Factory and industrial automation systems must reliably connect human operators, machinery, computers, and sensors over communications links. This process typically starts with raw materials that are moved through a series of workstations where a product is formed, measured, calibrated, inspected, packed, and shipped, all under the control of a factory automation system.
These systems start with supervisory control and data acquisition (SCADA)
architectures, where computers and networked communications systems provide high-level supervision and control of the
production processes. The SCADA systems are often
located remotely from the actual production facilities, and remote operation is usually accomplished using cloud data services (CDSs), which provide data links and group interoperability. SCADA systems manage and monitor factory performance by controlling machines through local programmable logic controllers (PLCs) and receiving feedback through networked sensors that guide their work. The PLCs interface with the process plant or machinery. Remote input/
Figure 1 : Remote I/O components form the nerve system of a modern automated factory. (Image source: Banner Engineering)
output (I/O) components are the communications backbone of the automated factory, as shown in Figure 1. Discrete sensors and actuators monitor and control local operations. Their signals are linked using appropriate hubs and are sent to the master for local processing before being sent to the SCADA system.
Industrial data buses Automated machines can use many sensors or actuators, but their direct connection to the control room would result in large and expensive cables. To avoid this situation, designers have developed several sensor buses to consolidate these connections. Modbus and IO-Link are two widely used networks (Figure 2).
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