A industrial automation It is fundamental to improving the control and efficiency of operations in the industry. It is not limited to the application of advanced technologies, but also involves cultural changes, new worldviews, and a strong focus on innovation.
In the current context, automation has become the foundation of Industry 4.0, integrating itself so deeply that, when we talk about industry in the future, automation will be a mandatory and implicit component.
With automation, industries can optimize processes, reduce costs, increase productivity e improve product quality. This is achieved through the use of automated systems, robots, artificial intelligence, the Internet of Things (IoT), and data analytics.
Therefore, we will explain what it is, what the benefits are, and how to implement industrial automation in your company. Follow along!
What is industrial automation?
Industrial automation is the application of technologies and equipment to automate common tasks and functions in the day-to-day operations of an industry.
In this way, it acts as an aid to managers because it defines a new production standard that is more precise, faster, and more consistent. In other words, it increases the... operational control, The ability to coordinate various aspects of production in a centralized manner.
This type of technology establishes the operational characteristics of the industry today, through highly intelligent standardized systems that define new ways of operating an industrial production system.
In summary, industrial automation represents the introduction of disruptive technologies such as Artificial Intelligence (AI), the Internet of Things (IoT), and robotics in industrial processes.
Therefore, it differs from mechanization, in which machinery is used to assist the work of operators.
In automation, a complete system of advanced technologies is used to to manage operational processes. For this to be possible, automated equipment is usually connected to a control system.
Types of industrial automation
Industrial automation can be categorized into several specific groups, which vary according to their level of flexibility and adaptation to processes.
Here are the different types of industrial automation:
Fixed automation
In fixed automation, a system controls the repetitive task operation patterns. Therefore, it is ideal for an environment with large-scale production and little customization.
For example, an automotive assembly line needs to ensure that all cars have the same predefined safety features.
Another example is... Production of simple products, such as screws, where a model of the part is produced multiple times, following the same operational standard.
Programmable automation
Programmable automation allows controllers to play a more active role. They act by doing adjustments in the production process according to the needs of each stage of the operation.
In other words, it's a set of adaptable equipment for creating different products, according to the needs of each item. Generally, this type of automation is more profitable in the long run, as it allows for customization of the production process.
In electronics factories, for example, machines are configured to assemble different types of circuits and, therefore, utilize programmable automation.
Flexible automation
Flexible automation is often understood as a hybrid type between the two previous models, in which it is possible adapt the system automatically during the process.
Because of its high adaptability, it is used in industries that make custom parts, mainly with the help of advanced technologies such as Artificial Intelligence and robotics.
Integrated automation
Integrated automation combines various types of automated systems in a centralized manner., In this context, processes are coordinated with each other. The idea is to integrate them to improve product quality without necessarily spending more resources.
This type of automation is widely used in companies seeking complete integration of industrial processes, from start to finish.
Benefits of industrial automation
Regardless of the type of industrial automation chosen, it will offer several important benefits to your company, such as increased productivity, reduced operating costs, improved product quality, and greater workplace safety.
Here's a detailed explanation of each one:
Increased productivity
With intelligent systems controlling production and executing operations with greater consistency, it is possible to produce more, meet demands, and guarantee the quality of manufactured products.
This is the main factor contributing to the expansion of the industry: its ability to to meet ever-increasing demands, without compromising the quality of deliveries.
Reduction of operational costs
Reducing operational costs through automation is achieved by decreasing problems arising from errors and the need to hire personnel. Furthermore, the Optimizing resource use important resources, such as energy and supplies.
Improvement in product quality
With automation, machines operate according to programmed standards and, provided they are properly maintained, maintain the same characteristics across all products. Therefore, it is possible to have... control over what is produced, with a greater focus on quality.
Greater safety in the workplace.
Industrial automation reduces the risk of workplace accidents e increases production safety. This is because the machines are operated through control centers located away from the production line, ensuring the safety of the operators.
Furthermore, industrial automation systems have security mechanisms which interrupt the operation when a problem is detected.
Essential components of industrial automation
Industrial automation utilizes several components to modernize a factory's production line. These components have different functionalities, depending on the specific needs of each company.
Learn about the main components of industrial automation:
Electronic products and relays (EPRs)
They are essential for industrial automation, as they operate in control and protection of electrical circuits. In other words, EPRs are responsible for monitoring and regulating the current flow, in order to ensure the correct operation of the equipment.
Sensors and actuators
Sensors are devices whose function is to detect and measure physical variables, They also monitor the operation of machines and help provide accurate data for automation systems, such as temperature, pressure, and the presence of objects.
The actuators, in turn, execute commands, converting control signals into actions Physical processes, such as valve movement or motor operation.
Contactors
Contactors are devices used to to control activation and deactivation of high-current electrical circuits.
They are commonly used to power electric motors and other industrial equipment.
Softstarters
These devices are used for to control the soft start of electric motors., reducing mechanical and electrical impact during startup.
In practice, they help to extend the lifespan of engines and reduce energy consumption.
Supervisory Control and Data Acquisition (SCADA) systems
Their function is to monitor and control industrial processes in real time. To do this, these systems perform the following: data collection, processing and display, In addition to providing a good interface for operators to remotely control equipment and processes.
Here are some examples of use:
- Monitoring of electrical networks;
- Water treatment systems;
- Production control in factories.
Equipment for controlling generators
These devices ensure the stable and consistent operation of power generators.
One of the most important components is the automatic voltage regulator, which keeps the generator's output voltage running constantly.
How can I implement industrial automation in my company?
Automating industrial processes is something that most companies can do, but for the result to be satisfactory, good planning is essential.
It's not enough to replace people with robots; it's necessary to evaluate and understand in which situations this is possible and what the best methods are for each application.
Therefore, it's important to follow a step-by-step process. Here's how it works:
- The first stage of an automation project is the defining objectives. In this way, it is possible to understand what the priorities and best opportunities are;
- Next, it is necessary to stipulate a What model should be followed and what are the ideal resources for it?;
- Next, it is important organize the documentation so that there is control over this implementation.
- It is essential that managers invest in training and in motivating the team. This will help achieve good results regarding the quality and productivity of the team.
- It is necessary choose a system and the equipment according to the specific needs of the industrial operation.
Industrial automation is a necessity for industries.
A industrial automation It is a fundamental pillar in the Industry 4.0 era, bringing significant advancements to various sectors.
As you have seen, the benefits are clear: increased productivity, reduced operating costs, and greater safety for workers.