DETROIT – There are many different control systems in industrial automation, but they all serve the common purpose of controlling the process. If you’re looking to reduce manpower and automate your production process, you’re primarily searching for the leading control systems to use. We’ll discuss the four main types of control systems used in industrial automation, so you can understand what each type does and how it is used in industry.

Remote Terminal Units (RTUs)

Remote terminal units (RTUs) qualify as one of the most reliable industrial automation solutions. RTU is a microprocessor-controlled electronic device that interfaces objects in the physical world to a distributed control system or SCADA (supervisory control and data acquisition) system by transmitting telemetry data to a master system, and using messages from the master supervisory system to control actuators and devices in the physical world.

RTU systems are commonly found in water, gas, and electric distribution industries, as careful monitoring and control are needed to ensure effective distribution over large geographic regions.

These units require careful prototyping and PCB assembly to ensure they perform as intended. Careful calibration is often necessary to prevent mistakes and more accurately interpret incoming data. 

Robotics and Industrial Motion Control

Robotics and industrial motion control are some of the most advanced, yet commonly used automation systems in manufacturing. There’s been a surge in robotics demand over the past few years, with robots being programmed to perform tasks such as welding and assembly, loading or unloading parts, and palletizing items.

Industrial robots comprise several significant components, including the controller, actuators, sensors, and end effectors. The controller is the robot’s “brain” and receives input from the sensors to determine movement commands for the actuators.

The actuators convert these electrical signals into mechanical motion that moves the robot’s arms and grippers. Sensors are used to detect various aspects of their environment, such as proximity to objects, temperature, force, and torque. These sensors are used as feedback for the controller to make adjustments in real-time.

The end effector is the mechanical component that interacts with parts on a production line, such as welding guns or suction cups.

Programmable Logic Controllers

A programmable logic controller (PLC) is a type of industrial computer that monitors inputs from machines and switches outputs to motors, valves, and other equipment based on a set of programmed instructions. The first PLC was developed in the early 1970s by Allen-Bradley, and they have become a staple in industrial automation due to their flexibility, low cost, and ease of use. PLCs are often used with RTUs to provide more comprehensive control over a system.

Distributed Control Systems

A distributed control system (DCS) is an industrial automation system in which controllers are spread throughout the plant or factory. This allows for more decentralized control over machines and processes, improving efficiency and response time. DCSs usually consist of central processing units (CPUs), a network infrastructure, and I/O modules that allow controllers to communicate with sensors and actuators.

Modern DCSs are typically used in more extensive industrial settings, such as oil refineries and battery manufacturing plants, but can also be helpful for smaller operations like sewage treatment centers. Using a distributed control system allows operators to monitor the status of thousands of machines simultaneously without visiting each one individually; this is ideal for industrial settings where human-machine interaction is dangerous. Remote video monitoring further ensures that operators can maintain oversight safely and efficiently.

Using a distributed control system allows operators to monitor the status of thousands of machines simultaneously without visiting each one individually; this is ideal for industrial settings where human-machine interaction is dangerous.

While there are numerous other control systems in industrial automation, these four should give you a good idea of what types are available. It’s important to remember that every system has its pros and cons, so make sure to do your research before investing in one.

This article was provided by James Hunt.