The 5 Most Commonly Used Components in Industrial Automation

Companies like IQElectro specialize in delivering the core components that make these systems efficient and reliable. From sensors to PLCs, each part plays a vital role in keeping operations running smoothly.

In this article, we’ll take a closer look at the five most commonly used components in industrial automation. These components appear in everything from small machines to large factory systems. 

1. Programmable Logic Controllers (PLCs)

PLCs are the brains of most automated systems. These compact computers control machines and processes. They read data from sensors, make decisions based on that data, and then send commands to other devices.

You can program a PLC to do almost anything—from turning on motors to counting parts. They’re popular because they’re reliable, easy to reprogram, and built to handle tough industrial environments. A well-known example is the 5069-L320ER Controller, a compact yet powerful PLC that offers fast processing, integrated safety, and flexible communication options. It’s ideal for mid-size applications that demand high performance.

Modern PLCs also offer network connectivity so they can share data with other machines and with central systems. This helps businesses monitor performance and fix problems quickly.

2. Sensors

Sensors are like the eyes and ears of an automation system. They gather real-time data from the environment and send it to the PLC or controller. There are many types of sensors, each built to detect specific things.

For example:

1. Proximity sensors detect if an object is nearby.
2. Temperature sensors measure heat levels.
3. Photoelectric sensors use light to detect objects.
4. Pressure sensors track gas or liquid pressure.

Without sensors, automation wouldn't be possible. They give machines the awareness they need to make smart decisions and respond to changes instantly.

3. Actuators

Actuators turn electronic signals into physical movement. When a PLC decides to move something, it sends a signal to an actuator. The actuator then performs the action.

There are three main types:

1. Electric actuators – These use electric motors to create movement.
2. Pneumatic actuators – These use compressed air to drive motion.
3. Hydraulic actuators – These use pressurized fluid for heavy lifting.

Actuators open and close valves, push and pull parts, and move robot arms. Without them, machines would have no way to interact with the physical world.

4. Human-Machine Interfaces (HMIs)

HMIs let humans interact with automated systems. They display real-time information and let operators give commands or adjust settings.

A basic HMI might be a simple screen with buttons. More advanced systems use touchscreen displays with dashboards, graphs, and alert systems. HMIs help technicians monitor performance, troubleshoot problems, and maintain safety. When paired with PLCs, HMIs become powerful tools. They allow for better communication between humans and machines.

5. Industrial Communication Networks

In a fully automated system, all components must talk to each other. That’s where industrial communication networks come in. These networks connect PLCs, sensors, actuators, HMIs, and other devices.

Popular communication protocols include:

1. Ethernet/IP
2. Modbus
3. Profibus
4. DeviceNet

These systems allow machines to share data quickly and reliably. This is essential for real-time control and coordination. A good communication setup reduces delays and keeps everything in sync.

Modern factories often use Industrial Internet of Things (IIoT) technologies. These connect machines to cloud systems for analytics, maintenance alerts, and remote control.

Final Thoughts

Industrial automation depends on a few key components working together. PLCs control the system, sensors provide input, actuators create movement, HMIs allow human oversight, and communication networks tie everything together. These five parts form the foundation of most automated setups. Automation is here to stay—and it’s getting smarter, faster, and more connected every year.