Digitalization and automation in mechanical engineering: control, sensor technology, software

Technological control of industrial processes

Automation and digitalization have structurally changed mechanical engineering. While classic disciplines focus on mechanical functionality and material mastery, mechanical engineering in automated systems is expanding to include information technology, sensor technology, and software-based levels. The goal is not to replace mechanical technology, but to precisely control, monitor, and optimize it. This makes machines more reproducible, more efficient, and easier to integrate into higher-level production systems. The following disciplines form the technical foundation of this change and are now an integral part of modern mechanical engineering applications.

Automation technology

Automation technology deals with the automatic control and regulation of machines, systems, and processes. It ensures that defined processes are carried out reliably without continuous human intervention. It is based on clearly defined process models, state logics, and safety concepts. In mechanical engineering, automation is not an end in itself, but serves to ensure process stability, product quality, and economic efficiency. Typical applications can be found in series production, assembly, packaging technology, and continuous process plants. The central tasks of automation technology are:

• Analysis and modeling of technical processes
• Definition of control sequences and state logic
• Integration of sensors and actuators
• Implementation of safety-related functions

Robotics and handling technology

Robotics and handling technology expand mechanical engineering with flexibly programmable motion systems. Industrial robots take on tasks that require high repeatability, speed, or ergonomic relief. These include welding, assembly, palletizing, and installation work. In addition to robots, handling technology also includes grippers, axis systems, and conveyor systems. The precise coordination of mechanics, drive, and control is crucial to ensure safe and reproducible movements. Typical components of robotic systems are:

• Industrial robots with multiple axes
• Gripper and tool systems
• Positioning and transport systems
• Safety and collision protection systems

Mechatronics

Mechatronics combines mechanics, electronics, and information technology to create functional overall systems. In mechanical engineering, it is less a discipline in its own right than an interdisciplinary development approach. The aim is to solve functions not exclusively mechanically, but through the interaction of several technical levels. Typical mechatronic systems include servo-electric drives, adaptive grippers, and intelligent valve systems. Mechanical components are specifically supplemented by sensors, actuators, and software. Mechatronic systems are characterized by:

• Close coupling of mechanics and electronics
• Software-supported functional expansion
• Compact design with high functionality

Sensors and measurement technology

Sensors and measurement technology provide the data basis for automated and digitized machines. Sensors record physical variables such as position, force, pressure, temperature, or flow rate, making conditions measurable and evaluable. In mechanical engineering, the reliability of sensors is crucial. Measured values must be reproducible, robust, and available under industrial conditions. The data obtained is used not only for control purposes, but also for monitoring quality, wear, and process stability. Typical areas of application for sensor technology are:

• Position and location detection
• Force and torque measurement
• Pressure and flow measurement
• Condition monitoring of components

Control and regulation technology

Control and regulation technology processes sensor data and implements the resulting actions. Controls follow defined sequence plans, while regulations continuously compare target and actual states and correct deviations. Programmable logic controllers and industrial control systems are predominantly used in mechanical engineering. These take over both logical sequences and time-critical motion and process control. The differences between control and regulation can be summarized as follows:

Industrial software and embedded systems

Industrial software and embedded systems add a digital functional level to mechanical engineering. Embedded systems are computer-based systems that are permanently integrated into machines and perform specific tasks there. These include control systems, drive controllers, and safety modules. Industrial software also includes user interfaces, visualization systems, and communication interfaces. They enable the parameterization, monitoring, and integration of machines into higher-level production IT. Typical functions of industrial software are:

• Machine operation and visualization
• Data acquisition and logging
• Communication with control systems
• Diagnostic and maintenance functions

Consolidated view

Automation and digitalization are changing mechanical engineering not just in isolated areas, but structurally. Mechanical systems remain the foundation, but are functionally enhanced by sensor technology, control systems, and software. The disciplines described are closely interlinked and together form the basis of modern industrial production systems. Mechanical engineering for automation and digitalization is therefore not a separate special field, but rather a logical further development of classic engineering principles under digital conditions. The importance of mechanical engineering in terms of energy, the environment and sustainability is also clear in many respects.