Introduction to Industrial Automation Levels

Home / Applications / Introduction to Industrial Automation Levels
Introduction to Industrial Automation Levels

There are numerous ways to explain the tiers of an Industrial Automation Process, but the simplest of all is the subsequent hierarchical triangle of three stage representation of a regular Industrial Automation Application.

Introduction to Industrial Automation Levels

Control Level

The Control Level is the mid-degree inside the hierarchy and that is the extent where all the automation associated applications are finished. For this cause, commonly, Programmable Logic Controllers or PLC training in Coimbatore are used, which provide real-time computing capability.

PLCs are typically carried out the usage of 16-bit or 32-bit microcontrollers and run on a proprietary working device to meet the actual-time necessities. PLCs also are capable of being interfaced with several I/O devices and may speak through diverse conversation protocols like CAN. 

Supervisor Level 

Sitting at the pinnacle of hierarchy, the manager degree normally consists of an Industrial PC, that is commonly to be had as a desktop PC or a Panel PC or a Rack-established PC. These PCs run on popular working structures with a unique software, normally supplied by way of the supplier for business system control.

The foremost purpose of the software is technique visualization and parameterization. A special business Ethernet is used for communication, which may be Gigabit LAN or any wireless topology (WLAN).

Field Level

The terminal equipment like Sensors and Actuators are categorized into Field Level within the hierarchy.

The sensors like temperature, optical, stress and so forth. And actuators like vehicles, valves, switches etc. Are interfaced to a PLC through a discipline bus and the verbal exchange among a Field Level device and its corresponding PLC is usually primarily based on a point-to-factor connection.

Both stressed and WiFi networks are used for conversation and the use of this communication, the PLC also can diagnose and parameterize numerous components.

Additionally, an industrial automation procedure system additionally calls for  fundamental systems. They are:

Security and Protection 

The power requirements of different systems in exclusive ranges of the hierarchy may be extraordinarily one of a kind. For example, PLCs normally run on 24V DC, at the same time as heavy cars run on either 1-section or three-phase AC.

So, a wide variety of right input power supply is needed for a trouble-unfastened operation. Additionally, there must be security for the software program getting used to govern the PLCs as it can be without problems be changed or corrupted.

Considering all the above-stated levels and their corresponding components, an ordinary Industrial Automation System may have the subsequent structure.

Introduction to Industrial Automation Complete System

Types of Industrial Automation Systems


Now that we have visible a touch bit about the format of an ordinary industrial automation device, let us continue with the discussion of the special kind of Industrial Automation Systems. Industrial Automation Systems are normally classified into four types.

  • Fixed Automation System
  • Programmable Automation System
  • Flexible Automation System
  • Integrated Automation System

Fixed Automation System 

In a Fixed Automation System, the production gadget is constant with a fixed set of operations or tasks and there are rarely any adjustments to these operations. Fixed Automation System is usually used in continuous float processes like conveyors and mass production structures.

Programmable Automation System 

In Programmable Automation System, the series of operations as well as the configuration of the machinery can be modified using digital controls. This system requires a great amount of time and effort to reprogram the machines and typically utilized in batch manner production.

Flexible Automation System 

A Flexible Automation System is typically, continually controlled through computer systems and are frequently carried out in which the product varies regularly.

CNC machines are the guess instance for this system. The code given by means of the operator to the laptop is specific to a specific process and based totally at the code, the system acquires the vital equipment and gadget for the manufacturing.

Integrated Automation System

An Integrated Automation System is a set of impartial machines, procedures and statistics, all operating synchronously under the command of a unmarried manage machine to put into effect an automation machine of a manufacturing system.

CAD (Computer Aided Design), CAM (Computer Aided Manufacturing), computer-managed tools and machines, robots, cranes and conveyors are all incorporated using complicated scheduling and production manipulate.

Advantages and Disadvantages of Industrial Automation


  • The assignment done by using human operators involving tedious physical work can be without difficulty replaced.
  • Human operators can keep away from working in risky manufacturing environments with excessive temperatures, pollutants, intoxicating factors, or radio-energetic materials.
  • The obligations that are hard for a standard human operator may be easily executed. These duties consist of lifting heavy and large hundreds, working with extremely tiny gadgets, and so on.
  • Production is always faster and the value of the product is substantially much less (while as compared to the equal product this is produced with guide operation).
  • Several nice control exams can be included in the production system to provide consistency and uniformity.
  • The economic system of the industry can be notably stepped forward, which has a direct effect on the same old of the dwelling.


  • Loss of jobs. Since, the majority of the work is carried out by way of machines, the requirement for manual labor is very much less.
  • All the preferred duties can not be automated using contemporary technology. For example, products with abnormal shapes and sizes are best left for manual meeting. (This fashion seems to be converting with superior computers and algorithms).
  • It is viable to apply automation companies in Coimbatore for sure system i.E. Excessive-quantity manufacturing, repeatable and constant merchandise.
  • The preliminary cost of enforcing an automation system is very high.
  • A set of professional employees is continually a demand for protection and carrier.

Leave a Reply

Your email address will not be published.

  • Partner links