Industrial control systems - how to design them and integrate them with modern automation solutions?

Estimated reading time: approx. 10 minutes

TL;DR:

• Industrial control systems are the foundation for efficient and safe production lines.
• Key components include PLCs, industrial networks and I/O devices.
• Integration with robotisation and vision systems increases productivity and plant flexibility.
• Real-time data monitoring allows for quick decisions and reduced downtime.
• System security and comprehensive service are important aspects of the plant's long-term operation.

Table of contents

• Introduction
• What are industrial control systems?
• Key elements of modern control systems
• How to plan an industrial control system?
• Integration of industrial control systems with robotisation
• Control systems versus production monitoring and data analysis
• Selected challenges in implementing industrial control systems
• How can Michale Automation help?
• Examples of industrial control system applications
• Practical conclusions and recommendations
• Summary
• FAQ

Introduction

Industrial control systems are nowadays the foundation of any efficient production line. Ensuring smooth and reliable control of machines or equipment has a direct impact on the quality, safety and speed of product manufacture. In an era of increasingly complex industrial processes, rising labour costs and changing market requirements - well thought-out automation and control systems allow companies to increase competitiveness and adapt to constant challenges.

From this article, you will learn why industrial control systems are so crucial in today's reality, what it looks like to design and implement them, and understand the benefits that integrating control with modern technologies such as robotics and vision systems can bring. We will also cover the topic of integrating multi-level whole plant systems, which is often the key to staying competitive in an increasingly automated world. We look forward to reading!

What are industrial control systems?

Industrial control systems are a set of systems, devices and software designed to manage the operation of machines, production lines or entire plants. Their main purpose is to provide:

• continuity and stability of processes,
• safety (of both operators and equipment),
• optimum performance,
• the ability to adapt quickly to changes in production.

They are distinguished above all by their high resistance to environmental conditions (e.g. temperature, dust, vibration) and reliability in 24/7 operation. In control systems, 'intelligence' - reacting to sensor data and optimising processes in real time - is also key.

Key elements of modern control systems

PLCs and industrial computers

Industrial PLCs (Programmable Logic Controllers) or specialised industrial computers are the basis of any control system. With these we can:

• process and analyse sensor signals,
• control actuators, valves, robots, vision systems,
• collect data for further analysis.

PLCs are used in most standard production processes, where reliability and simplicity of operation are required. Industrial PCs, on the other hand, are coming into their own in more advanced implementations, such as when integrating with AI systems or processing large amounts of data (so-called Big Data).

Industrial networks and communication protocols

No matter how precisely a controller is programmed, it must be able to communicate with other devices and systems in the company. In the industrial world, protocols such as:

• Ethernet/IP,
• Profinet,
• EtherCAT,
• Modbus,
• OPC UA.

Real-time (or near real-time) communication allows operators to maintain line continuity and respond rapidly to any irregularities.

Input/output devices (I/O)

Sensors, operator buttons, signalling devices or vision cameras send process status information (inputs) to the controller. The outputs, on the other hand, enable physical control of the machine - the decision to start a drive, open a valve or initiate a robot. Modern systems are characterised by high precision and high data transmission rates, which translate into dynamic process monitoring.

How to plan an industrial control system?

Analysis of production and environmental needs

The first step is to determine the production requirements. Are we dealing with a continuous or batch process? On what scale is the production to take place? What are the environmental conditions (e.g. high temperature, humidity or explosive atmospheres) in the plant? Is robotisation also involved - e.g. welding stations, packaging lines or robotic quality control stations? Clear answers to these questions make it possible to match the right equipment and design stable control systems.

Choice of hardware and control architecture

Based on an analysis of production needs, a specific system architecture is selected - centralised or distributed control system. In the former case, all key decisions are processed at a single point, while in the distributed approach, controllers can be located closer to individual machines, which promotes faster response times and a higher level of safety for a given process.

Software and visualisation (SCADA/HMI)

In modern industrial installations, automation alone is not enough. SCADA (Supervisory Control and Data Acquisition) visualisation systems and HMI (Human Machine Interface) panels play a huge role. They enable operators to have a real-time overview of the line's operation, to see key parameters (e.g. temperature, pressure, rotation speed) and to react quickly to alarms. Visualisation minimises the risk of downtime while introducing ergonomics and transparency into production management.

Integration of industrial control systems with robotisation

The growing demand for flexibility and automation is making robotisation a key component of industrial control systems. At Michale Automatika, as an official distributor of SIASUN robots, we implement customised robotic workstations for companies. But how do you actually combine line control with industrial robots to maximise the potential of these devices?

Why integrate robots with existing controls?

• Process optimisation: The robots operate precisely and continuously, allowing productivity to be increased at the assembly, welding or packaging stages, for example.
• Minimising errors: Properly configured control systems and robots significantly reduce the risk of production defects.
• Saving time and labour costs: One robot can replace several manual workstations and, in addition, provide a constant work rate around the clock.

How is the integration process taking place?

- Requirements analysis: It establishes where the robot can bring the greatest benefit (e.g. whether to focus on a welding, packaging or quality control station).
- Technology selection: A suitable industrial robot model, drive parameters and possible vision systems are selected.
- Implementation in the controller: It is necessary to program the PLC appropriately to control the robot (e.g. by synchronising workpiece pick-up and put-down).
- Testing and optimisation: After correct implementation, tests are carried out, safety parameters are modified and work cycles are refined.

Many companies are choosing to robotise various stages - from welding to loading and unloading machinery. However, the key is to understand that even the best robot will not be fully effective if it lacks a well thought-out and reliable control system. If you would like to learn more about robotisation services, please visit
robotisation in our company.

Control systems versus production monitoring and data analysis

Another increasingly important aspect in the operation of fully automated plants is the ongoing monitoring of production. Many entrepreneurs aim to integrate control systems with software such as ERP (Enterprise Resource Planning) or MES (Manufacturing Execution System). This makes it possible to:

• observe the progress of orders in real time,
• optimise the operation of specific equipment (e.g. energy consumption),
• automatically generate reports,
• easier management of resources (planning of raw materials, organisation of logistics).

In addition, the data collected by control systems can be used to analyse productivity, assess quality and detect anomalies. For example, early detection of a drop in robot performance or an increase in energy consumption in a particular area allows remedial measures to be taken immediately, before a more serious breakdown or downtime occurs.

Selected challenges in implementing industrial control systems

Complexity of integrating devices and protocols

Today's plants use a variety of technologies - from legacy systems to the latest robots and controllers. Ensuring that they work seamlessly together requires an experienced automation design team.

Systems security (cyber security)

Control systems, which often rely on a network connection, are vulnerable to hacking attacks or unauthorised intrusions. Good practices include network segmentation, permission control, data encryption and regular updates, among others.

Maintenance and service

In an era of rapid market change, it is important to have a well thought-out service strategy and to establish regular maintenance schedules. The control system requires software updates and periodic checking of key components. Technical support is particularly important for extensive lines combining multiple machines.

How can Michale Automation help?

Michale Automation is a team of experienced engineers and specialists who have been designing, implementing and servicing industrial control systems for a variety of industries for years. Our company provides end-to-end solutions - from the idea, through the design and construction of machines or production lines, to the implementation and training of employees.

What makes us different?
- Customised approach: we start each project by understanding the client's needs, analysing the industry and production environment.
- Experience in robotisation: We are an official distributor of SIASUN robots, which allows us to create robotic workstations with a high degree of flexibility.
- Comprehensive support: we provide not only the design and delivery of equipment, but also a range of additional services, such as the implementation of robotic welding, painting or packaging stations.
- Turnkey approach: We provide a turnkey control system and maintenance service to ensure the long-term reliability of the production process.

If you would like to find out more about robotisation services, please visit
robotisation in our company.

Examples of industrial control system applications

Robotisation of welding

In welding processes, automatic control plays one of the most important roles - ensuring the robot's uniformity and precision throughout the cycle. The integrated control allows:

• maintain constant current and voltage parameters,
• adjust the speed of the bond,
• monitor the temperature and quality of the weld in real time.

The result is reproducible and high quality and reduced material waste. If you are interested in the topic of welding robotics in more depth, check out
Robotisation of welding - our offer.

Robotisation of packaging

Packaging at the end of the production line often requires fast and repetitive operations. The use of robots with the appropriate control system allows:

• automatically detect and sort products,
• package them up,
• prepare for palletisation and dispatch.

Integrating the controller with the robot makes the whole process run smoothly and allows staff to concentrate on supervisory tasks.

ROI calculation in robotisation

When considering whether to invest in industrial control systems with robotic workstations, it is worth performing a profitability analysis. It is crucial to compare the investment outlay with the anticipated savings, taking into account both the reduction in production time and the reduction in errors.
For a quick and efficient estimate of cost-effectiveness, you can use the
ROI calculator welding robotisation.

Of course, an analogous procedure can also be applied to other processes, such as painting, sanding or packaging.

Practical conclusions and recommendations

- Start with an analysis: Before you plan to expand or upgrade the control system in your plant, carry out a thorough process and needs analysis. Take into account current and future requirements (e.g. planned production growth).
- Ensure the right choice of technology: PLCs are perfect for standard processes, but you may need more sophisticated solutions (industrial computers, vision systems, integration with AI).
- Plan for the long term: Implementing control and robotisation requires an investment. However, it is worth taking a long-term view, taking into account production stability, quality issues, employee safety and the possibility of scaling the system in the future.
- Think about training: Success in automation is not only about state-of-the-art equipment, but also a workforce that is properly prepared for change. Introducing operators to the operation of control systems and robots avoids numerous errors and downtimes.
- Take care of the service: Regular maintenance, replacement of wear and tear components and software updates are the best way to avoid sudden failures.

Summary

Industrial control systems are the backbone of operations in automated production plants. They are responsible for the smooth, safe and efficient operation of machines and facilitate integration with modern solutions such as industrial robots, vision systems or ERP platforms. However, it is important that the process of designing and implementing control systems is carried out with due care - from needs analysis, through technology and equipment selection, to implementation and employee training.

Whether in large factories or smaller plants, industrial automation helps to reduce errors, optimise costs and respond rapidly to any changes within production. If you are wondering what our detailed offerings in the area of control system design and implementation services look like, please visit
Industrial automation services.

With many years of experience and knowledge of the specifics of different industries, Michale Automatics can offer you comprehensive support on the way to improving production processes and increasing the profitability of your business.

We encourage:
- read other articles on our blog,
- use the ROI calculator,
- contact for a detailed analysis of your production line.

Share this article or leave a comment if you have additional questions. Together, let's build a future based on reliable, integrated and efficient control systems!

FAQ

How long does it take to implement automation in a company?
The implementation time depends on the complexity of the processes and available resources. It can range from a few weeks for simple solutions to several months for extensive projects and large integrations.

Does automation mean redundancies?
Usually no. Automation allows employees to focus on more creative and strategic tasks, while freeing them from monotonous tasks. Many companies use this to retrain and develop their team professionally.

Does robotisation only pay off for large companies?
Today, advances in technology are leading more and more small and medium-sized companies to turn to robotisation. Costs are coming down and flexible solutions can deliver a favourable return on investment even for smaller operations.