What is process automation?
Manufacturing process automation has paved the way for safer, more efficient and more productive manufacturing plants. With human intervention and error minimised, manufacturers are reaping the rewards of more consistent, streamlined production processes. But what exactly is industrial automation, and how can it help your business? Bürkert explains everything you need to know about process automation here.
What is manufacturing process automation?
Manufacturing process automation involves using control systems that leverage technology, including specialised equipment and software, to automate production processes. This area of industrial automation utilises an interconnected network of valves, actuators, controllers, sensors and other hardware to monitor and control process parameters, such as temperature, pressure and valve switching – to name but a few.
What are the benefits of manufacturing process automation?
Manufacturing process automation provides manufacturers with a number of key benefits. Chief among them is the minimisation of human input and, therefore, error. Where once an operator was required to monitor analogue and digital measurements, sensors and software now monitor performance instead. Any deviation from the norm results in an automatic adjustment, maintaining operational efficiency, safety and productivity.
Industry applications for manufacturing process automation
Manufacturing process automation enables process manufacturers to develop consistently high-quality products that can be delivered to the customer quicker. For instance, in the production of pharmaceuticals, food and beverages. Remote monitoring also reduces the risks to human safety in challenging operating environments, such as those encountered in oil and gas production or in the chemical industry.
Types of manufacturing process automation
The growth in manufacturing process automation shows no signs of slowing down and is likely to continue its upward trajectory for many years to come. Bürkert continues to be at the forefront of this trend, thanks to our Efficient Device Integration Platform (EDIP) that encompasses sensors, fluidic control devices and control units to provide manufacturers with a modular, expandable network of industrial automation devices.
Our EDIP-equipped technology supports the following types of process automation:
Centralised automation
Centralised automation entails combining a programmable logic controller (PLC), control components and a power supply in a single, centralised location – typically a control cabinet. This method of industrial automation follows a control pyramid structure, whereby sensor data is transmitted upwards to the PLC for control commands to then be transmitted back down the pyramid to the actuators.
Bürkert offers an impressive range of hardware for centralised automation systems. A prime example is the compact Type 8652 AirLINE valve island, which is optimised for installation at the bottom of the control cabinet and features a user-friendly LC display for quick and easy diagnostics. We also provide purpose-built control cabinets that can be configured to your specific requirements for even greater process reliability.
AirLINE – the valve island optimised for process automation
- Safety-related shut-off of valves possible
- Higher plant availability with PROFINET S2 (system redundancy)
- Process reliability through pneumatic functions
- Optimised for installation at the bottom of the control cabinet
- EX-variants: ATEX / IECEx Zone 2, CCC, cURus HazLoc CL I, II, III Div 2
Decentralised automation
The more modern and increasingly popular decentralised automation concept removes the hierarchical control pyramid structure and replaces it with a network of interconnected devices. Control is distributed to dedicated, autonomous controllers throughout the system. This results in less wiring, less maintenance, and the ability to integrate a new process with minimal downtime or impact on productivity.
Bürkert can provide intelligent pneumatic process control valves for all your production processes. Decentralised automation systems integrate key automation functions – such as pilot valves, electrical and optical position feedback, and fieldbus interfaces – within the process valves themselves. As such, this flexible concept significantly reduces the number of cables and compressed air lines needed.
We offer a complete range of intelligent and uniquely integrated solutions for decentralised automation. For instance, the Type 8691 control head delivers contact-free, inductive valve position registration for the decentralised automation of Bürkert process valves in our ELEMENT range. Meanwhile, the Type 8694 digital electropneumatic positioner provides contact-free positioning with remote setpoint adjustment via a 4 - 20 mA signal or AS-Interface.
Control head for decentralised automation of ELEMENT process valves
- Contact-free inductive valve position registration (Teach function)
- Colour illuminated status display
- Integrated pilot air duct in the actuator
- Fieldbus interface AS-Interface, IO-Link or Bürkert system bus (büS)
- With ATEX II cat. 3G/D / IECEx approval
Process automation components from Bürkert
Our aforementioned Efficient Device Integration Platform (EDIP) has paved the way for the intelligent networking of devices. This is thanks to the Bürkert system bus digital interface, which is based on (and compatible with) the CANopen industrial standard. Other popular industry standards – such as PROFINET, EtherNet/IP, Modbus TCP and PROFIBUS – can also be integrated using our Type ME43 fieldbus gateway.
Fieldbus gateway
- Gateway for industrial Ethernet and fieldbus standards
- Simple configuration via Bürkert Communicator software
- Easy integration in the process control level through system-specific device description files
- “Batch controller” for precise dosing of liquids
- High system availability with PROFINET system redundancy S2
Bürkert provides independent consulting and flexible process control solutions from one convenient source. With a high degree of standardisation and cutting edge design, our solutions make the engineering and commissioning of automation systems easier and more affordable. Benefit from plant standardisation, easier monitoring and diagnosis, and reduced maintenance costs with process automation solutions from Bürkert.
For more information about any of our manufacturing process automation solutions, or to discuss your application requirements in more detail, please contact our sales team today on +44 (0)1285 648 720 or email sales.uk@burkert.com. Our knowledgeable experts will be only too happy to offer their advice and guidance.