Industrial automation is specific to the adoption of robotics, machines and control systems for tasks that have traditionally been undertaken manually. There’s no denying that this is a growing trend, with an increase in robot density from 71 robots per 10,000 employees in 2015 to 119 robots per 10,000 employees in 2023. The UK’s industrial automation market is also projected to grow from USD 8.42 billion in 2021 to USD 14.64 billion in 2028. It’s unsurprising given the potential to gain a competitive edge, with improvements in productivity and efficiency, through automation.
Despite the growing trend, the UK lags behind other leading manufacturing nations in the adoption of automation technologies. Great adoption will support sustainable growth and increases in productivity to ensure that the UK maintains global competitiveness.
Let’s explore the essential concepts and advantages for manufacturers new to the field.
What is Industrial Automation?
Industrial automation involves the use of machines for the performance of tasks with minimal human input. Such machines are operated via a range of control systems such as programmable logic controllers (PLCs), computer numerical control (CNC) systems and robotics. These systems send commands for the completion of manufacturing activities with greater accuracy and efficiency than can be achieved by human workers. The use of automated systems also enhances the productivity, safety, and quality of manufactured products.
The scope of industrial automation continues to increase, with applications across industries such as automotive manufacturing, food and beverage processing, and pharmaceuticals. Such increasing adoption is vital when it comes to maintaining competitiveness and driving the growth of the UK manufacturing sector. Industrial automation also increases the potential for personalisation, with environmental benefits such as reduced waste and CO2 emissions.
The key components of industrial automation include:
Programmable Logic Controllers (PLCs)
These industrial computers are designed to automate and control manufacturing processes and equipment. Made to withstand use across a range of industrial environments, they allow for rapid control and customisation of various industrial processes. PLCs are increasingly integrated with cloud connectivity and artificial intelligence for more advanced performance.
Human Machine Interface (HMI)
The HMI is a user-friendly interface that enables human workers to monitor and control industrial machinery and automated processes. It is normally featured on a visual display for the review of real-time data, process information, and control options. Workers can use the HMI to monitor machinery status and quickly identify any issues.
Sensors and actuators
A range of sensors may be integrated to monitor and identify changes in physical properties, conditions, or events in the industrial environment. As an example, vision sensors allow for the detection of objects and inspection of manufactured product quality. Actuators receive and perform mechanical actions based on the signals from such automated systems. For instance, solenoid valves are used for the automatic control of fluid or gas flow.
What are the types of industrial automation?
There are a range of industrial automation systems, with those in the hard (or fixed) category designed for repetitive tasks and high levels of production. Integrated with dedicated hardware, these systems are typically installed in fixed locations for long-term use. Examples include automated assembly lines for vehicle manufacturing and conveyor systems for materials handling.
Programmable automation systems are designed for batch production, with flexibility in control of the automation process. Such systems can meet different process and output demands with only minor equipment changes needed. With a typically modular design, they allow for the easy integration of new components and scalability. Examples include programmable logic controllers, industrial robots, and flexible manufacturing systems.
Soft automation allows for even greater flexibility, with quick and easy product adjustments. This flexibility makes soft automation systems an ideal choice for manufacturers who must quickly adapt to market demands and fulfil the need for customised products. They can accommodate production changes through software updates, with little to no physical reconfiguration needed. Examples include robotic arms, which may be programmed for different assembly line tasks, and computer-controlled materials handling systems.
Industrial automation systems are also associated with benefits such as:
- Cost savings and increased profitability
- Increased worker safety
- Better decision-making through data analysis
- Scalability for business growth
Real-world Examples
Numerous real-world instances of industrial automation have been highlighted in the Machinery Update magazine. For instance, the November/December 2024 edition (page 23) focused on Panorama Antenna’s adoption of a Robitiq Screwdriving Solution. This robotic arm has allowed the improvement of quality through a uniform and repetitive assembly process, freeing up human workers to perform higher-skilled tasks such as soldering, connector assembly, and RF testing.
The January/February edition (page 12) highlighted the expansion of Omron’s S Series of collaborative robots with the addition of the TM25S. Combining increased payload capacity with a longer reach, this cobot is recommended as an ideal choice for palletising, mobile manipulation, and manufacturing applications such as welding. The T25S is also integrated with a vision system for the simplification of tasks such as package identification and part inspection.
Set to take place at Coventry’s CBS Arena from the 7th to the 8th of May, Automation UK will provide the opportunity to explore such innovative industrial technologies. With more than 100 exhibitors, this promises to be an unparalleled chance for visitors to see the benefits of innovative automation and robotics solutions. Go ahead and book your free ticket today.