A programmable logic controller (PLC) or programmable controller is an industrial computer that has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, machines, robotic devices, or any activity that requires high reliability, ease of programming, and process fault diagnosis.
Instrumentation is a collective term for measuring instruments, used for indicating, measuring, and recording physical quantities. It is also a field of study about the art and science about making measurement instruments, involving the related areas of metrology, automation, and control theory. The term has its origins in the art and science of scientific instrument-making.
Automation describes a wide range of technologies that reduce human intervention in processes, mainly by predetermining decision criteria, subprocess relationships, and related actions, as well as embodying those predeterminations in machines. Automation has been achieved by various means including mechanical, hydraulic, pneumatic, electrical, electronic devices, and computers, usually in combination. Complicated systems, such as modern factories, airplanes, and ships typically use combinations of all of these techniques. The benefit of automation includes labor savings, reducing waste, savings in electricity costs, savings in material costs, and improvements to quality, accuracy, and precision.
A distributed control system (DCS) is a computerized control system for a process or plant usually with many control loops, in which autonomous controllers are distributed throughout the system, but there is no central operator supervisory control. This is in contrast to systems that use centralized controllers; either discrete controllers located at a central control room or within a central computer. The DCS concept increases reliability and reduces installation costs by localizing control functions near the process plant, with remote monitoring and supervision.
Industrial process control (IPC) or simply process control is a system used in modern manufacturing which uses the principles of control theory and physical industrial control systems to monitor, control and optimize continuous industrial production processes using control algorithms. This ensures that the industrial machines run smoothly and safely in factories and efficiently use energy to transform raw materials into high-quality finished products with reliable consistency while reducing energy waste and economic costs, something which could not be achieved purely by human manual control.
Automatic test equipment or automated test equipment (ATE) is any apparatus that performs tests on a device, known as the device under test (DUT), equipment under test (EUT) or unit under test (UUT), using automation to quickly perform measurements and evaluate the test results. An ATE can be a simple computer-controlled digital multimeter, or a complicated system containing dozens of complex test instruments capable of automatically testing and diagnosing faults in sophisticated electronic packaged parts or on wafer testing, including system on chips and integrated circuits.
Computer-integrated manufacturing (CIM) is the manufacturing approach of using computers to control the entire production process. This integration allows individual processes to exchange information with each part. Manufacturing can be faster and less error-prone by the integration of computers. Typically CIM relies on closed-loop control processes based on real-time input from sensors. It is also known as flexible design and manufacturing.
A process automation or automation system (PAS) is used to automatically control a process such as chemical, oil refineries, paper and pulp factories. The PAS often uses a network to interconnect sensors, controllers, operator terminals and actuators. A PAS is often based on open standards in contrast to a DCS, which is traditionally proprietary. However in recent times the PAS is considered to be more associated with SCADA systems.
Direct digital control is the automated control of a condition or process by a digital device (computer). Direct digital control takes a centralized network-oriented approach. All instrumentation is gathered by various analog and digital converters which use the network to transport these signals to the central controller. The centralized computer then follows all of its production rules and causes actions to be sent via the same network to valves, actuators, and other heating, ventilating, and air conditioning components that can be adjusted.
Lights-out manufacturing is the methodology of fully automating the production of goods at factories and other industrial facilities, such as to require no human presence on-site. Many of these factories are considered to be able to run "with the lights off," but few run exclusively lights-out production. For example, in computer numerical control machining, the presence of human workers is typically required for removing completed parts and setting up tombstones that hold unfinished parts. As the technology necessary for total automation becomes increasingly available, many factories are beginning to use lights-out production between shifts to meet increasing production demand or to save money on labor.
Stored program control (SPC) is a telecommunications technology for telephone exchanges. Its characteristic is that the switching system is controlled by a computer program stored in a memory in the switching system. SPC was the enabling technology of electronic switching systems (ESS) developed in the Bell System in the 1950s, and may be considered the third generation of switching technology. Stored program control was invented in 1954 by Bell Labs scientist Erna Schneider Hoover, who reasoned that computer software could control the connection of telephone calls.
An industrial control system (ICS) is an electronic control system and associated instrumentation used for industrial process control. Control systems can range in size from a few modular panel-mounted controllers to large interconnected and interactive distributed control systems (DCSs) with many thousands of field connections. Control systems receive data from remote sensors measuring process variables (PVs), compare the collected data with desired setpoints (SPs), and derive command functions that are used to control a process through the final control elements (FCEs), such as control valves.
Autonomation describes a feature of machine design to effect the principle of jidoka (自働化)（じどうか jidouka), used in the Toyota Production System (TPS) and lean manufacturing. It may be described as "intelligent automation" or "automation with a human touch". This type of automation implements some supervisory functions rather than production functions. At Toyota, this usually means that if an abnormal situation arises, the machine stops and the worker will stop the production line. It is a quality control process that applies the following four principles:
- Detect the abnormality.
- Stop.
- Fix or correct the immediate condition.
- Investigate the root cause and install a countermeasure.
The following outline is provided as an overview of and topical guide to automation:
Manufacturing engineering or production engineering is a branch of professional engineering that shares many common concepts and ideas with other fields of engineering such as mechanical, chemical, electrical, and industrial engineering. Manufacturing engineering requires the ability to plan the practices of manufacturing; to research and to develop tools, processes, machines, and equipment; and to integrate the facilities and systems for producing quality products with the optimum expenditure of capital.
Instrumentation and control engineering (ICE) is a branch of engineering that studies the measurement and control of process variables, and the design and implementation of systems that incorporate them. Process variables include pressure, temperature, humidity, flow, pH, force and speed.
Packaging machinery is used throughout all packaging operations, involving primary packages to distribution packs. This includes many packaging processes: fabrication, cleaning, filling, sealing, combining, labeling, overwrapping, palletizing.
Automation engineering is the provision of automated solutions to physical activities and industries.
Automation technicians repair and maintain the computer-controlled systems and robotic devices used within industrial and commercial facilities to reduce human intervention and maximize efficiency. Their duties require knowledge of electronics, mechanics and computers. Automation technicians perform routine diagnostic checks on automated systems, monitor automated systems, isolate problems and perform repairs. If a problem occurs, the technician needs to be able to troubleshoot the issue and determine if the problem is mechanical, electrical or from the computer systems controlling the process. Once the issue has been diagnosed, the technician must repair or replace any necessary components, such as a sensor or electrical wiring. In addition to troubleshooting, Automation technicians design and service control systems ranging from electromechanical devices and systems to high-speed robotics and programmable logic controllers (PLCs). These types of systems include robotic assembly devices, conveyors, batch mixers, electrical distribution systems, and building automation systems. These machines and systems are often found within industrial and manufacturing plants, such as food processing facilities. Alternate job titles include field technician, bench technician, robotics technician, PLC technician, production support technician and maintenance technician.
PLC technicians design, program, repair, and maintain programmable logic controller (PLC) systems used within manufacturing and service industries ranging from industrial packaging to commercial car washes and traffic lights.
