Intelligent Automation

To remain competitive, industrial companies must embrace intelligent process automation to enhance their efficiency and productivity. The automation pyramid provides a useful framework for developing a successful automation strategy and understanding the communication structure of automated production. By fully exploiting automation opportunities and potential, industrial companies can position themselves for future success in an increasingly competitive market.

Contents

Why do companies use the automation pyramid?

What exactly is the "automation pyramid" or the ISA-95 model?

What are the different levels of the automation pyramid (from top to bottom)?

Where do I find IO-Link in the ISA hierarchy?

How to increase overall equipment effictiveness (OEE) with IO Link?

How does IO-Link support the IT-OT convergence?

Why do companies use the automation pyramid?

Companies use the automation pyramid to systematically integrate and manage automation technologies within their operations. Here are some key reasons why:

• Structured integration - the automation provides a clear framework for various automation technologies ensuring that each level of the system works seamlessly with the others.
• Enhanced efficiency - by organizing into hierarchical levels, companies can optimize production processes, leading to increased efficiency and productivity.
• Scalability - the structured approach allows for easy scaling of automation solutions as the company grows.
• Cost reduction: Efficient automation rduces operational costs by reducing downtime, and improving resource allocation.
• Quality control - Automation at different levels helps maintain consistent quality by monitoring and controlling production processes more effectively

What exactly is the "automation pyramid" or the ISA-95 model?

The ISA-95 model developed by the International Society of Automation (ISA), also known as ANSI/ISA-95, is an international standard for developing an automated interface between enterprise and control systems. It aims to improve communication and integration between different levels of manufacturing and business processes.

What are the different levels of the automation pyramid (from top to bottom)?

• Enterprise Level:

Function: ERP systems integrate various business functions such as finance, supply chain management, and human resources.?They provide a comprehensive view of the entire organization, enabling strategic planning and decision-making. Components: Enterprise Resource Planning (ERP) systems.

• Execution/Planning Level:

Function: MES bridges the gap between the shop floor and enterprise level, managing production workflows, quality control, and inventory.?It ensures seamless communication and data exchange between production and business operations. Components: Manufacturing Execution Systems (MES).

• Supervisory Level:

Function: SCADA systems provide real-time monitoring and control of multiple processes from a central location. They offer data visualiztaio nand basic decision-making capabilities. Components: Supervisory Control and Data Acquisition (SCADA) systems.

• Control Level:

Function: This level processes data from the field level and makes decisions to control the processes.?It involves executing control algorithms to manage machine operations. Components: Programmable Logic Controllers (PLCs) and Distributed Control Systems (DCS).

• Field Level

Function: This is the foundation of the pyramid, where real-time data is collected from the physical processes.?Devices at this level perform basic automation tasks like monitoring and controlling machinery. Components: Sensors, actuators, and other devices.

Where do I find IO-Link in the ISA hierarchy?

IO-Link is a standardized communication protocol (IEC 61131-9) designed for industrial automation. It facilitates bidirectional, point-to-point communication between sensors, actuators, and a master device, such as a PLC (Programmable Logic Controller). This means it is designed for the use in the field level and based on the 3-wire sensor and actuator connection without further requirements. Important to say: IO-Link does not replace a fieldbus, it is more the further development of the connecion technology for sensors and actuators. (Source: IO-Link)

What makes IO-Link a game changer in the field level of the automation pyramid?

• IO-Link as an universal interface providing a standardized interface for all devices, which simplifies installation and enhances functionality (similar to USB in computer technology).
• Flexibility and simplicity: The system includes an IO-Link master and devices (sensors or actuators) that communicate using standard industrial cables, making it easy to install and connect. Therefore it is highly economical.
• Enhanced control and communication: IO-Link allows for process monitoring, configuration, and error analysis directly from the controller, ensuring flexible and intelligent control concepts.

• Bidirectional data exchange: IO-Link allows for both sending and receiving data, enabling advances functionalities like remote configuration and diagnostics.
• Enhanced diagnostics: IO-Link devices can provide detailed diagnostics information which helps in predictive maintenance and trouble shooting.

How to increase overall equipment effictiveness (OEE) with IO Link?

IO-Links supports improving OEE in multiple dimensions

1. Simplified installation, configuration, and quick device replacement
2. Enhanced diagnostics and condition monitoring
3. Improved quality control

By leveraging the capabilities of IO-Link, it helps in maximizing machine uptime, optimizing production processes, and ensuring high-quality output, all of which contribute to improved OEE.

Interested to read more? Then, this intelligent automation and OEE-guide are a great source of information: Maximum performance: 7 steps to OEE excellence | Balluff

How does IO-Link support the IT-OT convergence?

The OT and the IT world are more and more connected. The ultimate situation of a full IT-OT convergence ist still a future vision, yet, companies take efforts to take best advantage of IT in OT. Consequently, the need for standardized interfaces and languages to bring OT data in the IT world is increasing continuously.

Agnostic software solutions, such as the Asset Data Provider (Asset Data Provider | Balluff) from Balluff are developed for the collection, pre-processing and delivery of data at the Operational Technology (OT) level. It supports the creation of a holistic data pipeline for IIoT applications such as predictive maintenance. One component of the software is based on edge computing technology and pre-processes data decentrally as well as delivers it efficiently, securely and in a resource-efficient way to the relevant IT systems such as Cloud, ERP or MES.

The automation pyramid more and more emerges into cyber physical systems. Therefore the RAMI 4.0 model has been developed. The difference to the ISA-95 approach is that it focuses on integrating cyber-physical systems and IoT, providing a holistic view of the entire manufacturing ecosystem. It has a broader scope, covering the entire lifecycle of products and integrating various technologies and systems. Both models are crucial for modern manufacturing, but they serve different purposes and complement each other in the context of Industry 4.0 and IIoT.

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