Even the most highly automated operations in manufacturing and processing plants are typically still far from full autonomy, but implementing the right automation technologies today makes it possible to add these more far-reaching features later.
My article in the June 2021 issue of Plant Services, titled Transitioning from Basic to Adaptive Automation, discusses how edge solutions pave the way for more integrated operations.
A Spectrum of OperationsMost modern facilities have moved past purely manual operations by incorporating automation, and perhaps by optimizing production to some extent. PLCs and HMIs have made this possible, but even better computing and remote connectivity options are needed to advance to the next phase of adaptive operations.
Advancing to AdaptiveTo achieve genuinely adaptive operations, the automation systems must locally analyze, predict, and resolve issues, requiring only minor human involvement for confirmation or exception handling. The right technologies are needed to connect and truly integrate all aspects of processes and personnel.
Foundation at the EdgeMost plant operators today have a fairly localized perspective of operations, based on the PLC/HMI data at hand, augmented by a few simple tools. Maintenance activities are likely reactive and costly due to required travel and unexpected downtime. Edge computing – in the form of edge controllers, edge computing devices, and edge gateways – is necessary to unlock:
Edge controllers are an evolution of PLCs, able to perform real-time control while also incorporating a general-purpose operating system in a safe and cooperative manner. Retrofitting an edge controller into an existing operation makes advanced computing possible, while using an edge controller for new installations provides an all-in-one solution.
Advancing to Adaptive AutomationEdge computing delivers immediate benefits, helping workers become ‘super operators’, by giving them visibility into more of the value chain by using available analytical tools to reduce risk and improve overall value. Edge controllers future-proof systems and make them ready for the eventual and inevitable move toward adaptive automation.
As edge computing implementations advance, the state of industrial automation will progress from basic to optimized, and eventually to a high degree of adaptive operation. Throughout all these phases, the secure remote connectivity offered by edge computing hardware and software will endure as an essential requirement.
More information on edge computing can be found on the Emerson industrial edge control solutions page.
This post originally appeared on LinkedIn.