The automation pyramid is a proven model that illustrates the various levels and areas of industrial manufacturing that can be automated independently of one another or in a sequential, building-upon-one-another manner. It provides clear guidance for the planning, implementation, and optimization of automated processes in industrial manufacturing. The pyramid is an indispensable tool, particularly for planning the automation of thermal processes, as it helps make the complexity of these systems manageable.
The Levels of the Automation Pyramid
The automation pyramid consists of five levels. Each level has its own tasks and technologies, which together enable efficient and seamless operations.
- Field Level
The field level forms the base of the pyramid and includes sensors, actuators, and field devices. These measure physical quantities such as temperature, pressure, or humidity and translate control commands into mechanical actions. In thermal processes, for example, temperature sensors and heating systems are of crucial importance. Communication with higher-level control systems typically takes place via fieldbuses such as Profibus, Modbus, or modern industrial Ethernet protocols. - Control Level
Programmable logic controllers (PLCs) are used at the control level. PLCs are the heart of this level and process signals from the field level. They precisely monitor temperature control or regulate heating processes. In the automation of thermal processes, PLC controllers play a key role in ensuring responsive and reliable process operations. - Management Level
The control level includes systems such as SCADA (Supervisory Control and Data Acquisition) and process control systems (PCS). These systems work closely with PLC controllers to enable the monitoring and control of processes. Data from the control systems is collected, analyzed, and visualized here. If the results of the analysis trigger an alarm, it is processed at this level. The data obtained at this level forms the basis for reports that are generated automatically. The supervisory level provides the data that operators need to make informed decisions. This is the only way to ensure efficient operations. - Operational Level
At the operational level, Manufacturing Execution Systems (MES) are used to link technical process control with business requirements. This is where production plans are coordinated with control systems, including PLC controllers. MES play a crucial role in optimizing energy efficiency and planning maintenance cycles based on data from the control level. - Corporate Level
The corporate level forms the top of the pyramid. Here, the focus is on strategic decisions and business considerations. Systems such as Enterprise Resource Planning (ERP), e.g., SAP, ensure that production processes are properly aligned with company-wide goals. Data from the MES and SCADA systems feeds into this level to support long-term planning.
Benefits of the Automation Pyramid for System Solutions
The automation pyramid enables companies like Demig to precisely plan and implement the automation of thermal processes for you. Its clear structure ensures that the individual automation steps are optimally tailored to their tasks and, at the same time, communicate seamlessly with the other levels. PLC controllers, in particular, play a key role in ensuring smooth and efficient process control.
Future Prospects
With the shift toward Industry 4.0 and the Industrial Internet of Things (IIoT), the traditional automation pyramid is changing. However, PLC controllers continue to play a central role, as they serve as a reliable interface between the various traditional levels and new technologies. Companies like Demig are driving this development forward with innovative solutions and ensuring that automation systems continue to function optimally even in an increasingly connected world.