Author: Ken Cheng

Over the years sensors and actuators play a crucial role in the world of industrial automation. They transformed the manual processes into highly efficient, automated systems. This is the run down of their history and evolution and how they are integral the automation industry.

A Tale of Two Components

What are Sensors?

A sensor is an electrical instrument that monitors and measures physical aspects of an environment and then sends an electrical signal to a control center when it detects pre-determined conditions. On the most basic level, sensors turn physical inputs into electrical signals that are output to the control center. Sensors can be used to monitor the health of equipment and status of a sensitive environment. One example is a sensor that can alert temperature changes to an operator if a unit gets too hot.

What are Actuators?

In contrast, actuators take electrical signals from control modules and turn them into physical outputs. They can perform a wide range of functions, from turning rotors and valves to virtually anything else. You can program them to control almost any physical action. An example of an actuator is a shutoff valve. When it receives a signal from a sensor or control module, it closes the valve. The actuator receives the input of an electrical signal and turns it into a physical action. 

The History of Sensors and Actuators

Both sensors and and actuators have their roots going as far back as the early 20th century. Basic switches and relays served as the first primitive forms of automation. These simple devices were used to detect changes in physical properties, such as temperature, pressure, and position, and to initiate mechanical actions accordingly. While this technology had very limited functionality at the time, they paved the way for the future of automation.

Pneumatic Actuators

In the early stages of automation, pneumatic actuators dominated the landscape due to their simplicity and reliability. Compressed air was used to control mechanical movements, making them ideal for industrial applications. However, the advent of electric actuators brought about a significant shift. Electric actuators, driven by motors, offered finer control, quieter operation, and the ability to integrate with digital control systems.

Sensors at the Turn of the Century

By the mid-20th century, sensors experienced a revolutionary transformation. Devices like thermocouples, strain gauges, and pressure sensors emerged, enabled precise measurements and real-time data acquisition. The integration of these sensors into industrial processes improved process control laying the foundation for more sophisticated automation systems.

Microprocessors Take the Stage

The introduction of microprocessors and microcontrollers in the 1970s and 1980s marked a turning point in sensor and actuator technology. These tiny computational devices allowed for on-board processing, enabling sensors to not only gather data but also interpret and transmit it intelligently. Smart sensors emerged, capable of self-calibration, data filtering, and communication with other devices, making them indispensable for complex automation tasks.

Sensors and Actuators Evolve

Integrating PLC’s

The 1980s brought sensors and actuators closer to the heart of industrial automation with the widespread adoption of PLCs. PLCs acted as the brain of automation systems, receiving input from sensors, processing it, and triggering actions through actuators. This integration simplified automation programming and allowed for more extensive and flexible control over industrial processes.

Internet Networking

The rise of the internet and networking technologies allowed sensors and actuators to communicate on a broader scale. Fieldbus protocols and industrial communication standards, such as Modbus, Profibus, and Ethernet/IP, facilitated seamless data exchange between devices and supervisory systems. This enhanced connectivity allowed for remote monitoring, predictive maintenance, and real-time process optimization.

Conclusion

From the simplicity of basic switches to the intelligence of smart devices, sensors and actuators continue to play a vital role in shaping the world of industrial automation. We can expect sensors and actuators to become even more integrated, intelligent, and indispensable, driving the industry towards unprecedented levels of efficiency and automation.

In the past we’ve covered the rise of automation in the industry. More specifically we’ve talked about the underlying anxieties of job loss and they human element being replaced as AI becomes more advanced. However, there’s never really been much coverage in regards to how this uncharted relationship between human and machine could lead to long term job growth. While the outlook of the human race keeping our jobs and being able to make a livable wage in the world of machines looks pretty grim. We have yet to be in the dystopian sci-fi world of Terminator. On the other hand, the discussion about the potential for job growth is seldom discussed. Too often we bring the machine aspect of automation into focus, but we don’t often talk about the human potential. These are a few ways Human-Machine collaboration becomes advantageous to job growth.

Job Creation in Automation Industries

As industries embrace automation, there is an increased demand for professionals with expertise in robotics, artificial intelligence, data analytics, and system integration. The development, deployment, and maintenance of automation systems require a skilled workforce, leading to job opportunities in these emerging fields.

Prioritizing Higher Value Tasks

Automation allows humans to transition from repetitive, mundane tasks to more complex and value-added responsibilities. As machines handle routine operations, humans can focus on tasks that require creativity, critical thinking, problem-solving, and decision-making abilities. This shift empowers employees to engage in challenging and fulfilling work

Skill Development

The introduction of automation technologies necessitates upskilling and reskilling of the existing workforce. Employees can receive training in areas such as system operation, maintenance, programming, data analysis, and process optimization. This investment in workforce development enhances employee skill sets, making them more valuable in the job market and fostering job growth.

New Job Roles and Specialization

Collaboration between humans and machines often leads to the emergence of new job roles and specializations. These include automation technicians, robot coordinators, data analysts, machine learning specialists, process optimization experts, and human-robot interaction designers. Job growth occurs as organizations create positions to address the evolving needs of their automated systems.

Entrepreneurship and Innovation

The rise of automation provides opportunities for entrepreneurship and innovation. Individuals can develop automation solutions, create startups focused on specialized automation services, or establish consulting firms that help organizations adopt and optimize automation technologies. These entrepreneurial ventures contribute to job creation and economic growth.

Support and Maintenance Roles

As automation systems become more prevalent, the need for support and maintenance personnel also increases. Skilled technicians are required to install, configure, troubleshoot, and repair automation equipment. This includes tasks such as sensor calibration, programming updates, and diagnosing system issues. The growth in automation installations leads to job opportunities in these support and maintenance roles.

Collaborative Robotics

Collaborative robots, or cobots, are designed to work alongside humans, enhancing productivity and safety. These robots require human operators for programming, monitoring, and collaboration. As the adoption of cobots increases, job opportunities arise for individuals skilled in operating and coordinating the interactions between humans and robots.

Job Expansion

The adoption of automation in one industry often leads to job growth in related industries. For example, the increased use of automation in manufacturing can drive job growth in industries such as component manufacturing, robotics engineering, software development, and logistics.

Final Thoughts

While automation can lead to job displacement in certain areas, the overall impact of human-machine collaboration tends to be positive for job growth. By leveraging the strengths of humans and machines, organizations can create new roles, upskill their workforce, and drive innovation, contributing to the growth of the job market in automation-related industries.

Introduction

With the evolution of technology becoming more sophissticated stresses the importance of faster and more efficient communication. In the early days of machinery, the way humans interacted with equipment would be with pullies and levers. While this system made labor easier, it still required a lot of physical involvement and manpower. Also because workers had communicate manually, orders on each level took a while to convey. As manufacturing and industrial processes advanced, there was more progression in the way humans and machines interacted.

In a previous article, we discussed the Second Industrial Revolution which was characterized by the expansion of electricity. The modern concept of automation begins around this time. Hefty ropes, pullies, and levers eventually became surpassed by switches and buttons. No longer did a team of workers pull heavy chains to raise and lower heavy objects. The use of electricity meant that motorized pulleys and wenches could replace these tasks with a push of a button. This development also meant faster response times in between processes, therefore resulting in faster production times.

While this by far made production in factories a lot faster and more efficient. The need to be more streamlined meant factories still needed to up the game on productivity. This is where the HMI enters the story.

A Brief History

In the Beginning

While we are hard pressed to find one today, the earliest HMI can be traced back to the typewriter. Invented in the 1860s, the device provided a tangible connection between human input and machine output. While the typewriter is considered rudimentary by today’s standards. A person able to punch keys and output the information onto paper marked a milestone in machine interfacing. However, the biggest progress for HMI technology comes about during the 20th century.

The 20th Century

The mid-20th century saw the rise of computers. Unlike the typewriter, these powerful machines and their interfaces evolved from punch cards to command-line interfaces. This later would progress to graphical user interfaces (GUIs). By 1965 the Royal Radar Establishment developed the first touch screen. Popularized by Xerox PARC’s Alto computer in the 1970s, the GUI allowed users to interact with computers through visual representations such as icons, windows, and menus. Ths technology saw niche use in industries like air traffic control. However, it wasn’t until the 1980s that it gained widespread recognition. Two prominent examples of devices being the Hewlett-Packard HP-150 and the Atari 520ST. Touchscreens revolutionized the way users interacted with machines, providing a more intuitive and direct method of input. Another significant advancement in HMI was the introduction of voice recognition systems.

HMI in the Digital Age

Recent years have witnessed the rise of virtual and augmented reality as emerging interfaces. Virtual reality (VR) and augmented reality (AR) technologies have gained significant traction. VR immerses users in computer-generated environments, while AR overlays digital information onto the real world. These immersive technologies are opening up new possibilities with training and the way operators interact with equipment.

What is HMI?

In the world of industrial automation, Human-machine interface (HMI) plays a crucial role in completing tasks. It enables effective communication and interaction between humans and machines in manufacturing and industrial settings. HMIs serve as the primary interface through which operators monitor and control industrial processes. These interfaces provide real-time data visualization, alarms, and controls that allow operators to make informed decisions and respond quickly to changing conditions. They typically consist of touchscreens, graphical displays, and input devices such as keyboards or keypads. HMIs are used to manage a wide range of industrial automation systems, including robotic assembly lines, control panels, and supervisory control and data acquisition (SCADA) systems.

The use of HMIs in industrial automation has greatly enhanced productivity, efficiency, and safety in manufacturing environments. HMIs in minimize human error and help with downtime. They allow operators to visualize critical information, receive real-time alerts, and respond promptly to abnormal conditions. HMI’s provide clear and concise displays, making it easier for operators to interpret data and make informed decisions. Furthermore, HMIs implement preventive maintenance strategies by providing insights into equipment performance and condition monitoring. By integrating advanced functionalities like data analytics and predictive maintenance, HMIs contribute to proactive approaches in industrial automation.

Conclusion

As industry continues to evolve we already seeing the integration of VR and voice commands in HMI technology. At this point the questions is not so much about “Can we do it?” but rather how streamlined and cost efficient can they be? Only time can tell.

When discussed in the context of sustainability, the average person might not think of industrial automation as ‘sustainable’. After all, when we think of industrial automation our brains turn to the worst thoughts. We think of dirty machines sucking up enormous amounts of energy while being in factories outputting copious amounts of waste. However, recent decades have shown companies moving towards sustainability. Not just because of environmental issues, but also as a means to cushion the cost of manufacturing.

As the world continues prioritizing sustainable practices, industrial automation has emerged as a potential solution for reducing environmental impact. However, there are concerns about whether industrial automation in general is sustainable.

What is Sustainability?

What do we mean by “sustainability”? According to the United Nations, sustainability is defined as “meeting the needs of the present without compromising the ability of future generations to meet their own needs.” In short, sustainable practices should not harm the environment in ways that can obstruct future generations from thriving.

Common Sustainability Concerns

One major concern is the energy consumption of automated systems. Automated machines require significant amounts of energy to operate, especially during the initial stages of setup and installation. This high energy consumption leads to increased greenhouse gas emissions and contributes to climate change. Additionally, companies design automated systems to operate at full capacity, regardless of the actual product demand. This can result in overproduction, leading to a waste of materials, energy, and resources.

Another concern is automation is the displacement of human workers. Automation usually results in job losses for human workers. This is especially true when performing repetitive and monotonous tasks. This not only affects the livelihoods of these workers but also has social implications. Extreme unemployment and income inequality can lead to social unrest and economic instability.

The Road to Sustainability

The direction of sustainability in industrial automation needs plenty of improvement. However, current trends show a shift by companies toward a sustainable goal. This includes things like reducing waste, improving energy efficiency, and safety conditions for employees.

When talking about efficiency, companies using sensors and software in manufacturing processes can reduce material waste. They achieve this by accurately measuring and cutting materials to exact specifications. This reduces the amount of scrap material wasted and lowers the overall environmental impact of the manufacturing process. Additionally, automated systems can optimize production schedules and reduce downtime, resulting in less energy waste and lower carbon emissions.

When people talk about employees regarding sustainability in industrial automation. They often think of job security as the thing to fear when it comes to automation. However, when discussing sustainability, employee safety often gets left out of the conversation. Keeping healthy and uninjured employees also counts as sustainability. Automation allows machines to complete the most dangerous tasks. This reduces the risk of injury or death to workers. Companies can use automated safety systems to detect potential hazards and shut down machinery if necessary.

Regarding environmental sustainability, having more efficient manufacturing does help stave off environmental impacts. It also has more efficient logistics that can result in better sustainability. Automated vehicles can optimize routes, reduce fuel consumption, and lower emissions by avoiding traffic congestion and reducing idle time. This not only benefits the environment but also saves time and money for businesses. Additionally, automated warehouses can reduce the need for large, energy-intensive storage facilities. This lowers the overall environmental impact of the supply chain.

The Outlook

The general consensus seems to be that industrial automation has the potential to be a sustainable solution. Especially if implemented responsibly and with consideration for the broader social and environmental implications. While there certainly exist concerns that need addressing. The overall evidence suggests that automation may be a key tool when pursuing long-term sustainability.

Industry 4.0 has become the standard labeling of our society reaching the fourth industrial revolution. Previous revolutions have been marked by game-changing inventions that have significantly impacted our way of life. The first was the steam engine. The second is mass production via electrical power. The third is the use of electronics and network infrastructure otherwise known as the ‘digital age’. Now we approach the fourth industrial revolution, one highlighted by the boom of computer technology.

The Predecessors

First Industrial Revolution

The first industrial revolution landed between the years 1760 and 1840. Its mainly characterized by the innovation of steam/water powered. Other significant milestones also include the growth of textile and iron production. As well as innovations in agriculture and mining. The first industrial revolution also saw a boom in middle-class growth.

Second Industrial Revolution

The second Industrial Revolution has at times been called the “technological revolution” which took place between 1871 and 1914. While by today’s standards, the technological leap may not seem that significant, for that time society saw these advancements as nothing less than groundbreaking. The biggest innovations to come from that era included the railroad and telegraph lines. These innovations widely improved people’s ability to not only have mainstream access across the continent but also to share ideas a lot faster.

Probably the most revolutionary advancement around this time was the streamlining of electricity. With this innovation, electricity could be in not only in homes but also to better run machines in factories. Pushing them to develop the modern production line that we know today.

Third Industrial Revolution

The third industrial revolution is marked towards the end of the 20th century. Advancements in things like Boolean logic and computer language code were huge game changers in setting up the way computers and machines communicate with one another. Speaking of communication, one innovation that really took off during this time and has had a massive effect on multip generations is the internet.

The Fourth Industrial Revolution

Building off of the third industrial revolution, the fourth industrial revolution takes digitalization to a whole new level. Many of the technological advancements during this time have roots in communication and being able to access data faster and more widely. While the third revolution brought forth the internet, the fourth revolution focused on making it faster with things like broadband. This compounded with the need to make it more mobile brought forth 3G, 4G, and 5G technology as well as devices that can use them.

Industrial Automation and Industry 4.0

Industry 4.0 isn’t just a phenomenon impacting the tech sector. Innovations regarding industrial automation can be found here as well. One of the main effects of Industry 4.0 on industrial automation is the emergence of smart factories. Smart factories utilize advanced technologies such as robotics, and machine learning, to make more efficient manufacturing processes. One Deloitte report found that smart factories can improve productivity by up to 20%, reduce maintenance costs by up to 30%, and reduce energy consumption by up to 20%. This is made possible by the integration of real-time data analytics, which allows for predictive maintenance, intelligent quality control, and optimized production planning.

Another impact of Industry 4.0 on industrial automation is the increased use of collaborative robots, also known as cobots. Unlike traditional industrial robots, which are typically isolated from human workers, cobots can work alongside humans in a shared workspace. They are designed to be safe, easy to program, and flexible, which makes them ideal for small-batch and custom manufacturing. Cobots can also be easily reconfigured to perform different tasks, which enables manufacturers to quickly adapt to changing market demands.

Conclusion

From its beginnings in simple textile manufacturing to its evolution to digital information, industrialization continues to move the gears of globalization while leaving a huge impact on culture and economics. Industry 4.0 continues to move the needle of automizing and producing goods that are not only more efficient to make, but cost-effetive too. As we progress with more advancements in digitalization we very well could be seeing Industry 5.0 centered around AI, but that has yet to be seen.

Low-code programming is an emerging trend promising to revolutionize software applications’ development and deployment. Utilizing visual modeling tools and pre-built components, low-code programming helps developers create and customize applications quickly and easily, without the need for extensive coding skills. Not only is it shaking up the world of software development, but it is making big splashes in the world of industrial automation. This is especially so when we talk about PLCs.

The Current Language of PLC

In another blog, we covered ladder logic. This is the primary coding language that PLCs use to function and perform tasks. Ladder logic is based on an older coding language known as C. Traditionally, coding in languages like C requires a mix of prompts formatted in very specific ways. This requires a well-versed coder programming the PLCs. The other challenge is not only that a person has to know the coding language, but also just be able to visualize how it all works together. Lines of code don’t always get along with each other. This sometimes results in an unexpected outcome not seen in the initial programming. This generally gets referred to as a “bug”. A good programmer must be one that can recognize, isolate, and debug what is causing these issues.

What is Low-Code Programming?

Low code is defined as a software development approach that requires little to no coding to build applications and processes. Instead of complex programming languages, it utilizes visual interfaces with basic logic and drag-and-drop capabilities in a development platform. This quick and simple alternative to conventional software development continues to grow in popularity.

Applying Low Code to PLC

While the trend of low code exists predominantly in the field of programming and development. It is also a concept being adapted to the field of industrial automation. More specifically, PLCs can adapt the low code model as traditionally they operate on a basic programming language.

The Advantages of Low-Code

There are several advantages to systems using a low-code environment. These advantages include faster times, better productivity, increased flexibility, and reduced costs.

With faster times, developers create applications much faster than traditional coding methods. They use pre-built components and visual modeling tools, to assemble and customize applications without the need for extensive coding.

Faster Times – Low coding allows PLC programmers to input programs much faster and not restricted by traditional coding methods.

Better Productivity – With less effort and time required than traditional programming, facilities can operate faster and more efficiently. An engineer can program a PLC much easier.

Increased flexibility – PLC programmers can quickly debug/modify the program of a PLC a lot easier than finding lines of code and rewriting them when the situation changes.

Low Cost – Low code programming will in the long run be less expensive, as unlike traditional programming, the PLC programmer does not need to have extensive knowledge of coding.

Future Outlook

Ultimately, the outlook for low code’s place in the world of industrial automation appears more prominent than ever. While there are concerns about how it will impact the future labor force. At its core low code serves as another example of automation making a specialized position obsolete. In the end, Low code’s multifaceted advantages of being flexible, quick, and cost-effective make it very appealing to companies across the industry, meaning that (for the time being at least) it’s here to stay.

PLCs have been crucial for the advancement of industrial automation. Their ability to increase functionality at decreased cost makes them widely used across automated systems. Not only do they have the ability. PLCs are able to give both simple and complex instructions to a variety of systems.

Like any other machine, PLCs are also prone to breaking and having their own issues. An entire PLC cabinet full of devices, blinking lights, and wires can seem intimidating. However, sometimes the issue might be one that can be resolved simply and easily. So before you call a technician to come service your system, here are a few simple troubleshooting you can do that could save your company some time (and money).

Input/Output(I/O) Failure

This is probably the most common failure that affects PLCs. This is usually due to the relationship between the internal and external situations not establishing a connection. This generally gets fixed by finding out what relationship is not being established and isolating the issue.

Signal Interference

This occurs when there is either electromagnetic interference (EMI) or radio frequency interference (RFI). EMI occurs when a PLC is very close to a large motor or any device that creates an electromagnetic field. Lightning striking a device can also cause an EMI issue. ERFI happens when a PLC is next to a transmitting device for a prolonged period of time. Both of these interference will over time degrade the functionality of a PLC. The best thing to do is to position your PLC somewhere far apart from anywhere that can cause either EMI or RFI. If that is not possible, there are also options for protective housings for your PLC.

Memory Corruption

Corrupt memory issues often occur from interference. They also commonly happen when power to the PLC suddenly gets cut off and not properly rebooted. A popular precautionary measure often taken is simpling backing up data to a storage device. A good preventative measure is to not only keep PLCs away from areas of interference but also places with high temperature and humidity.

Power Loss

In industrial automation, machines rely on consistent power to operate. In the event of a sudden power outage (power grid failure, rolling blackouts, etc) it’s generally a good idea to have an alternate or backup power source to rectify the situation should power failure occur.

Communication

A paramount function for PLCs is their ability to communicate with not only one another but also with other equipment like HMIs and drives. Usually, these devices all communicate via Ethernet cable because of their speed and reliability. Ensuring that wires rest properly connected and away from any obstruction or positioned anywhere that might cause them to crimp or get cut, can help prevent a communication error.

Conclusion

In a perfect world, machines run flawlessly 24/7 with no maintenance required. However, in reality, the inevitability of even the most well-kept facility system failing at some point is unavoidable. That being said, following the steps above can help mitigate the wear and tear of your PLC system and get the most life out of them.