Automation systems – find manufacturers and suppliers

Automation systems control, monitor and coordinate technical processes in machines, production plants and industrial processes.

They detect operating states through sensors, process signals in controllers and trigger defined responses through actuators, drives or other components. This allows recurring processes to be carried out reliably, process data to be recorded and machine functions to be interconnected.
Depending on the application, automation systems consist of programmable logic controllers, decentralised input and output modules, fieldbus and communication systems, operator and monitoring units, as well as higher-level control and visualisation systems.
Simple solutions automate individual machine functions. More extensive systems, by contrast, connect complete production lines, identification systems, motion control components, positioning systems and operational control technology.
The following provides an overview of typical types, applications, advantages and selection criteria for automation systems.

Types of automation systems

Control and PLC systems

Programmable logic controllers coordinate the logical and timed operation of machines and plants.
They process input signals from sensors, push-buttons or measuring devices and use this information to control motors, valves, cylinders, contactors and other actuators.
Compact controllers are suitable for clearly defined machine functions. Modular PLC systems can be expanded with additional input and output modules, communication modules, safety functions and technology modules.
Microcontrollers or embedded control systems can also be used for small applications with limited installation space.

Control and visualisation systems

Control and visualisation systems display machine states, process values, messages and operating functions in a clear format.
Operator panels, industrial PCs and HMI systems allow users to enter setpoints, select operating modes and identify faults.
Higher-level control systems can combine several machines or plant sections. They record production data, archive process values and support the monitoring of complex processes.
Depending on the application, alarm management, recipe management, reporting functions and connections to production or enterprise software may also be required.

Fieldbus and bus systems

Bus systems connect controllers, sensors, actuators, drives and decentralised input and output modules through shared communication lines.
Fieldbus systems reduce wiring requirements and enable the rapid exchange of control, diagnostic and process data.
Established solutions include PROFIBUS-based systems, various industrial Ethernet systems and manufacturer-specific communication systems.
Transmission speed, number of participants, cable length, real-time capability and compatibility with the existing automation environment are important selection criteria.

Remote I/O systems

Remote I/O systems record input and output signals locally, close to the sensors and actuators.
The data is transmitted to the central controller through a communication network. This reduces long individual cable runs and enables more compact control cabinet designs.
Modular remote I/O stations can process digital and analogue signals, temperature values, counter functions and safety-related signals.
Their degree of protection and design must be suitable for the intended installation environment.

Motion control systems

Motion control systems coordinate the controlled movements of servo, stepper or other electric drives.
They control the position, speed, acceleration and torque of individual or multiple axes.
Such systems are used in packaging machinery, robotics, machine tools and handling equipment, among other applications.
Precise synchronisation and short response times are particularly important in multi-axis applications.

Positioning systems

Positioning systems move workpieces, tools, sensors or machine components to defined positions.
They may consist of a drive, guide, position measuring system, controller and control software.
Linear, rotary and multi-axis solutions are available depending on the application.
Important characteristics include positioning accuracy, repeatability, load capacity, speed and available travel.

Identification and barcode systems

Identification systems record and track workpieces, products, containers or load carriers within automated processes.
Barcode, RFID and other automatic identification systems are used for this purpose.
The recorded data can be used for production control, quality assurance, traceability and warehouse management.
Reading range, data carrier type, environmental conditions, movement speed and connection to the control system are important selection criteria.

Automatic web guiding and traffic control systems

Web guiding systems detect the position of continuous materials and correct their lateral movement.
They are used, for example, with films, paper, textiles and metal strips.
Traffic control systems, by contrast, monitor and control traffic flows, access points or internal transport routes.
Both types of system combine sensors, control technology, communication and suitable actuators to form an automated overall solution.

Complete automation solutions

Complete automation solutions include the planning, programming, installation and commissioning of all required components.
These may include controllers, control cabinets, sensors, drive technology, safety functions, visualisation and data communication.
Such systems are often adapted to specific machines, production processes and existing IT structures.
In addition to technical design, careful coordination of interfaces and all participating components is required.

Applications of automation systems

Mechanical and plant engineering

In mechanical and plant engineering, automation systems control movements, machining operations, material feeds and safety functions.
They coordinate individual components and ensure that the intended processes are carried out in the correct sequence.
Modular control architectures make it easier to adapt systems to different machine sizes and equipment variants.

Manufacturing and assembly technology

In manufacturing and assembly lines, automation systems connect machining stations, robots, testing equipment and conveyor systems.
They monitor process steps, identify workpieces and document quality or production data.
Recipe management and automatic changeover can be important in production environments with a high number of product variants.

Process industry

In the chemical, food, pharmaceutical and process industries, automation systems regulate continuous and batch processes.
They record parameters such as temperature, pressure, flow rate, fill level and concentration and control valves, pumps, dosing systems and agitators.
High requirements for availability, documentation and process safety may require redundant controllers and special process control systems.

Conveyor, warehouse and logistics technology

In conveyor systems, warehouses and distribution centres, automation systems coordinate material flow.
They control conveyor belts, roller conveyors, storage and retrieval machines, sorting systems and automated guided vehicles.
Identification and positioning systems ensure that goods and load carriers are assigned to the correct destination.

Energy and building technology

Automation systems monitor and control energy generation, distribution, ventilation, heating, cooling and other technical installations.
They can record operating data, coordinate loads and provide transparency regarding energy consumption.
Reliable communication and remote control systems are particularly important for widely distributed installations.

Advantages of automation systems

• Repeatable and controlled process sequences
• Increased productivity and plant availability
• Reduced need for manual intervention
• Improved process monitoring and diagnostics
• Recording and evaluation of production data
• Increased positioning and manufacturing accuracy
• Faster response to faults and process deviations
• Flexible adaptation to different products and processes
• Networking of machines, plants and control systems
• Support for quality assurance and traceability

Important selection criteria for automation systems

Scope and complexity of the application

The first step is to define which machine functions, process steps and plant sections are to be automated.
The number of input and output signals, required axes, processing speed and desired degree of automation are decisive.
Possible future expansions should also be considered when selecting the system.

Control performance and real-time capability

The controller must be able to process programs, signals and communication tasks within the required cycle times.
Short and predictable response times are necessary for fast movements, multi-axis applications and time-critical processes.
A simpler controller may be sufficient for less dynamic applications.

Interfaces and communication

Automation components must communicate reliably with one another and, where necessary, with higher-level systems.
Fieldbuses, industrial Ethernet protocols, serial interfaces and connections to databases, MES or ERP systems must be assessed.
Open and documented interfaces make integration and future expansion easier.

Operation and visualisation

User interfaces should reflect the actual tasks of machine operators and maintenance personnel.
Important information must be immediately recognisable. This includes operating states, setpoints and actual values, warnings, faults and maintenance information.
Multilingual user interfaces may be required for machines used internationally.

Availability and fail-safe operation

The required system availability depends on the consequences of a possible plant shutdown.
Redundant controllers, communication paths, power supplies or data storage systems may be useful for critical processes.
Diagnostic functions and a clear system structure simplify troubleshooting and reduce downtime.

Functional safety

Safety-related functions must be designed in accordance with the risk assessment.
These may include emergency stop functions, safe shutdowns, safety door monitoring, safely limited speeds and safe movement ranges.
Suitable safety controllers, sensors and actuators are required depending on the machine and application.

Environmental conditions

Temperature, dust, moisture, vibration, electromagnetic interference and aggressive media can influence the selection of components.
Control cabinets, operator panels and decentralised modules must provide adequate protection for the intended environment.
Additional requirements apply in potentially explosive, hygienic or particularly harsh environments.

Expandability and life cycle

An automation system should be adaptable to future production requirements.
Modular hardware, scalable software and available communication interfaces make later expansions easier.
Spare parts supply, software maintenance, manufacturer support and long-term component availability should also be checked before procurement.

Integration and technical support

Complex automation systems require close coordination between mechanical engineering, electrical engineering, software development and production.
The manufacturer or system integrator should understand the application and be able to support design, programming, commissioning and documentation.
Clearly defined responsibilities and fully specified interfaces reduce risks during implementation.

Summary

Automation systems control, monitor and network machines, plants and industrial processes.
They include PLCs, control and visualisation systems, fieldbuses, remote I/O systems, motion control solutions, positioning systems and automatic identification technology.
Depending on the application, individual machine functions or complete production and process plants can be automated.
The main selection criteria include functional scope, control performance, communication, operation, safety, environmental conditions and expandability.

Automation systems are available from various manufacturers and suppliers. Comprehensive information about manufacturers and suppliers of automation systems from around the world can be found on Exportpages.