Automation Integration
Connect Industrial Automation Systems into One Coordinated Environment
Manufacturing facilities rarely contain automation equipment installed at the same time or supplied by a single manufacturer. Production environments evolve over many years, resulting in different PLC platforms, machines, control panels, drives, SCADA systems and communication technologies operating alongside one another.
The challenge is making these systems communicate reliably.
Industrial automation integration connects individual machines and control systems so information, commands and production states can move between equipment where required.
Stratos integrates new and existing industrial automation systems, helping manufacturers connect PLCs, machinery, control panels, SCADA platforms and industrial networks without unnecessarily replacing equipment that remains suitable for continued operation.
What Is Industrial Automation Integration?
Industrial automation integration is the process of connecting separate control systems, machinery and industrial technologies so they can operate and exchange information as part of a coordinated environment.
Integration may involve:
PLCs.
Production machinery.
Industrial control panels.
Remote I/O.
Variable Speed Drives.
HMIs.
SCADA systems.
Instrumentation.
Industrial networks.
Existing legacy systems.
The level of integration required depends on how equipment needs to interact and what information needs to move between systems.
PLC Integration
PLCs are frequently at the centre of automation integration projects.
A PLC may need to communicate with:
Other PLCs.
Production machinery.
Remote I/O.
Drives.
HMIs.
SCADA systems.
Instrumentation.
Third-party equipment.
Integration requires more than establishing communication between two devices.
The PLC software also needs to interpret incoming information correctly and determine how the wider control system should respond to equipment states, commands and faults.
Integrating Different PLC Manufacturers
Individual machines are often originally supplied as standalone systems.
As production requirements develop, those machines may need to operate as part of a wider production line.
Machine integration may involve sharing:
Ready signals.
Running conditions.
Production states.
Product information.
Fault conditions.
Line speeds.
Start and stop requests.
Interlocks.
Production counts.
Clear communication between machines can help coordinate production flow and prevent one system from operating incorrectly when equipment elsewhere in the line is unavailable.
Control Panel Integration
New automation equipment often needs to be incorporated into existing electrical control infrastructure.
As a control panel manufacturer, Stratos can assess whether integration requires modifications to an existing panel or the development of additional control panel equipment.
Integration may involve:
Additional PLC hardware.
Remote I/O.
Communication gateways.
Industrial network switches.
Variable Speed Drives.
Safety equipment.
Additional power supplies.
New control circuits.
Panel modifications.
Considering the electrical and software requirements together helps ensure new equipment is integrated correctly into the wider control system.
SCADA and HMI Integration
Integrating production equipment with SCADA can provide wider visibility across machines and processes that previously operated independently.
SCADA integration may provide access to:
Machine status.
Process information.
Production output.
Equipment faults.
Alarm conditions.
Setpoints.
Historical information.
Operational KPIs.
HMIs can also be developed or modified to provide operators with appropriate visibility and control of newly integrated equipment.
Stratos considers both the supervisory application and the PLC systems generating the underlying information.
Industrial Network Integration
Reliable automation integration depends heavily on industrial communications.
Depending on the existing systems, integration may involve:
PROFINET.
PROFIBUS.
EtherNet/IP.
Modbus TCP.
Modbus RTU.
Industrial Ethernet.
OPC UA.
Communication gateways.
The appropriate method depends on the equipment being connected and the operational requirements of the system.
Network architecture should also consider reliability, future expansion and appropriate separation between industrial and wider business networks.
Integrating Legacy Automation Systems
Older automation equipment does not always need to be replaced simply because newer technology is being introduced.
Legacy PLCs and machinery may continue to perform their primary control functions reliably while requiring integration with newer equipment.
Integration options may include:
Communication gateways.
Additional PLC interfaces.
Remote I/O.
Protocol conversion.
SCADA connectivity.
New supervisory systems.
Data collection.
Where legacy equipment presents a genuine support or obsolescence risk, integration can also form part of a phased automation modernisation strategy.
Automation Data Integration
Automation integration is increasingly about connecting information as well as physical equipment.
Data from PLCs and production machinery can potentially be used by:
SCADA systems.
Historian systems.
Industrial dashboards.
Reporting systems.
Remote monitoring.
Maintenance systems.
Production management tools.
Bringing information together can provide a broader understanding of production performance and equipment condition.
However, data integration should be designed carefully so increased connectivity does not create unnecessary complexity or cyber security risk within the control environment.
Testing Integrated Automation Systems
When multiple control systems are connected, testing needs to verify both individual equipment operation and communication between systems.
Testing may include:
PLC communications.
Machine handshakes.
Data exchange.
Equipment interlocks.
Network communication.
Fault conditions.
SCADA data.
Operator commands.
Production sequences.
Recovery following communication loss.
Testing abnormal conditions is particularly important because integrated systems need to respond predictably when another machine or communication link becomes unavailable.
Supporting Integrated Automation
Integrated automation environments continue to evolve as equipment is added, replaced and modified.
Ongoing support may include:
PLC communication checks.
Network fault finding.
Control panel inspections.
SCADA integration support.
Software backup management.
Documentation updates.
Obsolescence monitoring.
System health checks.
Integration of additional equipment.
Where ongoing engineering support is required, maintenance and service contracts can provide structured support across the connected PLC, control panel, SCADA and industrial network environment.
Why Choose Stratos for Automation Integration?
Successful automation integration requires an understanding of both the systems being connected and the production environment in which they operate.
A communication link alone does not create an integrated control system. PLC logic, machine states, network architecture, control panels and operator interfaces all need to respond correctly when equipment interacts.
Stratos combines PLC programming, control panel engineering, SCADA and HMI development and industrial networking expertise to integrate automation across the complete control environment.
Whether you're connecting existing machinery, introducing new production equipment or bringing multiple automation platforms together, our engineers develop practical integration solutions around the systems already operating within your facility.
Connect Your Industrial Automation Systems
Separate machines and control systems do not need to remain isolated.
Stratos integrates PLCs, production machinery, control panels, SCADA systems and industrial networks to create connected automation environments that improve communication, production coordination and operational visibility.
Speak to our engineers about integrating new equipment, connecting existing machinery or bringing multiple industrial automation systems together.
Frequently Asked Questions
What is industrial automation integration?
Industrial automation integration connects PLCs, machinery, control panels, SCADA systems and other industrial equipment so they can exchange information and operate as part of a coordinated production environment.
Can different PLC manufacturers communicate with each other?
Often, yes. PLCs from different manufacturers can potentially exchange information using compatible industrial communication protocols or gateways. The appropriate solution depends on the controllers and existing network architecture.
Can new machinery be integrated with older equipment?
Yes. Existing machinery can often be integrated with newer automation through PLC communications, I/O, industrial networks or communication gateways without automatically replacing the older equipment.
Can existing machines be integrated into SCADA?
Potentially. Where suitable data and communications are available, existing PLCs and machinery can be connected to SCADA to provide centralised equipment status, alarms, production information and historical data.
Do you support integrated automation systems after installation?
Yes. Stratos can provide ongoing support across PLCs, industrial networks, control panels and SCADA systems. Maintenance and service contracts can also provide structured support as the integrated automation environment develops.