It is the combination of control devices, power supplies and commercially available technologies that has helped the automation system become more and more complete, bringing outstanding productivity and high reliability.

In the content below, Intech Group will help you learn in detail about the important components in the automation system and how they coordinate to create a synchronous, optimal solution for production.

What is an automation system?

An automation system (or automatic control system) is a set of devices and technologies used to control machines and production lines without direct human intervention. Instead of manual operation or relying on traditional chain-gear mechanisms, modern automation systems apply industrial computers, sensors, controllers and electric actuators to ensure more precise, fast and stable operation.

Components of an automation system and subsystems

An automation system is made up of many subsystems, each of which plays an important role in ensuring safe, accurate and efficient operation. Below, Intech Group will provide you with information about the components of an automation system to help businesses choose the right solution.

Power distribution system

The main task of the power distribution system is to supply power to motors, drives and controllers. To ensure safety, the system must be equipped with disconnecting devices such as switches, circuit breakers, plugs, etc., along with an insulating layer to protect wires and electrical components. In addition, overcurrent protection devices such as fuses and circuit breakers help reduce the risk of short circuits, overloads and limit the risk of fire and explosion.

Motor and transmission control system

The motor is the heart of the machine, so the motor and transmission control system is the core component. This system allows starting, speed regulation, rotation direction control and ensures stable operation of the motor. Commonly used devices include starters, inverters, speed controllers and soft starters. At the same time, the system needs to integrate overload protection, phase loss, abnormal voltage and ground connection to maintain safety in production.

Safety System

The safety system plays a role in protecting people and equipment during operation. When an incident occurs, it ensures that the machine stops promptly and properly. Common devices include safety relays, limit switches, light curtains and safety controllers (Safety PLCs). For simple machines, safety relays can handle emergency stops, while complex lines often use Safety PLCs to manage multiple safety devices at the same time.

Programmable Controllers and I/O

Depending on the scale and complexity, businesses can choose PLCs, PACs or industrial PCs. They are designed in many different sizes, from compact for simple applications to large configurations for complex lines.

The highlight of modern controllers is the ability to program on the same software platform. This allows the design engineer the flexibility to choose a controller based on the number of I/O points, processing speed, and specialized functions such as PID control or data processing.

I/O (Input/Output) connects the controller to sensors and actuators. Today, distributed I/O architectures are preferred because they reduce wiring and transmit data more efficiently. Protocols such as IO-Link allow data to be transmitted from sensors to controllers along with diagnostic information and device status, improving accuracy and monitoring capabilities.

Communication systems

Industrial communications are an indispensable element in the components of automation systems. A modern system needs to integrate multiple high-speed Ethernet ports and serial ports to connect to HMIs, computers, production management systems, and even enterprise platforms.

Popular protocols such as EtherNet/IP, Modbus TCP/IP support fast and stable data exchange between devices and controllers. In addition, many systems still maintain old communication methods such as RS-232 or RS-485 for increased flexibility.

Human-machine interface (HMI)

From touch screens, text displays, to modern industrial displays, HMIs allow monitoring machine status, reporting errors, adjusting parameters and executing operating commands.

Each application will require a different level of HMI. For simple machines, only a message display screen is needed; while for complex lines, HMIs must provide detailed information, advanced access and the ability to handle production recipes.

In addition, HMIs can also connect to multiple devices in the network, support protocol conversion and even send data to the cloud for remote analysis. Some modern HMIs incorporate secure Internet access, allowing the operator to control the machine from anywhere.

Applications of automation system components in practice

Applications in manufacturing industry

In industrial production, automation system components are deployed to manage the entire chain, from raw material preparation to finished product packaging system. Devices such as sensors, programmable logic controllers (PLCs), industrial robots, robotic loading stations, AGVs and multi-function displays, along with IoT solutions such as OEE, EEC or MMS help increase productivity, reduce errors and ensure product quality.

For example:

- Toyota: With the philosophy of "Lean Manufacturing" and the Just-in-Time model, Toyota has applied a comprehensive automation system in production and logistics management, making Toyota a global icon of lean production management.

- Vinamilk (Vietnam): A domestic enterprise applying automation systems to milk production. The Mega Factory in Binh Duong is equipped with a fully automated production line from raw material import, production, packaging to smart warehouse storage, helping Vinamilk improve productivity, reduce costs and export products to more than 50 countries.

Application in building automation

In the field of construction and building management, the automation system is integrated through the BMS (Building Management System) solution. The automation components help control lighting, HVAC systems (heating - ventilation - air conditioning), fire alarm management, security control and energy monitoring. Thanks to that, smart buildings operate cost-effectively, improve safety and bring a more comfortable experience to people.

Application in healthcare

Automated medical devices, surgical robots, automated testing systems or patient data storage and retrieval systems have contributed to improving the quality of medical examination and treatment, while optimizing operating processes in hospitals.

For example:

Vinmec (Vietnam): Vinmec hospital system applies Da Vinci surgical robot, automation in electronic medical record management (EMR) and AI imaging system to improve accuracy, reduce risks and bring better experience to patients.

Application in agriculture

In agriculture, automation helps convert traditional production methods to high-tech agriculture. Soil moisture sensors, smart irrigation systems, drones and agricultural robots are important components to help farmers monitor crops, save costs and increase productivity.

Application in transportation and logistics

Automation systems are also applied in traffic management, warehousing and logistics. Smart traffic signal control systems, fleet management, automated warehouses, conveyor belts and loading and unloading robots help improve operational efficiency, reduce labor costs and limit risks during transportation.

Applications in energy and environment

In the energy industry, automation plays an important role in smart grid management, energy consumption monitoring and power station operations. In the environmental field, automation systems are used to control water and air quality, waste treatment and wastewater treatment plants.

- EVN (Vietnam Electricity Group): EVN deploys smart grids and automatic control centers. SCADA/DMS systems are integrated to monitor, distribute and automatically restore power in the event of a problem. This helps improve stability, minimize power outages and ensure sustainable energy supply.

It can be seen that the components of the automation system not only play a role in industrial production but also extend to many fields such as construction, healthcare, agriculture, transportation or energy. The synchronous and effective application of these components brings high productivity, cost savings, increased safety and improved quality of life. Intech Group specializes in providing automation solutions, industrial conveyor systems, robot loading and unloading stations, smart warehouses, AGV self-driving vehicles, etc. If you want to learn more and deploy a suitable system, please contact Intech Group immediately for detailed advice and support in the digital transformation process.