For more than 40 years, distributed control systems (DCSs) have helped producers of the world's goods bring their products to market. Today’s technological innovations promise that the control systems of tomorrow can accelerate innovation and improve operations.
The future of process automation and control systems combines the reliability of traditional DCS with the agility of cloud/IT ecosystems. New systems will be modular, standards-based, secure and data-driven—enabling faster projects, new digital services, higher autonomy and measurable sustainability gains, all while protecting existing automation investments.
According to a whitepaper from ABB, “A confluence of user-driven initiatives towards openness, security and interoperability is motivating change in automation system development.” The need to significantly renew the technology is being met. Here’s what new process automation and control systems look like and how they will support industrial needs into the future.
The high level architecture of the new process automation systems (PASs) includes an evergreen control core: a hardened, deterministic, safety and cyber secure control layer that remains stable and available. The extended digital environment is a separate, connected edge/cloud layer for non time critical monitoring, analytics, apps and IIoT services. Modern systems have a clear separation of concerns, so innovations can be introduced in the extended layer without risking core operations.
Modularity, portability and standards will be key. Containerized control engines and application modules that are hardware agnostic run on industrial controllers, edge nodes, on-prem servers or in the cloud. Standard information models and protocols (OPC UA, PA DIM) are used and there will be alignment with OPAF / NAMUR NOA for interoperability and plug-and-produce workflows.
Automated orchestration manages where modules run, load balances resources, enforces availability SLAs, and hides complexity from operators. Digital twin validation and virtual commissioning are used to test changes before pushing systems into production. An “evergreen” approach to the system lifecycle means a continuous, validated evolution of software with minimal disruption to operations.
Improved security posture
Cybersecurity is baked into modern automation and control systems and designed to evolve. Key techniques such as secure by design and zero trust approaches are included. These encompass component identity, authentication/authorization, signed artifacts and hardened interfaces.
At the data level, data flow is separated using data diodes and edge gateways so non-critical IIoT traffic does not undermine the core.
Faster engineering and project execution
Modern systems streamline engineering and promise faster execution. Decoupled hardware and software engineering—including parallel workflows, late binding, smart junction boxes and reusable pre tested modules—shorten schedules and reduce rework. Automated engineering tools such as smart PI&Ds and control-logic code generation accelerate system delivery.
Digitalization, analytics and business models are also improved. Edge analytics combined with cloud-based artificial intelligence and machine learning (AI/ML) produce insights that lead to actions for improving optimization, predictive maintenance, emissions and ESG reporting.
App marketplaces and subscription (SaaS/PaaS) models software enable fast adoption of new digital capabilities, as well as cost-effective pay as you use programs and trials.
Workforce impact
Modern process automation systems support remote operations and fewer on-site specialists. Greater reliance on digital native tools, augmented reality, and operator assistance systems enhance both operator satisfaction and efficiency. Knowledge is preserved even as experienced staff retire through the use of modular libraries, digital twins and AI augmented expert systems.
A gradual evolution toward greater autonomy is possible. Modern systems can support a six level taxonomy (range of 0–5) that moves from manual operation to fully autonomous in defined situations. Humans partnered with AI support—such as augmented reality and mobile tools for field personnel—enable decision making, remote supervision and higher value engineering tasks.
Visit ABB’s website to learn more and to download the whitepaper, “The DCS of Tomorrow.” It is the company’s guide to “simplifying and accelerating innovation with continuity.”
