Unlocking Industrial Potential: How ABB Automation Extended Bridging the IT/OT Gap
The industrial world is shifting from rigid, proprietary systems toward flexible, modular ecosystems. Stefan Basenach, ABB’s Senior Vice President of Automation Technology, recently introduced "Automation Extended." This program redefines how companies approach modernization without risking operational stability. While traditional Distributed Control Systems (DCS) prioritized reliability above all else, modern markets demand much more. Today, operators must balance uptime with sustainability, cybersecurity, and rapid digital innovation.
Evolving from Traditional DCS to Modular Ecosystems
For decades, the DCS served as the unbreakable backbone of process industries. These systems ensured that chemicals processed and energy flowed without interruption. However, the rise of Industry 4.0 revealed a significant flaw in these legacy setups: lack of flexibility. Conventional hardware often struggled to integrate new IIoT and data analytics tools. As a result, many plants faced a difficult choice between aging infrastructure and risky, expensive "rip-and-replace" migrations.
Implementing the Separation of Concerns Principle
The core of ABB’s Automation Extended is a concept called "Separation of Concerns." This architecture splits the automation landscape into two distinct but connected zones. First, the Control Environment handles real-time, deterministic tasks where safety and availability are paramount. Second, the Digital Environment acts as a sandbox for innovation. Here, engineers can deploy AI, predictive maintenance, and edge computing. Because these layers remain separate, software updates in the digital zone never threaten the core control systems.
Protecting Legacy Investments through Incremental Modernization
One of the most significant barriers to factory automation upgrades is the sheer cost of hardware replacement. ABB addresses this by enhancing existing platforms like System 800xA® and Symphony® Plus. Instead of a total overhaul, Automation Extended allows for step-by-step digital adoption. Consequently, even decades-old plants can now access modern AI-driven performance analysis. This approach maximizes the Return on Investment (ROI) while minimizing the potential for human error during transitions.
Empowering the Next Generation of Digital-Native Engineers
The industrial workforce is undergoing a massive demographic shift as veteran operators retire. To fill the knowledge gap, new systems must be intuitive and collaborative. Automation Extended provides advanced visualization and decision-support tools that resonate with younger, digital-native engineers. These tools preserve the proven logic of the PLC and DCS layers while making data more accessible. Therefore, human expertise is augmented by technology rather than replaced by it.
Author Perspective: A Pragmatic Path to Autonomous Operations
In my assessment, ABB's strategy reflects a maturing view of industrial automation. We are moving away from the hype of "total digital transformation" toward more pragmatic, hybrid models. By adopting the NAMUR Open Architecture (NOA), ABB is essentially "future-proofing" the plant floor. This modularity is not just a technical feature; it is a business necessity. Companies that fail to decouple their software from their hardware will likely find themselves trapped in expensive, obsolete cycles within the next decade.
Achieving Sustainability Goals through Data Continuity
Sustainability is no longer optional due to tightening global regulations. Meeting these targets requires a tight integration between process control and electrical systems. Automation Extended enables continuous condition monitoring and real-time energy insights at scale. These capabilities help managers identify waste and optimize resource consumption across entire fleets. By keeping data connected and consistent, industries can finally align their production goals with their net-zero ambitions.
