Personal and industrial computers have revolutionised how we learn, play and work. But they raise questions about how to manage the separation between hardware and software. This applies in all environments, but is especially crucial within the manufacturing and industrial sectors. In today’s industrial landscape, where automation arguably reigns supreme, the relationship between hardware and software is tightly bound. When engineers choose a specific manufacturer’s programmable control system, they often lock themselves into a particular programming environment. It’s like buying a house and realising that you can only furnish it with furniture from a single store. But what would the industrial landscape look like if we could break free from these constraints? Historically, hardware has been the main topic of most discussions about improving manufacturing processes, managing efficiency and maintaining sustainability. However in recent years, the collection of data and the flexibility of software has started to take centre stage. In many applications, upgrading machinery can now begin with the software. Companies are questioning what production assets they need, and what geographical layout best suits their needs? By decoupling software from specific hardware, they can empower themselves to design control systems that adapt seamlessly to their processes. As the Industrial Internet of Things enables virtualisation, the gap between the physical and digital worlds can be bridged. Using data, machines can communicate effortlessly, sharing information across virtual networks. This can lead to much higher efficiencies, with sustainability becoming a reality rather than merely a buzzword. The right hardware will always needed. However with modern developments in software, we cannot overlook how important it is to exploit the possibilities that they offer. In manufacturing, hardware is the sturdy backbone – the gears, the motors, the sensors, the actuators, and so on. It keeps the factory floor humming. Without reliable hardware, our grand visions of automation would remain mere lines of code. Like a symphony without instruments, the software might compose the melody, but it’s the hardware that brings it to life. We must not forget that machines must be able to endure harsh conditions such as extreme temperatures, vibrations, dust and wear-and-tear. While well-designed hardware can withstand these challenges, the key is to achieve uninterrupted production. A faulty sensor or a worn conveyor belt can disrupt an entire process. Hardware components also are crucial for safety. A sensor detecting an obstruction on an assembly line can trigger an immediate halt, avoiding accidents without any delays. But software brings flexibility, adaptability and intelligence to the factory floor. It also allows us to create digital twins and simulate production scenarios, test algorithms, and optimise processes, all without disrupting real-world operations. So, how do we strike the right balance? The answer lies in synergy – the harmonious collaboration of software and hardware. The UK manufacturing sector should embrace both technologies, and by leveraging software-defined automation alongside robust hardware, manufacturers will certainly gain a competitive edge both domestically and internationally. A smart factory is one where software optimises production lines, while hardware ensures precision and reliability. By nurturing expertise in both software development and hardware engineering, we can bridge the divide and create a powerful workforce for tomorrow. Automation through software allows us to re-imagine our journeys toward agility, efficiency and innovation. Of course, it is harder to visualise the benefits of a software installation, compared to buying a new machine, but by embracing virtualisation, and blurring the lines between software and hardware, the result can be a dynamic ecosystem where machines adapt, learn and evolve alongside us and each other. As we stand at the crossroads, let’s embrace the power of software-defined automation. As we did with other revolutions, let’s break free from the old constraints, just as early PCs liberated us from mainframes. Software allows us to pivot, respond rapidly to market shifts, and customise products, while hardware ensures resilience and keeps the wheels turning. Combining the two will allow industry to thrive, sustainability to bloom, and innovation to know no bounds. n * Gambica is the trade association for the automation, control, instrumentation and laboratory technology sectors in the UK. You can get in touch with Nikesh Mistry on 020 7642 8094 or nikesh.mistry@gambica.org.uk, or via the Gambica Web site: www.gambica.org.uk Bridging the divide between hardware and software Effective industrial automation depends both on reliable hardware and flexible, dynamic software. Nikesh Mistry*, Gambica’s sector head for automation, argues that we need both elements to work together effectively and that bridging the gap between the two will allow industry to thrive, sustainability to flourish, and innovation to break free. September 2024 www.drivesncontrols.com 48
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