What is Industrial Automation (IA)?
Industrial automation refers to the comprehensive technologies and systems used to automate manufacturing, assembly, inspection, and other processes in factories and production sites—particularly in the manufacturing industry—without human intervention. It encompasses the use of industrial robots, computer control systems, various sensors, and advanced technologies such as IoT and AI. The primary objectives are to improve productivity, reduce costs, stabilize quality, lessen the workload on human operators, and ensure worker safety in hazardous environments. Tasks that were traditionally performed by humans can now be autonomously controlled through devices such as PLCs (Programmable Logic Controllers) and industrial robots, enabling, in some cases, continuous 24-hour operation. Furthermore, the integration of IoT, AI, and big data enables real-time collection and analysis of production data and process monitoring. This advancement facilitates production line optimization and predictive maintenance, thereby accelerating the realization of smart factories.
Industrial Automation and Factory Automation (FA)
Industrial automation and factory automation are often regarded as synonymous, but they are, in fact, distinct concepts. Industrial automation refers to the automation of processes across a wide range of industries, including but not limited to manufacturing—covering sectors such as energy and logistics as well. Factory automation, on the other hand, is positioned as a subset of industrial automation. It specifically focuses on automating and improving efficiency within factory production processes through technologies such as industrial robots. Additionally, within the broader field of industrial automation, there are related terms such as Process Automation (PA)—which applies mainly to the chemical and energy industries—and Manufacturing Automation (MA), which is often used interchangeably with factory automation. The usage of these terms varies depending on region and context.
Industrial Automation and Gears
In the technologies that support industrial automation, gears play an extremely important role as mechanical components responsible for transmitting torque and speed, as well as changing the direction of force. The most common type, spur gears, transmit power between parallel shafts and are widely used in applications such as robots, machine tools, and conveying systems. Worm gears, used between non-parallel and non-intersecting shafts, provide a high reduction ratio in a compact space and also feature a self-locking capability. Bevel gears are suitable for changing shaft angles, and one of their variants, the hypoid gear, offers a high reduction ratio and is frequently used in compact systems such as within robotic joints. Rack and pinion mechanisms, which convert rotational motion into linear motion, are key components for positioning in automation equipment and are commonly used in systems like gantry robots, alongside ball screws as representative linear motion mechanisms. Furthermore, in areas where highly precise control is required—such as in robotics—strain wave gear mechanisms, which combine multiple gears to minimize backlash, are often employed. Gears used in industrial automation are manufactured with advanced processing technologies such as grinding and heat treatment to ensure high precision and hardness, enabling them to meet the demanding requirements of modern industrial environments.