How do you cope with the complexity and diversity of industrial automation systems and devices?

?? How do you minimize the risks associated with using complex industrial automation systems? Consider using systems that have options for replacement parts outside the original equipment manufacturer. Also consider designing a system that has a mix of components from 2 or more vendors that are competitors yet have components that are or can be compatible with one another. This will help you minimize risks associated with solely relying on one vendor and help avoid vendor lock in. ?? Like to support this

Not all automation ideas are suitable or perfect for the automation process. Before we build we need to make sure about the compatibility and the risks. There are many legacy system's which fails on automation even today.. but there are couple of the tools which enrich the capabilities of automation at some extent. So it's always better to choose right process by evaluating and the right tool by system thorough testing

magine your industrial automation system as a puzzle. To navigate the complexity and diversity of this puzzle, you need pieces that fit together seamlessly. That's where scalability and modularity come in. Scalability is like having extra puzzle pieces in your box, ready to expand your picture when needed. It's about planning for growth and flexibility. When your business evolves, you can easily add or replace components without starting from scratch.

Standardization, Documentation, Modular Design, Layered Architecture, Scalability these are the key point to handle the complexity

From a software development perspective, you would use a modular, low coupling, high cohesion approach. This way, you can easily change or modify both software and hardware. To keep things modular, hardware-independent, and easy to test, consider using Model-Based Design. With code generation for most PLCs, you can develop and test functionality in simulation. Testing in simulation is key to tackling software complexity. Then you import code to your PLC IDE for integration and deployment. You could change hardware depending on the performance you need, as complexity grows.

Testing your industrial automation system is like putting it through a rigorous workout. You want to make sure it can handle anything that comes its way. Functionality testing is like checking if every part of your machine does what it's supposed to do. It's ensuring that each component plays its role effectively and efficiently, just like a well-rehearsed orchestra.

Testing in simulation is a step change for PLC software development. Using a model of the plant you can iteratively develop controls, while constantly performing tests in simulation. Of course, the earlier you identify software errors, the easier will be to fix them. Ideally, you would fix any significant bugs before ever using the real hardware, outside of simulation. The typical steps when using Model-Based Design would be performing modeling, control design, and desktop simulation. Afterward, code generation for your PLC IDE and Hardware-in-the-Loop testing. Only after thoroughly testing and validating your algorithms, would you deploy them on the production-ready automation equipment.

Integrating industrial automation systems is like harmonizing different instruments in an orchestra. Each instrument has its unique sound, but when they come together seamlessly, they create a beautiful symphony. Similarly, in the industrial world, systems and devices vary in their functions and protocols. To cope with this diversity, integration is crucial. It's like ensuring that every instrument in your orchestra can follow the same sheet music and play in sync.

Most projects are not greenfield. Utilize gateways to integrate legacy systems and devices into the larger ecosystem. Utilizing gateways allows you to retain existing functionality while meeting your minimum technical requirements.

Es importante ser exigentes al momento de adquirir cualquier maquinaria o sistema para que desde un comienzo sea totalmente integrable a los sistemas existentes. Hacerlo desde la base del proyecto es importante, si no se resuelve en la instancia de proyecto normalmente sera un dolor de cabeza mas para el equipo de mantenimiento.

Las actualizaciones de hardware/software de automatización son normalmente muy resistidas por los equipos a cargo de producción, porque por una parte implican una erogacion importante y por otra parte afecta a la produccion con tiempos de parada que se pueden alargar. Son pocos los que que ven como la continuidad del negocio se ve seriamente amenazada simplemente porque no se planificaron adecuadamente paradas que impliquen actualización de por ej. PLCs/DCS o E/S.

Don't let latest technologies winden the gap within you plant, try to keep your plants to as much as latest technologies out there, I know that might not be financial practical but that's the only way, migration at all level otherwise optimization and efficiency won't be realized. Learning from others and continuous improve your knowledge is key, unfortunately the industrial revolution is moving to fast to catch up immediately.

Learn not only from others in your own domain, learn from those in entirely different positions. For example in automation there is a lot we can learn from software development and IT. Most of our new technologies are not so new. No need to reinvent the wheel.

Have a roadmap. Know where you will go and have a strategy to get there. This helps cut down the noise of all the new toys, and helps you focus where it matters for you and your career.

A quite good task automation, means optimize or minimize the human intervention on that task. On a company means the same, so in an optimum scenario the coompany must get automated by just a single person. If the 99.9% of the industrial tasks can be automated, giving a better perfomance, why still working on that tasks ? Some day must get dissapeared. Thanks for sharing, regards, fcq.