Recent developments in software-defined automation (SDA) and Universal Automation are rapidly transforming the traditional industrial automation model. The shift to open software-centric methodologies and tools is now well underway and closed, manufacturer-dependent options are fast becoming a thing of the past.
This new way of automation is fantastic news for business.
When automation hardware is decoupled from software, automation functionality can be deployed on a platform of choice. This ultimately empowers a company to make decisions based on what makes the most sense for its performance and business needs, allows it to better meet the ever-changing demands of the post-pandemic consumer-driven world, and smooths the transition into the digitalised future of Industry 4.0 and beyond.
Taking industrial automation to new heights with virtualisation
The separation of hardware and software also enables new types of virtualisation to be applied to the industrial space, further advancing traditional automation paradigms and increasing overall efficiency.
In traditional IT, the term ‘virtualisation’ is commonly used to describe a scenario where several virtual machines (VMs) are set up on a single server. When used in industrial automation, it has various meanings, but the premise is much the same—a move from physical to virtual.
For this purpose, we are referring to when a process that was traditionally only possible with hardware and software combined has been digitalised, leveraging the power of software to become more virtual.
Digital Twins
The introduction of digital twin modelling in software such as EcoStruxure Machine Expert Twin allows machine builders to drag and drop from a predefined catalogue of objects to design, optimise, test and validate digital models of real machine solutions in a virtualised environment before commissioning. They no longer need to experiment with physical hardware to achieve optimised results. This can significantly increase efficiency by saving time to market by up to 50 per cent and commissioning time by up to 60 per cent compared to traditional approaches.
Soft PLCs & iPCs
When it comes to the all-important programmable logic controller (PLC), virtualisation enables the move to a ‘soft PLC’, such as the EcoStruxure Automation Expert virtualised controller, a hardware-agnostic, software-based PLC which can be run on any Windows or Linux server, industrial PC (iPC) or microcomputer, no matter the supplier. Multiple instances of this virtualised controller can be installed in the same piece of hardware and configured, deployed, and maintained simultaneously and independently from one another. It also offers the ability to make changes to the process without stopping production – minimising downtime, reducing costs, and providing the all-important flexibility and agility required to thrive in today’s demand-driven, dynamic consumer landscape.
With features like rugged designs, extended temperature ranges, and compatibility with industrial protocols, Schneider Electric’s Harmony iPC (formerly Magelis iPC) is made to withstand the harsh conditions prevalent in manufacturing facilities. Acting as the user’s visualisation and control terminal, it’s a powerful, purpose-built, industrial-ready hardware choice for running soft PLC machines and plant control systems.
Reusable engineering
Then there is EcoStruxure Automation Expert’s software-centric, in-built smart design and engineering capabilities, allowing for processes or techniques to be piloted in one location and rolled out quickly to others.
Deploying new processes or replicating and modifying existing ones is much easier within virtualised environments. This reusable engineering significantly reduces time to market, increases engineering efficiency, and can offer an edge over the competition.
As the industrial landscape continues to advance and we transition even further into the Software-Defined Automation era, these digitised, virtualised smart manufacturing environments will undoubtedly continue to set new standards in interoperability, ease, and efficiency for the next generation of industrial automation.
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