In modern automation, machines rarely operate passively, they need to move, react, and control their environment efficiently.

Whether it’s regulating the flow of liquids or gases, an essential component manages this task with precision and reliability: the solenoid valve. 

What is a Solenoid Valve?

A solenoid valve is an electromechanical device designed to convert electrical signals into a mechanical action.

This action, in turn, opens or closes a valve to control the movement of fluids within a system.

Solenoid valves are indispensable in automated processes because they deliver a combination of precision, speed, and reliability that manual valves cannot match. 

In this article, we will learn what a solenoid valve is, how it operates, its types, advantages, and applications. 

Components of a Solenoid Valve?

A solenoid valve is essentially a combination of two key components:

• The Solenoid: This is an electromagnet that generates a magnetic field when energized.
• The Valve Body: This houses the mechanical components responsible for opening or closing the fluid path.

The solenoid consists of a coil of wire wound around a ferromagnetic core. Within the core, a plunger or piston made of ferromagnetic material moves in response to the magnetic field. 

When electricity passes through the coil, a magnetic field is generated. This magnetic field pulls the plunger, which in turn either opens or closes the valve’s orifice, regulating fluid flow.

Mathematically, the magnetic force   acting on the plunger can be expressed as:

Where:

This equation shows that the plunger’s movement depends on the coil current and the geometry of the magnetic circuit.

How a Solenoid Valve Works

The operation of a solenoid valve is straightforward yet remarkably effective. Its functionality can be broken down into four stages:

De-energized State:

In this default state, a spring holds the plunger in position. In a normally closed (NC) valve, the plunger blocks the fluid path, preventing flow.

In a normally open (NO) valve, the plunger allows fluid to flow freely without electrical input.

Energized State:

When an electrical current flows through the solenoid coil, a magnetic field form. This field exerts a force on the plunger, moving it against the spring’s resistance.

Valve Actuation:

The plunger’s movement either opens or closes the valve’s orifice. This simple mechanical action precisely controls the fluid or gas flow.

Return to Default:

Once the electrical signal stops, the magnetic field disappears. The spring then pushes the plunger back to its original position, returning the valve to its de-energized state.

The entire process takes milliseconds, enabling high-speed and highly accurate control, crucial in modern automation systems.

Key Components of a Solenoid Valve

A solenoid valve contains multiple components working in concert:

Valve Body

The main housing of the valve, constructed from brass, stainless steel, or plastic. It contains the orifice, ports, and internal passages.

Solenoid Coil

The electromagnet generating the magnetic field to move the plunger.

Plunger (or Piston)

A movable component that opens or closes the valve. Its material is usually ferromagnetic.

Spring

Provides the restoring force to return the plunger to its default position when the coil is de-energized.

Orifice

The opening in the valve that the plunger covers or uncovers to control fluid flow.

Ports

The inlet and outlet connections for fluid or gas. The number of ports defines the valve configuration (e.g., 2-way, 3-way).

Types of Solenoid Valves in Automation

Solenoid valves come in several configurations, chosen according to specific application needs.

By Operating Principle

Direct-Acting Valves

The solenoid directly opens or closes the valve. These are simple, fast, and ideal for low pressure and low flow rate applications. No fluid pressure difference is required to operate the valve.

Pilot-Operated Valves

A small solenoid controls a pilot valve, which uses the system’s fluid pressure to operate a larger main valve. These are suited for high flow rate and high-pressure systems and are more energy-efficient.

Semi-Direct Acting Valves

This type combines features of direct and pilot-operated valves. They can operate at low or zero pressure while handling moderate-to-high flow rates.

Equation for Fluid Flow Through a Solenoid Valve:

By Flow Path (Number of Ports)

2/2-Way Valves

Two ports and two positions, acting as a simple ON/OFF switch.

3/2-Way Valves

Three ports, two positions. Can direct flow to multiple paths or vent pressure, commonly used for single-acting cylinders.

4/2, 4/3, and 5/2 Valves

More complex configurations to control double-acting cylinders or sophisticated fluid paths.

By Default State

Normally Closed (NC)

Closed when de-energized; opens when powered. Most common type.

Normally Open (NO)

Open when de-energized; closes when powered. Useful in fail-safe applications where uninterrupted flow is critical.

Advantages of Solenoid Valves in Automation

Solenoid valves bring numerous benefits to automated systems:

Fast Response Time

Switching occurs in milliseconds, essential for precise and high-speed operations.

Remote Control

Electrically actuated, allowing centralized or remote operation, ideal for inaccessible or hazardous areas.

Reliability and Durability

Few moving parts ensure a long service life, even in harsh industrial environments.

Compact Design

Small footprint allows installation in tight spaces and manifold mounting.

Low Energy Consumption

Modern solenoids are highly efficient, reducing operational costs compared to other actuators.

Automation of Fluid Control

Replaces manual valves, improving efficiency, safety, and productivity.

Applications of Solenoid Valves in Automation

Solenoid valves are widely used in multiple industries:

Pneumatic Systems

Control compressed air to operate actuators, cylinders, and tools.

Hydraulic Systems

Direct hydraulic fluid to control heavy machinery in manufacturing and construction.

Water Treatment

Manage water and chemical flow for precise dosing and processing.

Food and Beverage Industry

Control ingredient flow and cleaning fluids in automated dispensing and bottling systems.

Medical Equipment

Regulate gases and fluids in devices such as ventilators and dialysis machines.

Automated Sprinkler Systems

Efficient irrigation by controlling water distribution across multiple zones.

Industrial Processes

Used for mixing, dosing, and distributing fluids in pilot plants and full-scale production lines.

Key Takeaway: What is a Solenoid Valve?

In this article, we will learn what a solenoid valve is, how it operates, its types, advantages, and applications.

Along the way, diagrams and equations will help illustrate the concepts more clearly, providing both practical and theoretical insight.

The solenoid valve is a cornerstone component in automation. It creates a seamless link between electrical signals and fluid power, enabling precise and reliable control.

From simple on/off functions to complex directional control, solenoid valves are versatile, fast, and efficient.

As automation technologies evolve, the solenoid valve continues to play a critical role in industrial control systems, offering reliability, compactness, and energy efficiency.

Its simple operating principle combined with robust performance makes it indispensable for modern industrial processes.

FAQ: What is a Solenoid Valve?

What is the main difference between normally open and normally closed solenoid valves?

Normally open valves allow flow when de-energized, while normally closed valves block flow until energized.

Can solenoid valves handle high pressures?

Yes, especially pilot-operated and semi-direct acting valves designed for high-pressure systems.

How fast can a solenoid valve respond?

Many solenoid valves switch in milliseconds, suitable for high-speed automation.

Are solenoid valves suitable for hazardous environments?

Yes, especially explosion-proof or stainless-steel designs for corrosive or flammable environments.

Can they be used in both liquids and gases?

Absolutely. The design may vary slightly depending on the medium, but solenoid valves can handle air, water, oil, and other fluids.

A Programmable Logic Controller (PLC) is a specialized digital industrial computer. It has been designed and ruggedized to reliably handle automation and control tasks in industrial environments where dust, vibration, heat, and electrical noise are present.

It constantly monitors the state of connected input devices, makes logical decisions using a custom user-defined program, then updates the state of output devices.  

This article introduces the fundamental steps for programming a PLC using Totally Integrated Automation Portal (TIA Portal) software from Siemens. It explains the importance of TIA Portal as a development tool. 

Then, it describes how to configure the software, and shows step-by-step instructions to create a program using ladder logic (LD).

Finally, it walks through the process of downloading the program into a real PLC and verifying its operation.

The Siemens TIA Portal

The TIA Portal is Siemens’ flagship engineering framework. It is an all-in-one software suite that provides a single, unified platform for programming, configuring, and commissioning automation systems.

Instead of using multiple separate tools, TIA Portal integrates all essential automation engineering functions into one environment, making it easier for engineers to work efficiently.

Within TIA Portal, different engineering tools coexist in harmony. For PLCs, it uses STEP 7, which is the programming environment. For operator interfaces such as Human-Machine Interfaces (HMIs), it uses WinCC. 

For drive systems and motion control, it integrates Startdrive. This tight integration means that an engineer can configure hardware, program logic, and design operator panels in a consistent workflow.

Why choose TIA Portal?

TIA Portal is widely chosen because it significantly streamlines the entire engineering process.

It allows engineers to reduce development time, eliminate redundancies, and increase consistency across projects. 

The intuitive user interface, powerful libraries, and drag-and-drop features help make programming accessible, even to beginners.

Another advantage is its flexibility in supporting multiple international programming languages defined by IEC 61131-3. These include:

• Ladder Logic (LAD) – graphical, easy to understand, resembles electrical circuits.
• Function Block Diagram (FBD) – suited for process control and data flow.
• Structured Control Language (SCL) – text-based, similar to high-level programming languages.

This versatility makes TIA Portal a preferred choice for both newcomers and experienced engineers working on complex industrial automation projects.

The Best PLC Simulation Software in 2025

How to Write Your First PLC Program in Siemens TIA Portal

Step 1: Planning your first program

Define your application

Before any code is written, the very first step in PLC programming is planning. A well-structured plan ensures that the logic is clear, the requirements are met, and unnecessary mistakes are avoided.

Clearly define what you want the program to achieve. For beginners, it is best to start with a simple application that illustrates basic control principles.

Example application: A motor start/stop circuit using pushbuttons and an indicator lamp.

Requirements:

• A start pushbutton should turn the motor ON.
• A stop pushbutton should turn the motor OFF.
• The motor should remain running (latched) even after the start pushbutton is released.
• A status light should indicate when the motor is running.

This simple yet practical example teaches the concept of latching circuits, which is fundamental in PLC programming.

Define your inputs and outputs (I/O)

Every PLC program is connected to real-world devices. These devices are classified as inputs (information coming into the PLC) and outputs (commands sent from the PLC).

To avoid confusion, each device must be clearly listed, assigned a descriptive tag name, and mapped to a data type.

Step 2: Creating a new project

Launch TIA Portal

Open TIA Portal software from your desktop or start menu. Once the program loads, you will see the start screen with several options.

Create a new project

1. On the start screen, click “Create new project”.
2. Enter a project name, such as My_First_PLC_Program.
3. Choose a file path to save the project.
4. Click “Create” to confirm.

Configure a device

1. On the “First steps” page, click “Configure a device”.
2. Select “Add new device”.
3. Expand the Controllers folder.
4. Choose from the SIMATIC S7-1200 or S7-1500 series. (The S7-1200 is highly recommended for beginners due to its affordability and flexibility.)
5. Select the exact CPU model that matches your hardware.
6. Click “Add” to include it in the project.

Step 3: Hardware configuration

Assigning IP address

1. Once the CPU is added, the device view opens.
2. In the properties window at the bottom, select “PROFINET interface”.
3. Under Ethernet addresses, enter an IP address for the PLC, e.g., 192.168.0.1.
4. This address will be used later to connect the PC with the PLC.

Configuring I/O addresses

1. In the same properties, go to “I/O addresses”.
2. These addresses are where the PLC program links to actual hardware inputs and outputs.
3. By default, for an S7-1200, inputs often start at %I0.0 and outputs at %Q0.0.
4. Verify or adjust these addresses to match your application.

Step 4: Creating PLC tags

Open the default tag table

1. In the project tree, expand “PLC tags”.
2. Double-click “Default tag table”.
3. A table opens where you can create tags for your I/O devices.

Add your tags

1. Add a new tag for each I/O defined in the plan.
2. Assign tag names and data types (all BOOL in this example).
3. The software automatically assigns addresses, but they can be changed.

Step 5: Writing the Ladder Logic program

Open the Main Program Block (OB1)

1. Expand “Program blocks” in the project tree.
2. Double-click “Main [OB1]”.
3. This block runs cyclically and forms the backbone of the program.

Program Network 1: Start/Stop logic

This network contains the motor latching circuit.

1. From the Basic Instructions panel, drag a Normally Open Contact (NO).
2. Place another NO contact in parallel with it.
3. Add a Normally Closed Contact (NC) in series.
4. Place a Coil (=) at the end.

Wiring:

• Assign Start_PB to the first NO contact.
• Assign Motor_Running to the parallel NO contact.
• Assign Stop_PB to the NC contact.
• Assign Motor_Running to the coil.

Logic: If Start_PB is pressed OR Motor_Running is already latched, AND Stop_PB is not pressed, then Motor_Running stays ON.

Program Network 2: Status light

This network turns on the lamp when the motor is running.

1. Insert an NO contact.
2. Insert a Coil.
3. Assign Motor_Running to the contact.
4. Assign Motor_Light_ON to the coil.

Logic: If Motor_Running = TRUE, then Motor_Light_ON = TRUE.

Step 6: Simulating the program

Start the simulation

1. Save the project.
2. Select the PLC in the project tree.
3. Click “Start simulation”.
4. Confirm the pop-up window.
5. The program compiles and loads into the virtual PLC.
6. Select “Start all” to begin simulation.

Test with a watch table

1. Expand “PLC tags” → “Show all tags”.
2. Open the watch table.
3. Modify the Start_PB tag to True. Observe Motor_Running and Motor_Light_ON.
4. Return Start_PB to False – the motor should remain latched.
5. Change Stop_PB to True – the motor and lamp should turn off.

Step 7: Downloading to a physical PLC

Establish communication

1. Connect PC to PLC via Ethernet.
2. In TIA Portal, click “Go online”.
3. Select your network adapter.
4. Search for accessible devices.
5. Assign an IP if required.

Download the program

1. Right-click CPU → “Download to device”.
2. Select hardware + software.
3. Confirm settings → Load.
4. After download, choose “Start all modules”.
5. The PLC enters RUN mode.

Monitor and debug

1. Open OB1.
2. Enable Monitoring on/off.
3. Observe green power flow lines.
4. Use pushbuttons to test and verify outputs.

Key Takeaways: How to Write Your First PLC Program in Siemens TIA Portal

You have successfully gone through the process of planning, programming, simulating, and downloading a PLC program using Siemens TIA Portal.

This motor start/stop application demonstrates a core concept: latching circuits, which are the foundation of industrial automation.

By mastering this workflow, you now have a solid base to explore more advanced topics such as timers, counters, data blocks, and structured programming. Always remember to:

• Plan your project carefully before coding.
• Use descriptive tag names for clarity.
• Simulate and test your program thoroughly before deploying.

With experience, you will be able to create structured, scalable PLC applications that control entire production systems.

FAQ: How to Write Your First PLC Program in Siemens TIA Portal

What is TIA Portal used for?

TIA Portal is Siemens’ engineering software used to program PLCs, configure HMIs, commission drives, and manage industrial networks within one integrated environment.

Which PLCs can be programmed with TIA Portal?

TIA Portal mainly supports Siemens PLCs such as the S7-1200, S7-1500, S7-300, and S7-400, along with related devices.

Is ladder logic the only programming language available?

No. TIA Portal supports LAD, FBD, SCL, and also function charts, giving engineers flexibility in programming style.

Do I need real hardware to practice?

Not necessarily. TIA Portal includes PLCSIM, a simulation tool that allows you to test logic without a physical PLC.

How do I connect my PLC to TIA Portal?

You typically connect via Ethernet, assign an IP address, and then use the “Go online” function to establish communication.

Can I program safety PLCs with TIA Portal?

Yes, Siemens offers Fail-Safe CPUs that can be programmed in TIA Portal with additional safety libraries.

Industrial automation is changing and factories are becoming smarter. They are using more connected devices than ever before. These devices are not only sensors and machines, but also advanced controllers, cameras, and industrial robots. 

Each device generates large amounts of valuable data. Edge computing is a key part of this change because it processes data closer to its source.

This is at the “edge” of the network. In factories, this means the shop floor, production line, or even individual machines. 

Processing data locally instead of sending it far away creates faster responses, which brings many benefits for industrial automation.

It reduces delays and improves reliability. It also supports modern applications like predictive maintenance, robotics, and energy efficiency.

This article explains what edge computing is, its role in industrial automation, benefits, challenges, and finally, its future.

The shift from cloud to edge

Traditionally, data from factory sensors was sent to a central data center. This was for storage, processing, and analysis. Engineers would collect data, send it to the cloud, and wait for results.

But this can cause delays, called latency. Latency is a big problem for real-time automation.

Even a small delay of a few milliseconds can stop a robot arm from reacting correctly.

It can cause defects on a fast-moving assembly line. It can even affect safety systems that need instant action.

Cloud computing also has high costs for bandwidth. Industrial Internet of Things (IIoT) devices may produce gigabytes of data every second. Sending everything to the cloud wastes resources and money.

Edge computing offers a different approach. It puts processing power near the data source.

Devices like edge gateways, rugged servers, or intelligent PLCs do the work. These devices are installed directly in factories.

This local processing reduces latency. It improves responsiveness. It allows for real-time decision-making.

Operators and machines can act immediately based on local insights. At the same time, only important summaries or trends are sent to the cloud for higher-level use.

Architecture of industrial edge computing

The architecture of industrial edge computing can be thought of in layers. Each layer has its own role and purpose.

Device layer

This is the base layer. It includes all the devices that generate data. Examples are sensors, robots, and programmable logic controllers (PLCs). These devices collect huge amounts of data every second.

In a smart factory, hundreds of devices may be connected. They measure temperature, vibration, pressure, energy use, or product quality.

Without processing, this raw data is too large to handle. That is why the next layer is important.

Edge layer

This layer is right above the device layer. It contains edge servers and gateways. These process data locally and in real-time.

They filter out unnecessary or repetitive information. Only critical information is forwarded to the cloud.

For example, an edge device can check vibration data from a motor. If it detects an unusual pattern, it can send an alert instantly.

It does not need to wait for cloud approval. This layer is key for low-latency actions.

Cloud layer

This is the highest layer. It receives aggregated and analyzed data from the edge layer.

It is used for long-term storage, big data analytics, and historical insights. It helps with higher-level business decisions.

Managers can use this information for planning, forecasting, and improving efficiency. While the edge ensures fast responses, the cloud provides the big picture.

Benefits of edge computing

Low latency and real-time control

Speed is vital in industrial settings. Edge computing eliminates the delay of sending data to the cloud. Machines can react instantly.

For example, a robot can stop when a worker enters its zone. A conveyor belt can pause when a defective product is detected. This is crucial for safety-critical systems.

Optimized bandwidth

Industrial IoT devices produce massive amounts of data. Sending all this raw data to the cloud consumes bandwidth.

Edge computing processes data locally. It sends only relevant insights, like alarms or performance summaries, to the cloud. This reduces bandwidth usage and costs significantly.

Enhanced security

Processing sensitive data locally keeps it more secure. It reduces the risk of data being intercepted during transit to the cloud.

Many factories handle confidential production processes. Keeping this information on-site helps with data privacy and compliance with regulations.

Improved operational efficiency

Real-time insights on the factory floor help optimize processes. Machines can adjust automatically.

Operators can make faster decisions. This increases productivity and reduces waste.

High reliability

Edge systems can function even when cloud connectivity is lost. This is vital for remote sites or areas with poor internet.

For example, a mining site or offshore platform can still operate locally. This ensures operational continuity and safety.

Use cases in industrial automation

Predictive maintenance

Sensors on machines monitor performance. Edge devices analyze this data in real-time. They can detect early signs of a potential failure.

For instance, vibration data may show that a motor bearing is wearing out. This allows maintenance to be scheduled before a breakdown occurs. The result is less downtime and lower costs.

Automated quality control

High-speed cameras and sensors inspect products on the assembly line. An edge device processes the images instantly.

If it sees a defect, it can reject the product in milliseconds. This improves product quality, reduces waste, and maintains consistency.

Robotics and autonomous systems

Autonomous robots need to make split-second decisions. They process data from their sensors locally.

This allows them to navigate safely and perform tasks in real-time. Without edge processing, delays could cause collisions or inefficiency.

Supply chain optimization

Edge devices track inventory and monitor vehicles in real-time. For example, smart tags can report stock levels instantly.

Processing this data on-site allows for immediate adjustments. This helps optimize logistics and respond quickly to disruptions.

Energy management

Edge systems can monitor energy usage across a plant. They identify energy-intensive processes.

They can automatically turn off idle machines or adjust settings to save power. This reduces energy costs and supports sustainability goals.

Challenges of industrial edge computing

Integration with legacy systems

Many factories use older equipment. This equipment was not designed for modern digital architectures.

Integrating edge solutions with these machines can be complex and expensive. Custom adapters or upgrades may be needed.

Data management

Factories generate huge volumes of data. Managing and storing this data locally requires robust infrastructure.

If not planned well, local systems can become overwhelmed. Companies must design scalable storage and processing solutions.

Security concerns

Edge computing increases the number of potential entry points for cyberattacks. Each edge device can be a vulnerability.

Hackers may target gateways or servers. Strong security protocols and constant monitoring are necessary.

Skilled workforce

Managing edge infrastructure needs specialized skills. Workers must understand networking, cybersecurity, and industrial systems.

Many companies must invest in training or hire new personnel. Without skilled staff, projects may fail.

Scalability

Edge solutions must be able to grow with the business. Starting with pilot projects and planning for expansion is important.

Companies should design architectures that can scale easily without replacing everything.

The future of industrial edge computing

Convergence with 5G

5G networks offer high bandwidth and low latency. They enable seamless machine-to-machine communication.

With 5G, mobile robots and wireless sensors can exchange data instantly. This will further enhance industrial edge applications and expand flexibility on the factory floor.

Advancements in AI

AI models are becoming more powerful and efficient. They can be deployed directly on edge devices.

This will enable more intelligent and automated decision-making. For example, AI at the edge can predict quality issues, optimize robot movements, or adjust production schedules in real-time.

Standardization

Currently, the market has many different solutions. Each vendor provides its own hardware and software.

Standardization is needed for easier implementation. Open standards will simplify integration, reduce costs, and accelerate adoption of edge computing.

Key takeaways: Edge Computing in Industrial Automation

The present article detailed what edge computing is, its role in industrial automation, benefits, challenges, and finally, the future of this edge computing.

From this discussion, and without hesitation, we can say that edge computing is driving the next industrial revolution.

It moves data processing closer to the source and reduces latency and improves efficiency. It also enhances security and reliability.

Furthermore, challenges like legacy system integration and security must be addressed.

Skilled staff and strong planning are essential. But with careful preparation, the benefits are immense.

In addition, the future of manufacturing is autonomous and intelligent. Edge computing is a key enabler of this future. It bridges the gap between devices, people, and the cloud. It empowers industries to be faster, smarter, and more sustainable.

FAQ: Edge Computing in Industrial Automation

What is edge computing and how is it different from cloud computing?

Edge computing means processing data close to where it is generated (machines, sensors, etc.), instead of sending everything to a distant cloud. This reduces latency, bandwidth usage, and often improves reliability. 

Why is low latency important in industrial automation?

Many industrial tasks require instant or near-instant responses — e.g. safety systems, robotics, real-time quality control.

Delays (latency) can lead to defects, safety hazards, and inefficiencies. Edge computing helps by processing data locally so decisions happen quickly. 

What kinds of use cases are there for edge computing in factories?

Some common ones:

• Predictive maintenance (monitoring machine health and detecting failures early). 
• Quality control / visual inspection using computer vision. 
• Robotics and autonomous systems (robots that need fast sensor feedback). 
• Supply chain or warehouse optimization (inventory tracking, real-time visibility). 
• Energy management (monitoring usage, shutting off idle machines, optimizing consumption). 

What benefits can companies expect from deploying edge computing?

• Faster response times and real-time control. 
• Reduced bandwidth costs and lower cloud storage/transfer fees, since not all data is sent offsite. 
• Enhanced security and data privacy (sensitive data can remain local). 
• Improved operational resilience (able to operate even with unreliable internet). 
• Better cost efficiency in the long run, especially when many devices are involved. 

What are the challenges or drawbacks of edge computing in industrial settings?

• Integration with legacy systems (older machines not built for modern connectivity) can be difficult. 
• Limited computing resources on edge devices: less CPU, memory, storage than cloud data centers. 
• Security risks: each edge device can be a potential attack surface. Maintaining updates, ensuring encryption, securing physical access all matter. 
• Hardware management and maintenance are more complex when many edge devices are deployed. 
• Scalability: ensuring solutions grow well without overhauling everything. 

How does edge computing help with security and compliance?

Because data can be processed locally, there is less data in transit over external networks.

That reduces exposure to interception or external threats. It helps with data sovereignty rules, privacy laws, or industry-specific compliance.

Is internet connectivity still needed? What happens when connectivity fails?

Yes, connectivity helps for sending aggregated data, updates, or for cloud-based analytics.

But edge systems are designed to continue functioning even with intermittent or no internet. They carry out local control, safety, and monitoring even when disconnected. 

What role do AI and machine learning play at the edge?

AI/ML enable more intelligent analytics, anomaly detection, predictive models, and automation.

When deployed at the edge, they can act immediately on sensor data. For example, image recognition on defect detection, or anomaly detection in vibrations. 

How does 5G interact with edge computing?

5G offers high bandwidth and low latency wireless connectivity. It allows edge devices and sensors to communicate more reliably.

It enables you to place edge nodes further from wired infrastructure. It also supports mobile or moving devices.

When is edge computing not the best solution?

• When latency is not critical and cloud-based solutions are already meeting needs.
• When the cost of deploying and maintaining many edge devices outweighs the benefits.
• If infrastructure (power, cooling, environmental protection) is not sufficient for edge hardware.
• When data volumes aren’t large or when connectivity is reliable and affordable, so that cloud approaches make more sense. (In short: it depends on the use-case.) 

How should companies plan for scaling edge computing deployments?

• Start with pilot projects to validate use-cases.
• Use modular, flexible architectures so you can expand.
• Ensure hardware, software, and network standardization for interoperability.
• Plan for device lifecycle: updates, security, maintenance.
• Monitor total cost of ownership (TCO) including hardware, operations, and staff training. 

What hardware is needed for edge computing in industrial automation?

Edge computers, gateways, ruggedized servers, sensors with computing capability, PLCs with more advanced functionality.

They often need to be durable, able to handle vibration, temperature extremes, dust, etc. Also good networking (wired and/or wireless) and sometimes specialized accelerators (GPUs, TPUs) for AI workloads.

What standards or interoperability issues exist?

The market has many vendors, many proprietary systems. Standards like OPC UA, TSN (Time Sensitive Networking), and cross-vendor frameworks are becoming more important. Interoperability helps reduce integration costs

Industrial automation is the use of computer‑based control systems, or sometimes even analog ones. It’s about letting machines manage themselves with minimal human intervention.
It involves using machines, robots, and software to perform tasks that usually back then were performed by humans.

Core Components & How It Works

At the core of industrial automation systems are devices and technologies that monitor, control, and execute tasks, replacing or reducing the need for human intervention.

This includes hardware like PLCs (Programmable Logic Controllers), sensors, actuators, robotic arms, HMIs (Human-Machine Interfaces), and software systems such as SCADA (Supervisory Control and Data Acquisition) and DCS (Distributed Control Systems).

PLCs are industrial-grade computers that take input from sensors (such as temperature, pressure, or position sensors), execute programmed logic, and drive actuators (like valves, motors, or lights) accordingly.

The control strategy can be simple—such as turning off a motor when a temperature threshold is reached—or complex, such as coordinating an entire assembly line with hundreds of input/output points.

This is where SCADA systems or DCS platforms come in: they gather data from multiple PLCs or controllers, offer visualization dashboards, allow operators to supervise and control processes remotely, and provide historical logging for quality assurance and diagnostics.

Another major component is CAD/CAM (Computer-Aided Design and Manufacturing), which not only designs parts but also feeds into CNC (Computer Numerical Control) machines and automation paths. This seamless integration is a hallmark of advanced automation.

This control can be analog (e.g., pneumatic regulators, PID loops using analog signals) or digital (as in PLCs).

The ultimate goal remains the same: orchestrate all system components to operate autonomously and precisely.

Types of Industrial Automation

Industrial automation isn’t one-size-fits-all. Depending on production needs, scale, and complexity, different types of automation systems are implemented. These fall into four primary categories:

Fixed (Hard) Automation

This type is designed for high-volume, repetitive tasks. The machinery is configured for a specific process and cannot be easily changed.

Examples include automotive assembly lines or bottling plants. Fixed automation is known for high throughput but lacks flexibility.

Programmable Automation

Here, machinery can be reprogrammed to accommodate changes in product design or production sequence.

It’s widely used in batch production, for example, in chemical or food industries. Reprogramming takes time and cost, but it offers more adaptability than fixed automation.

Flexible (Soft) Automation

Flexible systems, often found in CNC machining and robotic systems, can easily switch between different product types.

The transition requires little to no downtime. This is where robots with vision systems, AGVs (Automated Guided Vehicles), and flexible manufacturing systems shine.

Integrated Automation

This is the future-focused approach combining all levels, from field devices to enterprise resource planning (ERP).

It leverages digital communication, centralized control, and software platforms like MES (Manufacturing Execution Systems) and IIoT (Industrial Internet of Things).

Integrated automation enables real-time data-driven decision-making, predictive maintenance, and seamless cross-system interaction.

Each automation type reflects a different degree of self-management and adaptability. The more integrated and flexible the system, the closer we get to fully autonomous industrial environments.

Benefits & Impact

Industrial automation makes machines run themselves, reducing human involvement to the essentials.
It enhances accuracy, efficiency, productivity, and safety while lowering operational costs.
It will increase accuracy, efficiency, productivity, and safety, and at the same time, we reduce the operational cost for our factories.
Automation frees workers from dangerous or monotonous tasks, enabling them to focus on higher‑value roles.

Enabling Trends: Industry 4.0 & IIoT

Industrial automation is being revolutionized by the Fourth Industrial Revolution, Industry 4.0, with smart devices, M2M communication, AI, and cloud integration.
Concepts like IIoT, digital twins, machine learning, and industrial robotics make production smarter, safer, and more adaptable.

Safety, Challenges & Future Outlook

Using PICs and SCADA in safety‑critical environments requires robust protocols and regulatory compliance. Cybersecurity risks (e.g., PLC vulnerabilities) are significant.

High upfront costs and complexity of integration can be barriers, yet trends like flexible and integrated automation systems lower these hurdles.

Looking ahead, expect growth in AI-driven automation, digital twin simulations, and fully lights-out smart factories.

FAQ: What Is Industrial Automation?

What is an example of industrial automation?

A classic example of industrial automation is a robotic assembly line in an automotive plant.

Robots handle tasks like welding, painting, or assembling parts with minimal human oversight.

These systems rely on PLCs, sensors, and actuators to perform repetitive actions with speed and precision.

What is automation in the industry?

Automation in the industry refers to the use of machines, software, and control systems to perform tasks that traditionally required human labor.

This includes monitoring processes, adjusting equipment, handling materials, and even making decisions based on real-time data.

What are the four types of industrial automation?

The four primary types of industrial automation are:

1. Fixed Automation – High-volume, repetitive tasks (e.g., vehicle assembly lines).
2. Programmable Automation – Customizable control systems for batch production.
3. Flexible Automation – Rapidly adjustable systems for varying products.
4. Integrated Automation—Fully networked and data-driven production environments.

Each of these represents a different approach to reducing manual labor and enhancing production flexibility.

These systems scale from rigid to highly adaptive setups depending on the industry’s needs.

What is a PLC in automation?

A PLC (Programmable Logic Controller) is a rugged industrial computer used to automate processes by monitoring inputs and controlling outputs based on a custom logic program.

They’re essential in managing repetitive tasks like turning motors on/off, adjusting valves, or reading sensor signals.

In practical use, “the use of PLC” is one of the most fundamental tools in industrial automation.

These controllers provide the decision-making brain of the system, ensuring operations run smoothly and according to programmed logic—even in harsh industrial environments.

Conclusion: What Is Industrial Automation?

Industrial automation means letting machines self-manage critical processes. It combines PLCs, robots, sensors, control systems and software to deliver safer, more accurate, efficient, and lower-cost operations.

As IIoT, robotics and AI advance, automation will only deepen its impact across industries.