ABB’s Automation Extended: Modernizing Industrial Control Systems Without Disruption

ABB has launched Automation Extended, a strategic evolution of its distributed control systems (DCS) designed to enable industries to modernize their operations without interrupting production. This new program offers a phased approach to adopting next-generation automation capabilities while safeguarding existing investments and ensuring continuous operation. The initiative addresses the growing need for industrial operations to adapt to volatile markets, cybersecurity threats, regulatory pressures, and a changing workforce.

Addressing the Challenges of Modern Industrial Automation

Industrial operators face a complex landscape of challenges, including market fluctuations, increasing cybersecurity risks, evolving regulatory requirements, and a shortage of skilled workers. ABB’s Automation Extended program is designed to help companies navigate these hurdles by enabling agility and accelerating innovation without compromising production. The program focuses on simplifying operations for a diverse range of skill levels and supporting the integration of advanced analytics and the Internet of Things (IoT).

How Automation Extended Works: A Separation of Concerns Architecture

At the heart of Automation Extended is a “separation of concerns” architecture. This approach creates two distinct yet securely interconnected environments:

• The Control Environment: This software-defined domain delivers deterministic control for critical processes, ensuring reliable and safe operation.
• The Digital Environment: Securely connected to the control layer, this environment supports advanced applications, edge intelligence, and real-time analytics. It leverages artificial intelligence (AI) and machine learning for decision support without altering established control structures.

This separation allows operators to deploy system performance monitoring, advanced analytics, and AI-powered decision support applications without impacting the core control layer responsible for safeguarding operations. The program supports a single automation service approach for lifecycle management and ongoing maintenance across both environments.

Key Features and Enhancements

ABB’s Automation Extended program introduces several key enhancements:

• Modular Software Delivery: New features are delivered through Extension Packs, allowing customers to stay on their base software version while adopting innovations independently and without disruption.
• Broad Operating System Compatibility: The system supports two generations of Microsoft operating systems, including Windows Server 2025/2022 and Windows 11/10, providing flexible upgrade paths.
• Virtualization Support: Compatibility with multiple virtualization platforms, including VMware and Hyper-V, enhances deployment options.
• Enhanced Security: The system incorporates native Microsoft Defender malware protection, IEC 62443-aligned security capabilities, improved certificate management, and updated core components.
• Advanced Technologies: Integration of technologies like an OPC UA backbone and a cloud-native architecture, utilizing containerization and orchestration, supports functions such as process anomaly detection, condition-based monitoring of critical assets, and modular engineering methods deployable across various hardware platforms.

Impact on ABB Technologies

Automation Extended will positively impact ABB technologies currently used in industries like metals, including ABB Ability™ Manufacturing Operations Management for Metals, ABB Ability™ Data Analytics Platform for Metals, Advanced Process Control (APC), Advanced Performance Management, and ABB Ability™ Connected Worker technologies. ABB aims to deliver increased resilience and growth in safety, productivity, and sustainability through this enhanced automation suite.

Availability

Access to Automation Extended will be enabled through upcoming releases of ABB Ability System 800xA, ABB Ability Symphony Plus, and ABB Freelance process automation systems.

For more information, visit abb.com.