing; a process plant may have its own special requirements. An experienced solution provider like ENPWS, with decades of experience in automation and robotics, can help enterprises implement a robust industrial wireless communication system by studying the operational requirements at length, and coming with the optimum solution that also factors in the total cost of ownership. Talk to us today! Reach us on rfq@enwps.com