What is an Automation Panel? What Parts Does It Consist Of?

What is an Automation Panel and What Parts Does It Consists Of?

In industrial facilities, machines communicate with one another, and production processes run smoothly. Behind these operations lies a critical structure: the automation panel, which is responsible for managing and securing the facility. But what exactly is an automation panel? What components does it include, and how does it work? In this article, we’ll answer these questions in detail and explore the working principles of automation panels.

What is an Automation Panel?

Automation panels are control systems that enable the centralized and automated management of operational processes. While they are most commonly used in industrial facilities and smart buildings, they are also found in other areas where automation plays a role. These panels are critical for powering electrical circuits and managing power distribution. Additionally, they play an active role in coordinating communication between various electrical components.

Main Components of Automation Panels

The components of an automation panel can, in a way, be compared to the human body. Just like our sensory organs, brain, and muscles work together to perform actions, automation components mirror this logic in how they operate. Each part plays a crucial role in sensing, processing, and acting—allowing industrial processes to be managed efficiently and effectively.

Control Devices

Control devices are the components often referred to as the brain of the system. They enable automation and ensure that processes are properly monitored and controlled.

Programmable Logic Controllers (PLC)

It is a component that processes data received from sensors and controls the outputs. By following pre-programmed instructions, it makes decisions and controls the movement of equipment. It has the capability of real-time control. Based on a microprocessor, it can work with both digital and analog inputs. These systems support various industrial communication protocols such as Modbus, Profibus, and Ethernet/IP.

Compared to relay-based control systems, PLC panels are less affected by dust, moisture, and magnetic fields, and they reduce wiring complexity inside the panel. PLC panels are effectively used in a wide range of applications such as complex factory automation, conveyor systems, motor speed control, and energy monitoring systems.

Remote Terminal Units (RTU)

It is a component commonly used for monitoring remote devices in automation systems. It is used to transmit electrical signals to distant devices. Rather than being preferred for complex systems, it is mainly utilized in scenarios where data security and reliability are prioritized. Additionally, it offers a more flexible structure in terms of configuration.

Human-Machine Interfaces

HMI (Human-Machine Interface) is the part of automation systems designed for human interaction. Through interfaces, users can monitor and control the automation system. It is presented with a user-friendly interface that is as free from technical complexity as possible.

HMI allows authorized and qualified personnel to input data, monitor the system, and issue commands when necessary. Data received from sensors is displayed in real time—either graphically or in a simplified format. Alerts and alarms based on this data are also monitored and managed through the interface.

Sensors

Sensors play a crucial role in providing data for industrial processes. They hold a vital and critical position in delivering fast, reliable, and precise information. These devices continuously monitor environmental variables—such as temperature, pressure, current, and voltage—and transmit the collected data to control systems.

Energy analyzers also serve as data-providing components. By measuring the energy consumed by the panel, they offer detailed insights for monitoring and optimization.

Actuators

These are the components that perform physical actions based on the output generated after the data provided by the sensors is processed by the control systems. Their operation is managed by the control systems.

Power Supply and Distribution Components in Automation Panels

This is the component responsible for providing the power necessary for the operation of the automation panel. It processes the electrical power coming from the energy source and supplies it to the system.

Fuses and circuit breakers are precautionary components designed to protect against potential issues with incoming power. Automatic fuses and circuit breakers help prevent problems such as overcurrent and short circuits.

Devices in the electrical panel that operate on low current and voltage are controlled using a relay module. One commonly used type is the thermal relay, frequently preferred in electrical panels. For high current and high voltage applications, the contactor component is used, serving as a fundamental element in motor protection.

Connecting and Cabling Components

These are the cables that provide the connection between the components making up the automation panel. The power supply process starts here and extends to the devices, and if present, to other automation systems as well. Automation panels also ensure the organization of the wiring. For this purpose, cable ducts are used, which help keep the cables neatly arranged and securely stored.

Other Components

Besides the main components we mentioned, automation panels also include smaller-scale and simpler elements that perform additional functions. Buttons (also known as switches) are used not only to turn the system on and off but also to control specific functions within the system. Indicators and signal lamps are used to display system status and information. For the safe operation of the system, grounding, fans, and filters are also employed. These components are important for keeping the system clean and protecting it from overheating.

The Importance of Automation Panels in Industrial Applications

Automation projects become safer, more efficient, and better organized with the use of automation panels. This is because automation panels don’t just automate energy distribution—they also enhance energy efficiency, workplace safety, and enable more precise management of processes.

Different types of automation panels are used depending on the solution requirements. These panels support uninterrupted power supply and are especially crucial in high-risk and critical areas like transformer stations, where both safety and energy efficiency are maximized.

Automation panels help keep equipment organized and contribute to extending the lifespan of components. Additionally, they reduce costs in the long term while preventing time and production losses.

Types of Automation Panels

Automation panels come in different types depending on the needs and application areas. Choosing the right type among these options is crucial for ensuring more efficient and stable system operation. In industrial automation, environmental conditions and industrial processes are carefully considered when making this selection.

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PLC Automation Panel

Automation panels that include PLCs fall into this category. They play a key role in automating production and operations in industrial facilities. PLC panels provide solutions for complex factory automation, conveyor systems, motor speed control, and energy distribution applications. While they are widely used across many sectors, they are particularly common in industries such as oil and gas, energy, water treatment, transportation, food, and beverage.

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RTU Otomasyon Panosu

An RTU automation panel is designed for monitoring and controlling remote devices. It is used to transmit electrical signals to SCADA and automation systems. Similar to PLC automation panels, RTU panels are commonly used in industries such as oil and gas, energy, water treatment, transportation, food, and beverage.

PLC vs RTU

While PLCs typically handle local control within a facility, RTUs are designed to communicate with remote field devices.

Motor Control Center (MCC) Panosu

MCC (Motor Control Center) panels are system panels that enable the manual or automatic, remote or local control of equipment such as motors, pumps, and fans. They are particularly preferred in applications where multiple motors need to be controlled within the same facility. These panels are typically designed to operate three-phase AC motors at voltage levels ranging from 200V to 600V.

Each motor circuit generally includes essential protection and control components such as contactors, motor protection circuit breakers, fuses, and load disconnect switches. Additionally, these panels are equipped with communication hardware that allows integration with PLC, SCADA, and central automation systems. Field motors and other electrical devices are automatically protected against voltage fluctuations through the MCC panel, thereby preventing potential damage to equipment.

Working Principles of Automation Panels

Automation panels are composed of a set of components that support automation systems. In the context of industrial automation, they enable the monitoring, analysis, and control of industrial processes. At its core, the process consists of a cycle where sensors collect data, this data is processed by control devices, and then transformed into physical actions with the help of actuators.

Data Gathering and Processing from Sensors

An automated control panel enables the collection of various types of data through sensors. To interpret the data gathered by sensors, control systems such as PLCs or RTUs are used. These systems continuously process the incoming sensor data and relay meaningful information to decision-making mechanisms.

Through sensors, environmental variables such as temperature, pressure, current, voltage, and level measurements are monitored. For example, the current value in a system is continuously tracked by sensors and shared with the control system. The control systems then use this data both for real-time monitoring and for making operational decisions.

Decision Making by Control Devices

Control devices are the components that interpret the data transmitted by sensors and enable the automation of the process. During data processing, these devices follow a set of programmed instructions. These instructions are executed in sequence to facilitate decision-making. The decision-making process can be modified by reprogramming the control devices according to specific needs and requirements.

Difference Between PLC and RTU on Decision Making Process

As mentioned earlier, control systems can be either PLCs or RTUs. PLCs operate by processing instructions in a sequential loop. However, this can sometimes lead to missing changes in the system if they occur before the loop completes. In contrast, RTUs record data chronologically, which prevents data loss from sensors and allows for faster response times. This ensures, for example, that in the event of a power outage, the decision to activate a backup power source is made without delay or data loss.

Control of Components via Actuators

Actuators enable the control of equipment by taking action based on the data received from sensors and control devices. They can be considered the output of the system, as they perform physical actions based on processed data and resulting decisions. For example, in the previously mentioned case, the activation of a backup power source is carried out by actuators.

Actuators also play a crucial role in enforcing certain rules. For instance, if control devices receive data from sensors indicating that the electrical panel door is open, this information is relayed to the actuators. In response, the actuators may prevent power distribution and trigger alarms or sirens.

System Monitoring by HMIs

An HMI (Human-Machine Interface) is a user-friendly interface that allows authorized personnel to monitor and manage the system. The user-friendliness of the HMI is crucial, as it facilitates more efficient and accurate system monitoring and management.

HMI plays a vital role in the efficient operation of the system. Through the HMI, data can be monitored, and input or control commands can also be issued. Additionally, it serves as an interface for system maintenance. Authorized service personnel use the HMI to perform necessary checks and maintenance procedures. To enter maintenance mode, it often requires scanning a magnetic card held by authorized service users.

System Integration and Remote Monitoring

Automation panels play a critical role in system integration within industrial facilities. By working in coordination with PLC and SCADA systems, they enable process monitoring and remote control. Technologies that are core components of Industry 4.0—such as IoT, artificial intelligence, and big data analytics—are integrated into the field through these panels.

Data is collected, analyzed, and used to optimize system performance via communication networks established among IoT devices. The panels manage this communication traffic, ensuring that devices operate securely and in sync. The operation of the system is based on a closed-loop control principle: data from sensors is evaluated by the control unit, and necessary outputs are executed via actuators. This continuous feedback mechanism ensures maximum stability with minimal human intervention.

Real-time data processing and signal integrity are of vital importance, especially in processes requiring rapid response. Accurate timing of RTUs directly affects system reliability and helps prevent potential failures.

Industrial communication protocols used for data transmission (such as RS-485, Ethernet TCP/IP, HART, etc.) enable different devices to communicate in a common language. Next-generation wireless technologies (like Wi-Fi 6) add benefits such as high bandwidth and low latency to this infrastructure. As a result, systems become more scalable, more flexible, and more intelligent.

Manufacturing and Installment of Automation Panels

Automation panels must be installed safely and in accordance with established guidelines to ensure stable and secure system operation. This means that all processes—from manufacturing to installation—must be carried out in compliance with relevant standards.

Manufacturing Process

The production process begins with designing the automation panel according to specific needs. Every aspect—from operation to maintenance—must be carefully and accurately planned.

Attention to such small details during the production phase greatly facilitates the panel’s installation, operation, and maintenance. Identifying faults, enabling quick interventions, and applying color coding to cables are particularly important in this regard.

Installing and Integrating

The installation of the automation panel involves connecting all devices together. Additionally, the authorization and training of responsible personnel are addressed at this stage. Upon delivery, the panel is provided along with the user manual, circuit diagram, and terminal connection point information.

Conclusion

Automation panels are indispensable components of modern industrial facilities and smart buildings. By enabling automatic control of industrial processes, they regulate energy distribution, ensure system protection, and enhance operational efficiency. These panels offer multifaceted benefits—such as energy savings, cost reduction, workplace safety, production continuity, and quality improvement—significantly boosting the competitiveness of businesses.

Contact us to make your automation systems safer and more efficient. Let’s plan the panels tailored to your specific application needs together.