9.1 Introduction: From Electrification to Automation
Following widespread electrification and the development of electronic computing technology, the focus of electrical engineering in the 20th century increasingly shifted towards the automation of technical processes. The goal was not only to power industrial processes electrically, but also to control, monitor, and optimize them autonomously.
Automation technology combines electrical engineering, computer science, control engineering, and mechanical engineering into an integrated systems approach. It forms the foundation of modern production systems.
9.2 Fundamentals of Control Engineering
Control engineering is the theoretical core of automation. It deals with influencing dynamic systems through feedback.
Key terms:
- Control variable
- Key performance indicator
- Control variable
- Disturbance variable
- Control loop
A typical closed control loop consists of:
- Sensor (measurement of actual size)
- Controller (comparison with setpoint)
- Actor (effect on the system)
- Process (system to be regulated)
Mathematically, such systems are often described by differential equations or state-space models.
9.3 Development of automation technology
Early forms of automation used mechanical and electromechanical controls. With the introduction of electronic components, more complex control systems emerged.
A milestone was the development of the programmable logic controller (PLC) . It replaced hard-wired relay controls with flexible, programmable systems.
Advantages of PLCs:
- High reliability
- Easy adaptability
- Modular design
- Industrial suitability
PLC systems have become the standard in industrial manufacturing.
9.4 Sensors and actuators
Automated systems rely on precise sensors. Sensors convert physical quantities into electrical signals.
Typical measurements:
- temperature
- Pressure
- speed
- position
- flow rate
- acceleration
Actuators convert electrical signals into mechanical or thermal effects, for example through electric motors, valves or heating elements.
The combination of sensors and actuators enables closed control loops.
9.5 Robotics
Industrial robotics is a significant application area of automation. Robots consist of:
- Electric drives
- Position sensors
- Tax calculators
- Communication interfaces
Control-related complex motion sequences require precise coordination of multiple axes. Electrical engineering provides the power supply, signal processing, and control logic.
Modern robots also utilize image processing and artificial intelligence.
9.6 Industrial Communication Systems
As production facilities became increasingly complex, networking individual components became necessary. Industrial communication systems enable real-time data transmission.
Examples of technical concepts:
- Fieldbus systems
- Real-time Ethernet
- Wireless sensor networks
- Edge computing
The integration of communication and automation technology forms the basis of networked production environments.
9.7 Industry 4.0 and cyber-physical systems
The concept of Industry 4.0 emerged in the 21st century. It describes the fourth industrial revolution, characterized by digitalization and networking.
Characteristics of Industry 4.0:
- Cyber-physical systems
- Real-time data analysis
- Self-optimizing production processes
- Digital Twins
- Interconnected value chains
Cyber-physical systems connect physical processes with digital information systems. Sensors collect process data, which is analyzed in real time and used for optimization.
9.8 Artificial Intelligence in Automation
The integration of artificial intelligence enables adaptive control strategies and predictive maintenance.
Application areas:
- Quality control through image analysis
- Predictive maintenance
- Optimization of energy consumption
- Autonomous mobile systems
AI extends classical control engineering with adaptive algorithms.
9.9 Safety and functional safety
Automated systems must meet high safety requirements. Errors can cause significant economic or human damage.
Key aspects:
- redundancy
- Fault tolerance
- Safety-related controls
- Electromagnetic compatibility
Functional safety is an integral part of modern automation.
9.10 Social and economic impacts
Automation led to:
- Productivity increase
- Globalization of production
- Structural change in the labor market
- Emergence of new qualification profiles
At the same time, it raises ethical and social questions, especially regarding employment and data sovereignty.
9.11 Future prospects
Future developments include:
- Autonomous factories
- Collaborative robotics
- Fully networked supply chains
- AI-supported process optimization
- Sustainable production systems
Automation technology remains a dynamic field that significantly shapes industrial development.
9.12 Summary
Chapter 9 shows how electrical engineering evolved from pure energy and signal technology to a comprehensive science of control and automation.
Key elements:
- Control engineering
- PLC systems
- Sensors and actuators
- robotics
- Industry 4.0
Automation marks a further evolutionary step in electrical engineering and forms the basis of modern industrial value creation systems.
