Industrial controls are systems and devices used in manufacturing to automatically monitor, manage, and perform industrial processes. Industrial controls can include hardware like sensors, actuators, and programmable logic controllers (PLCs), as well as software for managing manufacturing processes.
Industrial controls play a major role in optimizing manufacturing processes by reducing human error, maintaining consistent product quality, and ensuring all safety and environmental standards are being met. They are used across a wide range of industries, including automotive, aerospace, and chemical manufacturing, to name a few.
Industrial control solutions use sensors to collect real-time data from machines and processes. This data is leveraged by various controllers, like PLCs and distributed control systems (DCS), to carry out processes based on predefined instructions. Based on these instructions, the controller then sends commands to equipment and machinery, such as actuators or motors, to adjust the process as needed. These systems ensure processes run efficiently, safely, and with minimal human intervention.
What are the Benefits of Industrial Controllers?
When incorporated into wider manufacturing processes, industrial controllers provide a wide range of benefits. These benefits include:
- Increased efficiency: Industrial controllers enable manufacturers to automate processes, helping to reduce downtime and optimize operations for greater productivity.
- Improved accuracy: These systems and devices ensure precise control over machinery and processes. This enables processes to be carried out with minimal human intervention, reducing errors and enhancing product quality.
- Greater worker safety: Industrial controllers monitor and regulate dangerous conditions, helping to prevent accidents. They also enable workers to monitor dangerous processes from a safe location.
- Improved cost efficiency: Improved process efficiency, less waste, and fewer errors add up to cost savings for manufacturers.
- Real-time monitoring and control: Industrial controllers provide immediate feedback and real-time data, which can be leveraged for quick adjustments and improved decision-making in complex operations.
What are Different Types of Industrial Control Equipment?
While the types of industrial controllers used depend on the exact needs of the manufacturer, common industrial control equipment includes:
- Programmable logic controllers (PLCs)
- Human-machine interfaces (HMIs)
- Sensors
- Actuators
- Variable frequency drives (VFDs)
- Distributed control systems (DCS)
- Supervisory control and data (SCADA) systems
- Relays
- Industrial robotics
