Automation technology plays an important role in the digitization of companies. Through device and system automation, processes run automatically, and humans no longer need to take direct action. In production in particular, automation technology can therefore encompass not only the execution (process automation) but also the control of processes. The article shows which areas are affected by automation and why it is so important today.
The term industrial automation is used to describe measures designed to ensure that machines and systems are operated independently – i.e. without human involvement. The degree of automation is measured by the actual degree of independence of the respective machines. The term automation refers to complete automation, i.e. working systems that function largely without operator intervention.
Automation technology is an interdisciplinary field of Industry 4.0 that can be assigned to different disciplines. Mainly, this includes mechanical engineering and electrical engineering. For this reason, the various technologies and methods of automation technology are broadly diversified and are changing very quickly in some cases.
Originally, automation technology applications were mainly used in large-scale production as well as in energy and chemical technology. However, thanks to the increasing flexibility of systems, it is now also possible to automate the production of small batches and even individual items using automation technology.
Basically, a distinction is made between the following forms of automation technology:
The functions of automated systems extend to measuring, controlling, as well as regulating and communicating. The basics of automation technology therefore include these areas:
Metrology: Measuring physical quantities such as force, length, mass, pressure, time, temperature and electric current using special measuring sensors.
Sensor technology: using sensors to measure environmental conditions
Control engineering: creating programmable controllers
Control engineering: measuring controlled variables and comparing them with the reference variable (e.g. with field bus systems)
Programmable logic controller (PLC): Control and regulation of machines and systems
The automation systems mentioned are monitored centrally, in so-called man-machine interfaces. They can be self-adjusting on the basis of model-based controls – that is, the respective machine regulates its operation completely automatically. It is also possible for them to include monitoring with fault diagnosis.
The purpose of automation efforts is to provide tangible benefits for everyone involved. For example, automation technologies can take over dangerous or physically demanding work that would otherwise be left to humans. Automated processes and systems support and help people in planning and performing activities, in decision-making and service processes. In addition, production costs often fall significantly in the long term as a result of increased productivity.
Regardless of whether the processes are technically simple or complex, automation technology serves to optimize processes. In doing so, it can help to implement specified criteria – for example, the highest possible product quality or the conservation of natural resources.
Automation technology already plays an important role in digitized production processes. Industries in which automation technology has already been used for some time are the automotive industry as well as manufacturers of industrial spare parts and complex industrial machines, plants and systems.
The range of automated equipment is wide and includes all devices and systems that execute their processes automatically and acquire, process and output the information required for this purpose. Most automated systems consist of two interconnected subsystems – the automation object, which is specifically influenced, and the control or process control system, which exerts this influence.
While mechanized tools (for example drilling machines) support humans but still have to be operated by them, automated execution follows a program of fixed rules. The execution of the respective task is (predominantly) taken over by an automation device. The activity of the human is limited to monitoring and control.
In automation technology, a distinction is made between partial and full automation. Which definition applies in each case depends on the automated portion of the process:
Partial automation: While some process steps are automated, others are performed by humans. One example is the division into fine and coarse work in the processing of materials in manufacturing processes. Fine work continues to be carried out manually, while coarse or heavy work is automated – for example, using a robot or a CNC milling machine.
Full automation: One machine or software is responsible for the entire work process. Numerous production processes are already fully automated today. Software solutions are another example of fully automated processes.
An important application area of automation technology is industrial robotics . Industrial robots are programmable motion machines that can be used for assembly or machining, for example. Programmable means that the axes of the machines can be programmed in terms of movement sequence and angle without mechanical intervention. In some cases, these movements are also sensor-guided. In order to be able to carry out manufacturing tasks, the robots are equipped with tools or grippers.
The advantages of humans and robots working together (human-robot collaboration (HRC)) is that various applications can be implemented much more quickly and easily. Humans and machines work hand in hand: While the robots take on tasks that are, for example, unergonomic or required in inaccessible places, humans control and monitor the production steps.
The importance of automation technology can hardly be overestimated. The reason: automation technology goes hand in hand with rationalization. In industry in particular, this means less manual work for humans, which increases productivity. In addition, automated systems protect people during the operation of plants or during work that is harmful to health.
Automation technology also enables many applications outside industry that would not be possible without it. These include, for example, automatic payment transactions or automatically generated electricity bills. There are also household activities such as washing clothes with a washing machine.
Often associated with advancing automation technology is the fear that it could swallow up jobs as a result of the declining workload in industry. However, experts largely agree that automation also creates jobs. For one thing, the demand for ever more advanced machinery and equipment with higher levels of automation is increasing. It follows that products and value networks will have to be further developed. Companies will therefore have a greater need for additional – and above all appropriately trained – workers in the future.
Automation technology enables numerous processes that would not even be feasible if performed manually. The advantages of advancing automation technology include:
The question of when the use of automated solutions is no longer sensible or worthwhile depends primarily on economic considerations. The line is therefore drawn where automation solutions are more costly than conventional production.
After all, the automation of complex motion sequences and the use of elaborate robots, for example, can incur high costs. In many cases, it is simply more cost-effective to leave the work to human actors. As practice shows, this is particularly true in finishing – i.e., assembling products.
Automation technology also reaches its limits above all in fields of work that require creative decisions and flexible problem solving. Automated systems can only handle such tasks in rare cases, which is why they are usually better left to humans.
Automation technology has already been on the rise for several years. Automated solutions are used primarily to save time and costs. They are also less prone to error than human work and deliver higher quality overall. However, human skills are still needed in many areas. These include, for example, fields of work where creative decision-making is required.
