The Future of Industrial Automation – A Guide to What’s Next

Automation refers to the application of technology for controlling and operating a process or system with minimal or no human intervention. Industrial automation is a cornerstone in manufacturing sectors, enhancing productivity and precision.

Historically, many operations now automated were performed manually. The integration of automation technology in industries has revolutionised efficiency, saving time and resources by mechanising repetitive tasks.

In contemporary settings, automation permeates through various domains such as manufacturing lines, environmental control systems, process automation in transportation like autopilot functions, and complex communication networks.

Modern automation technology falls into three broad categories. These are:

Flexible Automation

Flexible automation systems are dynamic and capable of swift reconfiguration to accommodate various production requirements. This adaptability is not limited to the type of product or component manufactured but also extends to the volume produced.

Typically associated with industrial automation, flexible automation encompasses computer-controlled machining and modular assembly systems, allowing for seamless transitions between different production cycles.

Fixed Automation

In contrast, fixed automation systems are characterised by their rigidity and are designed for a specific set of operations. Changes in production necessitate the complete overhaul of the existing machinery, which can be costly and time-consuming.

Suited for high-volume manufacturing, fixed automation epitomises efficiency in repetitive tasks, often seen in continuous flow or assembly line environments.

Programmable Automation

Programmable automation strikes a balance between flexibility and fixedness and is tailored for batch production. Operators can reprogram the system to handle different batches, providing versatility without the need for physical alterations to the machinery.

This form of process automation is exemplified by CNC machines and 3D printers, which are redefining the landscape of future automation with their precision and customisability.

Perhaps the most significant recent advancement in automation has been the development of computer numerical control (CNC) technology. Computer-controlled systems allow precision and complexity on a level not previously possible in automatic systems.

Examples of CNC technology include:

• Computer-aided design (CAD) systems
• Computer-aided manufacturing (CAM) systems
• Programmable logic controllers (PLCs)
• Proportional-integral-derivative (PID) systems

PLCs are specialised computer systems administered by human operators, coordinating the flow of data between sensors and actuators within the system. They are designed to be physically rugged to resist the dust and vibration in factories and similar industrial settings. They range in size from modular to rack-mounted.

PIDs are designed to evaluate continual feedback from industrial machinery - in other words, they are control loop devices.

PLCs and PIDs are just two examples of a whole range of technology that has enabled the rapid advancement of industrial automation. Other examples include:

• Artificial Neural Networks - this is a form of artificial intelligence designed to learn from and respond appropriately to environmental input. Amongst many other uses, they are used in CNC systems
• Distributed Control Systems - these combine multiple autonomous devices across a single production process, each operating its own control loops
• Supervisory Control and Data Acquisition - SCADA systems allow close supervision of complex networks consisting of PLCs and similar equipment

As automation technology advances, it will inevitably have significant effects on society and different industries, as explored below.

Manufacturing

Manufacturing has been the focus of automation technology for decades, but new changes are constantly being implemented. Automation in manufacturing is all about efficiency, and it is expected that manual tasks will reduce as technology advances and processes become smoother, faster, and more effective.

Engineering

Beneath the girders and pistons, engineering is fundamentally about mathematics. The more accurate and well-honed a system or component is, the safer and more effective it will be. Automation and computerisation have helped to boost precision and safety, minimise errors and increase the efficiency of all fields within engineering.

Robots are perhaps the ultimate feat of automation - an innovative fusion of information technology with the more traditional disciplines of electrical and mechanical engineering.

These benefits, along with increasing affordability of powerful computing equipment, have driven a considerable, ongoing push to automate ever more engineering tasks. Just a few examples include drilling, grinding, welding and milling - primarily via CNC technology - sensors, and robotics.

Construction

Construction is yet another industry expected to undergo a significant transformation as automation technology grows ever more sophisticated. For example, the growing use of modular construction, in which buildings are constructed from units assembled off-site, has already begun to allow in-factory automation to rise in popularity in this industry.

Automotive

The automotive industry has already seen major changes thanks to automation, with industrial robots carrying out many previously manual production line tasks such as welding, assembly, and chassis painting. Robotic process automation (RPA) has brought a significant increase in reliability, accuracy and productivity to the automotive industry.

Modern cars have evolved considerably; sophisticated digital sensors and integrated computing devices are now standard, managing everything from automatically adjusting the chassis to compensate for uneven road surfaces to alerting the driver to free parking spaces.

Naturally, all this technology generates large quantities of data, and that wealth of data is expected to acquire an increasing commercial value to vehicle manufacturers. This is likely to only increase further over time.

In addition, sophisticated AI-driven analyses will allow driving events to be analysed in real-time, in order to generate reliable predictions and safe responses. This is the automation technology that will propel the self-driving car from its current experimental status firmly into the mainstream over the coming decades.

Retail

Like manufacturing, retail is an industry on the front line of automation. Significant changes have already been introduced in the form of self-checkouts, for example, but it is expected that the relationship between automation and the retail industry will continue to evolve over the coming years. This could lead to new opportunities in the face of increased automation, with staff reskilling and new positions opening up.