Control systems - the key to efficient production automation

Estimated reading time: 8 minutes

TL;DR:

• Control systems are the foundation of modern production automation
• Support real-time integration of machines, robots and sensors
• Proper implementation minimises human error and increases safety
• Cyber security and team competencies needed
• Rethinking robotics and controls increases efficiency by up to several tens of percent

Table of contents

• Introduction
• What are control systems?
• Application of control systems in industry
• Key benefits of implementing control systems
• Challenges in control system design and integration
• Integration of control systems with robotisation
• Practical steps for implementing a control system
• Case study - improving a production line
• Practical lessons from implementation
• Summary
• FAQ

Introduction

Industrial control systems play a fundamental role in the effective management of process lines, machines and robots. Their task is to enable fast and precise regulation of production processes, which in today's reality is becoming a decisive factor for a company's competitiveness. With well-designed control systems, efficiency and quality can be increased and errors due to manual operations can be reduced. In this article, we take a look at what control systems are, what they look like in industrial practice and the benefits and challenges of implementing them. After reading, you will learn how, in a few steps, we can use these solutions to make production more efficient and how Michale Automation can help.

What are control systems?

Control systems can be defined as a set of devices and software responsible for controlling the behaviour of machines, production lines and technological processes. Their operation is based on algorithms that analyse input signals (e.g. sensors, data from video cameras, information from MES or ERP systems) and decide on the appropriate output actions (e.g. actuator start-up, change of belt speed, activation of a robot).

There are several key components that make up an industrial control system:

• PLCs (Programmable Logic Controllers) - are basic, versatile devices designed to implement simple to complex control algorithms, typically used in small to medium-sized applications.
• PACs (Programmable Automation Controllers) - represent the next step in controller development, offering greater resolution of calculations and extensive integration possibilities with various communication protocols.
• Input/output (I/O) systems - responsible for exchanging signals between the control system and the machine or production line.
• SCADA/DCS software - master systems that enable monitoring, visualisation and management of the production process from the operator and management level.

Nowadays, IoT (Internet of Things) solutions are gaining popularity, allowing remote access to machine parameters and entire lines, which significantly increases the scope for real-time process control.

Application of control systems in industry

Control systems not only 'manage' the mechanical aspects of production, but also work with other layers of automation, such as vision systems (which detect defects), industrial robots (which perform repetitive tasks) or MES software (which manages the production schedule in detail). In practice, they can be found in almost every industry:

Heavy industry and metalworking

In an industry based on metalworking, where precision and safety are crucial, well-chosen control systems supervise the operation of CNC machines, hydraulic presses and other equipment used for moulding or cutting. The controller's fast response makes it possible to maintain reproducible product quality even under heavy line loads.

Food industry and packaging

Here, it is important to ensure high repeatability while maintaining food safety standards. Control systems are responsible for controlling temperature, pressure, raw material flow and automatic packaging or labelling. For example, packaging integrity can be monitored and quality deficiencies can be detected through the cooperation of PLCs with vision systems.

Mechanical engineering automation and assembly lines

Complex production lines are often integrated with robots, for example to assemble components. The control system coordinates robot movements, conveyor belt speeds and sensor signals so that the process runs smoothly and without collisions. It is worth mentioning that at Michale Automation we carry out many projects related to the construction of machines and production lines. You can read the details of our range of services at Automation and robotics services.

Key benefits of implementing control systems

Modern industrial plants rely on control systems because they translate directly into increased efficiency and quality. Here are the most important advantages:

Increased productivity

By automating repetitive activities, production cycle times can be reduced, making the whole process more efficient. For the entrepreneur, this means more products coming off the line at the same time, allowing him or her to compete more effectively in the market.

Reducing the risk of human error

Precision control minimises the number of inaccuracies or defects due to the human factor, which is particularly important in industries with high quality requirements. As a result, the company does not incur the costs of complaints or repeat production runs.

Improving safety

Control systems constantly monitor machine operating parameters and incoming sensor signals (e.g. temperature or pressure measurements). Their abnormal indications can result in the automatic shutdown of a machine before a breakdown or dangerous accident occurs.

Reduction in operating costs

Automated operation makes it possible to reduce the need for manpower. In addition, the improved quality and predictability of the process makes it possible to optimise the use of raw materials, energy or consumables. The company therefore achieves greater profitability with the same resources.

Challenges in control system design and integration

Despite the huge potential, implementations of complex control systems can be fraught with challenges:

Technological complexity

Modern systems sometimes require the integration of multiple subsystems - from PLCs to robots to industrial networks based on protocols such as Modbus TCP, EtherCAT or Profinet. Ensuring reliable communication between them is a complex process.

Need to prepare staff

Implementing the control system itself is one thing, but the key factor is the team. Operators, production leaders and maintenance services must be trained to take full advantage of the new system's capabilities, respond appropriately to alerts and diagnose any faults.

Digital security

There is increasing talk of the need to implement cyber security principles in the area of industrial control systems. Ineffective security in a robot or machine control system can expose a company to hacking attacks and can even lead to production stoppages.

Cost and life cycle

The provision of quality control components involves an investment that must be considered in detail. The discussion of return on investment (ROI) includes not only the purchase price of hardware and software, but also the future costs of maintenance, upgrades and potential upgrades.

Integration of control systems with robotisation

Increasing robotisation in various industries is making control systems the brains of the entire production process. They combine the world of digital planning (e.g. ERP system) with the real activities performed by machines and robots.

For example, the robot can receive instructions directly from the PLC, which has configured the detailed sequence of steps needed to weld a component. When the robot finishes its work, this information is sent to the host layer of the system, so that inventory can be updated or tool wear data can be transmitted. A full information exchange loop is therefore realised, from planning in the production system to real-time control of task execution.

Michale Automation's collaboration with renowned robot suppliers, including SIASUN, is worth highlighting. Their industrial robots can be comprehensively integrated into the production line. For details of SIASUN robots, see the description of the The SIASUN SR25A-12-2-01 robot - an example of innovative robotisation.

Practical steps for implementing a control system

Proper preparation is half the battle in an automation or robotics project using control systems. The most important steps are described below:

1. Analysis of needs and opportunities

The first step should be to define exactly which processes are to be controlled and to what extent. Is it just about belt speed control and temperature control, or is it about advanced robotisation of the packaging line? At this stage, issues relating to key industry requirements (e.g. moisture protection in the food sector or occupational safety in heavy industry) are resolved.

2. choice of technology

The most important thing is to choose the right PLCs, PAC controllers, communication protocols and possibly SCADA systems. In a large number of cases, it is worth using the experience of integrators such as Michale Automation, who are able to advise on hardware and software platforms tailored to the specific process.

3. design and testing

At this stage, a detailed machine or line control diagram is created. Functionality is divided into modular blocks, which facilitates subsequent diagnostics. Once the controllers have been programmed and the network configured, simulation tests are carried out (the so-called Factory Acceptance Test), before the system is put into the customer's final installation.

4. installation and commissioning

When the machines or lines arrive at the production facility, the integration team installs the equipment, cabling and ancillary equipment. There is also a production start-up (known as Site Acceptance Test). At this stage, communication between systems, including controllers and robots, is checked.

5. training and commissioning

Even the best control system can be useless if employees do not know how to operate and service it. Training for operators, the maintenance team and production engineers includes interpreting alarms and safely stopping the machine. Only then is the line ready to be integrated into the daily production cycle.

6. service and maintenance

The service life and reliability of control systems depend largely on regular maintenance and preventive measures. A company can opt, for example, for a service package to efficiently rectify failures and replace worn parts. You can read more about services related to service and bench maintenance in the Service and maintenance of automation workstations.

Case study - improving a production line

The implementation of control systems is best illustrated by a concrete example. Suppose a company in the metal industry wanted to improve the efficiency of welding components of steel structures. The process was previously based on manual work by welders, which resulted not only in increased labour costs, but also in constant fluctuations in weld quality.

Analysis and decision on robotisation

Michale's team of automation specialists assessed that the most effective method was to implement a robotic welding station together with a modern control system. As a result, the company has reduced cycle times and the number of quality deficiencies. If you would like to learn more about robotic welding, it is worth exploring our offering Robotisation of welding.

Integration and testing

The selection of PAC controllers and controllers was followed by a comprehensive combination with an industrial robot, a rotary table and next-generation sensors. This was followed by thorough productivity and quality tests. As expected, the line's productivity increased by 40% and the number of defects fell by several per cent.

Effects of implementation

• Reduced production time per steel component from 4 to 2.5 minutes
• Improved weld consistency - only 0.5% quality complaints
• Reduced labour costs and improved operator safety

Practical lessons from implementation

A few key recommendations can be made from the examples described and from experience at other sites:

• Start with a thorough analysis of your needs and technical conditions. It is not worth investing in far advanced solutions if they will not be used to their full potential.
• Remember safety - the automated workstation must comply with health and safety regulations and machine operating regulations.
• Ensure staff training. It is worth factoring into project budgets the costs associated with staff education.
• Plan for the long term. Take into account the possible expansion of the control system with additional modules or integration with new equipment.

Summary

Control systems are the heart of any modern production line. They are responsible for controlling equipment in real time, combine information from multiple levels of automation (sensors, robot, vision systems, ERP) and guarantee smooth process management. Their implementation allows the company to reduce costs, improve safety and achieve higher quality production.

At Automatyka Michale, we have an excellent understanding of the challenges and needs of businesses in implementing advanced control systems. As an official distributor of SIASUN robots, we combine state-of-the-art technological solutions with many years of experience in the Polish industrial market. If you are considering automation and robotisation of selected processes in your plant, we invite you to contact us.

Key information to remember:

• Control systems should always be tailored to the specific needs and conditions of the company.
• Critical to the success of the implementation is careful planning and the involvement of a well-trained team.
• Robotisation and control systems can make a significant difference in reducing costs, improving quality and increasing productivity.

We encourage:

• Check out other automation and robotics proposals at Robotisation - a modern approach to automation
• Ask questions about technical details or project planning via the contact form
• Subscribe to our newsletter to keep up to date with the latest news from the world of automation and robotics

With the right implementation of control systems, your company can take a significant step towards improving production performance, reducing costs and gaining a competitive advantage. If you need support in designing or integrating solutions, contact us - the Michale Automation team is here to provide expert assistance at every stage of the project.

FAQ

How long does it take to implement automation?
Implementation time depends on the scale of the project and the complexity of the processes. It can range from a few weeks for smaller improvements, to several months for extensive solutions and integration of multiple systems.

Does robotisation only pay off for large companies?
Currently, more and more small and medium-sized enterprises are opting for robotisation. Reduced technology costs and more flexible solutions make return on investment possible even with lower production volumes.

What competencies must the control systems team possess?
The team should have knowledge of PLC programming, automation system diagnostics, as well as a grounding in the area of mechanics and electronics. Knowledge of safety procedures and rapid response to alerts is also key.