By combining the advantage of Industry 4.0 models with advanced data analytics, Artificial Intelligence (AI) and Industrial Internet of Things (IIoT) we can introduce speed and precision to a wide range of factory operations, enhancing productivity and reliability. The rapid evolution of this technology and its integration across the enterprise is reshaping the ways manufacturers operate and produce high-quality goods.

Benefits include:

• Reduced periodic and manual checking
• Increased productivity
• Reduced production cost
• Improved product quality
• Increased flexibility
• Improved safety

Outlined below are three main levels of industrial automation applications:

Level 1 - Supervisor Level:

Mainly PC-based systems, such as industrial PCs (rack-mounted and panel) equipped with supplier-specific industrial process-control software for process parameterization and visualization. The intercommunication is based on a Gbit LAN or higher bandwidth backbone or Wireless topologies (WLAN). To avoid data loss and for safety reasons, Uninterruptable Power Supplies (UPS) are installed.

Core Components: Industrial PC, Panel PC, HMI, WLAN

Level 2 - Control Level:

This is the automation systems level where automation programs are executed. Systems on this level require high real-time capability and are based on a special controller architecture with its own proprietary OS running on it. High real-time compliant intercommunication bus protocols (according to IEEE 1588) are essential here.

Core Components: PLCs, HMI, Field Bus (CAN, EtherCAT, Profibus etc ), WLAN, Safety (SIL).

Level 3 - Field Level:

This level includes all terminal equipment, such as sensors and actuators collaborating with a peripheral PLC or remote I/O system, offering pre-procession of the collected data and communication to the main PLC via field bus.

Core Components: Micro PLC, Motor Control, Industrial Sensors, Actuator Drivers, Relays, Switches, Wireless Control (RFID, wireless sensor networks using IEEE 802.15.4 topology)