Industry 4.0 represents a significant leap forward in manufacturing, marked by interconnected systems, data exchange, and smart automation. Central to this transformation are two crucial concepts: the automation stack and the Industrial Internet of Things (IIoT). These two ideas are intertwined, driving the next wave of industrial innovation. In this blog, we’ll explore these concepts in a way that’s approachable for all readers, regardless of their technical expertise.
Understanding the Automation Stack: A Hierarchical Structure
The automation stack refers to the layered architecture of industrial automation systems. Each layer plays a distinct role, from data collection to higher-level decision-making. Together, these layers form the backbone of modern manufacturing operations.
Here’s a breakdown of the typical layers in an automation stack:
- Field Level: This is where sensors, actuators, and devices interact with the physical processes on the factory floor. These devices collect data (like temperature, pressure, or machine performance) and execute commands sent from higher levels.
- Control Level: At this level, Programmable Logic Controllers (PLCs) handle the control and monitoring of the physical processes. Think of PLCs as the brain of the system, interpreting data and issuing commands to field devices.
- Supervisory Control and Data Acquisition (SCADA): SCADA systems provide a visual interface for operators to monitor and control the process. They collect data from the PLCs and allow operators to adjust settings or intervene when necessary.
- Manufacturing Execution System (MES): This layer connects the shop floor to the business side of operations. It tracks production activities, manages scheduling, material flow, and quality control.
- Enterprise Resource Planning (ERP): The ERP system manages overarching business functions—such as finances, inventory, and human resources—integrating data from all departments to offer a complete view of the enterprise.
Traditionally, these layers operated somewhat independently, often leading to data silos and inefficiencies. However, with the advent of Industry 4.0, there’s a growing emphasis on interconnectivity and seamless data flow between all layers, blurring the boundaries of the automation stack.
IIoT: The Networked Backbone of Industry 4.0
The Industrial Internet of Things (IIoT) is the technology that connects all the devices and systems within a manufacturing environment. In essence, IIoT transforms traditional, “dumb” devices into intelligent, connected nodes that can communicate with each other and higher-level systems.
Key characteristics of IIoT protocols include:
- Openness: IIoT protocols are open, meaning they can connect devices from different manufacturers and systems without compatibility issues. This flexibility avoids vendor lock-in and fosters interoperability.
- Report by Exception: Rather than constantly transmitting data, IIoT devices report only when something significant changes. This method reduces unnecessary network traffic and optimizes bandwidth usage.
- Lightweight and Stateful: IIoT protocols are designed to be lightweight, meaning they don’t consume much bandwidth, even when handling large numbers of connected devices. Being “stateful” ensures that they always maintain awareness of the connection status, which ensures data integrity.
The Convergence of Automation Stack and IIoT
The automation stack and IIoT are not separate entities; they work together to drive innovation in Industry 4.0. IIoT enhances the automation stack by enabling real-time data exchange, better connectivity, and faster decision-making across all layers.
Here’s how they come together:
- Breaking Down Data Silos: IIoT connects all levels of the automation stack, breaking down barriers between systems and ensuring a seamless flow of information across the enterprise. This allows for faster, more informed decision-making, leading to better process optimization and improved efficiency.
- Data Lakes and Unified Namespaces: With IIoT, companies can create data lakes—central repositories where data from every layer of the stack is stored in a unified format. A unified namespace ensures consistent data identification, making it easier to analyze data across different systems.
- Edge Computing: IIoT pushes intelligence to the edge—closer to where data is generated. This means that smart sensors and devices can process data locally and act on it without waiting for instructions from central systems. This reduces latency and speeds up responses to real-time events on the shop floor.
The Inevitability of IIoT-Ready Sensors
In today’s world, many sensors are limited to basic functionalities like analog outputs. However, as technologies like Raspberry Pi become more affordable and accessible, integrating intelligence and connectivity into sensors is becoming more cost-effective. This shift will make IIoT-ready sensors the norm, providing richer data and seamless integration across industrial networks.
Smart sensors will reduce the need for multiple layers of data handling, as they’ll be capable of transmitting actionable insights directly to higher systems, further enhancing operational efficiency.
The Future of the Automation Stack and IIoT
As we move deeper into Industry 4.0, the traditional automation stack as we know it may become obsolete. Several key trends are driving this evolution:
- Convergence of Layers: As more intelligence and connectivity move to the edge, the distinct boundaries between layers of the stack will blur, creating a more fluid and adaptable structure.
- Centralized Data Lakes: With the rise of data lakes and powerful machine learning algorithms, the need for dedicated historians (typically used in SCADA systems for data storage) will diminish. Data will be analyzed directly from the lake, without the need for predefined models.
- Ubiquitous Connectivity: As IIoT becomes more pervasive, manufacturing environments will become networks of intelligent devices, all communicating and collaborating in real time. This seamless connectivity will accelerate innovation, data exchange, and optimization.
Impact on Integrators and Distributors
This evolution will also reshape the roles of key industrial players:
- System Integrators: They will need to evolve from traditional automation specialists into providers of comprehensive enterprise-wide solutions. This shift will require building expertise across all layers of the stack, adopting agile methodologies, and staying vendor-agnostic.
- Distributors: The days of selling only specific components are ending. Distributors will need to offer complete, integrated solutions that span the entire automation stack and focus on digital transformation rather than isolated products.
Conclusion: Embracing the Future of Industrial Automation
The convergence of the automation stack and IIoT is transforming the industrial world, creating smarter, more connected systems that allow for real-time decision-making, process optimization, and greater efficiency. While the path to fully embracing these technologies might present challenges, the benefits are undeniable.
As businesses evolve and adapt to Industry 4.0, they’ll unlock new opportunities for innovation, agility, and competitiveness. Those who embrace this data-driven, interconnected future will thrive in the next era of industrial automation.
