Drives & Controls May 2022

www.drivesncontrols.com May 2022 51 AUTOMATION n Universal automation could revolutionise industry C hange is a part of life. From the changing of seasons to the change in weather; the only constant we can expect, is that change is inevitable. With change comes adaptability. We must stay agile to acclimatise to our new landscape and navigate new challenges. Yet, in the current industrial automation industry, workers are constrained by closed, proprietary automation systems and production equipment. Currently, up to half of industrial engineers waste their valuable time and effort combatting this issue. Instead, they should be free to innovate, create value, drive efficiencies, enable sustainable growth, and drive forward greener initiatives. Technology can and should be used to empower teams, enabling smarter, faster, and more sustainable manufacturing, bringing on a new era for industrial processes. The solution? Universal automation: interoperable, software-centric automation systems that share a common IEC 61499 runtime. Change is inevitable. The last few years have made that abundantly clear. While nobody can predict the future, emerging technologies based on the principles of interoperability and universal automation allow us to react to volatile markets and deal quickly and efficiently with any changes in production environments. Moreover, they reduce waste by expanding the lifespan of hardware and improving circularity. According to both ARC Advisory Group and McKinsey, industry has yet to uncover key efficiencies estimated at $30–100bn per year. And this will only be possible if industry is transformed and embraces collaboration. Some may suggest that breakthroughs in machine learning, augmented reality, the IIoT and real-time analytics have made promising advances in manufacturing, meeting the demands of our current digital world. However, in reality, industry remains trapped by vendor lock-in, which limits machine-to-machine collaboration and the ability to integrate best-of-breed technologies. These incompatibilities hinder industry from innovations and cutting-edge products and systems, like becoming pioneers of a net- zero future through low-impact and carbon- neutral manufacturing. As the global economy strives towards a greener future, industry runs the risk of holding the planet back. Currently, industry is responsible for a staggering 32% of global carbon emissions. If the status quo is maintained, industry won’t be able to transition to sustainable models. Universal automation enables engineers to create and innovate, realising their full potential to reshape industry and move us forward into a sustainable Industry 4.0. We must ensure that ecology and technological advancement are compatible, nurturing innovation as industry becomes one of the cornerstones of a green recovery. This and more will be possible through universal automation, breaking the existing mould. Industrial collaboration is imperative. Only then can top engineering talent be revealed, bringing a new purpose to industry. Abolishing vendor lock-ins Standardisation is the answer to innovation. The IEC 61499 standard already provides a basis for integration and collaboration. Standardisation and the separation of hardware and software lifecycles have proved essential in the success of the IT industry. It has become second nature for computers and smartphones to run real-time applications. Universal automation makes this available for industrial processes and machines for the first time. The ability to port applications easily from one hardware brand to another will free up engineering time, giving automation professionals more scope for innovation. It will also help to make industrial operations more cost- and energy-efficient, extending the lifespan of hardware. Universal automation is already making major strides in the consumer-packaged goods, pharmaceutical and logistics sectors at companies such as gr3n and Master Systèmes. As the software is not limited by the hardware, adapting to change has never been easier or more cost-effective. If something goes wrong, universal automation applications can be used to troubleshoot and find the root cause of an issue four times faster, reducing unplanned downtime as well as materials being wasted in faulty products. If you are sceptical of universal automation, don’t be! The standardisation of screw threads revolutionised and democratised the landscape for manufacturing. It meant that machines could be made and repaired using standard screwdrivers, making this one of the first moves towards industrial standardisation. Imagine what we could achieve by standardising the platforms on which industrial automation software runs in our factories? n https://universalautomation.org The current model used for industrial automation is too limiting argues John Conway, president of UniversalAutomation.org, a non-profit group of more than 25 companies and organisations campaigning for a common software layer that will work across automation technologies of any brand. According to UniversalAutomation.org, the traditional automation model (left) locks users into vendors, limits interoperability, prevents portability, is hard to interface with IT systems, and is labour-intensive to engineer and operate. It argues that its model (right) offers vendor independency, interoperability, easy IT interfacing, efficient engineering and operation, as well as boosting innovation.