The Future of Automation Is Software-defined: Are You Ready?

Summary

In the rapidly evolving industrial landscape, Software-Defined Automation (SDA) is emerging as a transformative force, integrating Information Technology (IT) methodologies into Operational Technology (OT) use cases. This convergence is not merely a trend but a fundamental shift that is redefining the paradigms of industrial automation.​

Bridging IT and OT: A symbiotic relationship

Traditionally, industrial automation has been heavily reliant on hardware-centric solutions, leading to challenges in scalability, flexibility and adaptability. The advent of SDA marks a departure from this norm by emphasizing adaptive automation solutions that can be dynamically configured and updated. This shift marks a significant change in the perception of IT/OT convergence.

This integration facilitates:​

• Scalability: Software-defined systems can be easily scaled to accommodate growing operational demands without substantial hardware investments.​
• Flexibility: Modular software components allow for rapid reconfiguration and adaptation to changing production requirements.​
• Enhanced maintenance: IT methodologies, such as continuous integration and remote access, enable proactive system maintenance and updates, reducing downtime.​

By adopting IT mechanisms, industrial automation systems can achieve a level of agility and efficiency that mirrors modern IT infrastructures.​ This means that what was previously handled via a variety of platforms can now be combined on a central software infrastructure.

Embracing the industrial edge

This central infrastructure marks the emergence of edge computing–a method of processing data near its source. On the shop floor, Industrial Edge from Siemens enables decision-making directly where data is generated: at the machine level:

By deploying SDA on Industrial Edge, companies can achieve:​

• Converged functionality: Run control, human-machine interfaces and data analysis on the same infrastructure.
• Operational efficiency: Centralized processing leads to more efficient resource utilization and system adaptability.
• Centralized management: Use IT-Like update and management mechanisms to centrally orchestrate apps across machines, lines and factories.

Running real-world applications on virtualized runtimes

These benefits are now also accessible for automation solutions next to data processing. This was also what car manufacturer Audi wanted when they decided to virtualize their shop floor by implementing virtual PLCs from Siemens.

To make this happen both parties worked together closely. Audi developed Edge Cloud 4 Production to realize Audi’s vision of the 360factory–a fully connected, highly efficient and sustainable production environment. In the future, a wide variety of applications will run on this IT-based infrastructure and be managed centrally. One of these apps–which is also at the heart of automation–is the virtual PLC.

And of course, virtualizing the production does also include failsafe functionalities, so it was clear that they had to be virtualized as well.

Together, we successfully developed and deployed SIMATIC S7-1500V F–the world’s first TÜV-certified, failsafe virtual PLC. Already being implemented at Audi’s Böllinger Höfe factory in Neckarsulm, Germany, this innovation is a cornerstone of Audi’s 360factory vision, increasing production reliability, flexibility and efficiency at Audi.

Speeding up the engineering process

When approaching shop floor automation with a software-defined mindset you also want to streamline engineering processes with those tried-and-true methods from software development:

• State-of-the-art development: Leveraging software development methods like object-oriented and document-based programming to ensure modularization.
• Automated automation: Use software to automatically generate, test and deploy code to minimize manual work and errors.
• Collaborative development: With version controls, collaborative platforms and open-source platforms, engineers can team up, speeding up processes.

These practices accelerate development cycles and improve the quality and reliability of solutions.

Challenges and considerations

While the benefits are substantial, transitioning to SDA is not without challenges. Organizations must consider factors such as:​

• Legacy systems integration: Ensuring compatibility between existing hardware and new software-defined systems can be complex.​
• Skillset requirements: The convergence of IT and OT necessitates a workforce proficient in both domains, highlighting the need for targeted training and development.​
• Security implications: As systems become more interconnected, robust cybersecurity measures are imperative to protect against potential threats.​

Addressing these considerations is crucial for a smooth and successful transition to SDA.​ The good news is Siemens offers a proven portfolio that combines the market-leading Totally Integrated Automation (TIA) concept with Software-Defined Automation capabilities for greater scalability and adaptability.

The road ahead

The trajectory of industrial automation is unmistakably veering towards increased software integration. As industries continue to embrace digital transformation, the role of SDA will become increasingly pivotal. Organizations that proactively adopt and adapt to these changes position themselves at the forefront of innovation, ready to capitalize on the myriad benefits that SDA offers.​

In conclusion, Software-Defined Automation represents a paradigm shift in industrial operations, blending the robustness of traditional automation with the agility and scalability of modern IT practices. By harnessing the power of SDA, industries can achieve unprecedented levels of efficiency, flexibility and competitiveness in the ever-evolving global market.