Industrialization has been a powerful word for the past two centuries. From the birth of steam engines to the development of computational systems, industrialization has changed how industries work. New technologies have emerged, and demand for products has been efficiently supplied via mass production equipment. Overall, economies have continued to improve.
Towards the end of the twentieth century, the booming trend on converging machinery and automated control systems brought huge changes in various
industries. The major applications of industrial control systems lie within:
· Field instruments, like temperature and pressure transmitters in power plants and oil and gas operations and factories;
· Motion control on robotics for automotive assembly and metal processing;
Material injection and painting of products;
· Building automation on security access, occupancy sensors, and air handling units;
· Data acquisition for complex control systems in production lines and business operations;
Virtual prototyping for new products;
Medical electronics, and equipment controllers.
Instead of manually adjusting settings, knobs, and dials, machines can now be calibrated and operated via software. This enables repeatability in producing
same quality and design again and again. This also reduces the need for operators at every station during production which, in turn, also decreases human error.
The software also eliminates time otherwise spent manually operating machines, and factories can now operate 24 hours a day, even with less manpower.
Industrial control systems are cost-efficient solutions for almost every type of business and production.
Precision mechanics and machinery are also now possible with control systems. Seemingly impossible to do before, adjustments on machinery can
now be done more precisely. For example, temperature control on heated materials can be set accurately down to the decimal number . Lasers on
production can now be controlled to cut through materials with the utmost precision, based on designs and industry standards. Complex designs that require
hair-like gears and holes can now be created with ease. These systems remove barriers on product design that were brought by earlier production methods, and they allow automotive companies, electronic manufacturers, and other industries to explore newer designs that enjoy even better performance. These systems also allow industries to implement a tighter level of quality control on their operations.
Sensors and visual input enable controllers to monitor performance in real time. Motion sensors can indicate which parts of machinery don’t work, which
takes out the guessing game that comes with inspection and repair methods. This process saves the company time and money, as technicians don’t need to tear the machines apart just to see which parts are not working. Early detection and repair also reduce the likelihood of major outages.