ABB Automation Extended: Modernizing Industrial Control Systems Without Disruption

A New Path for Industrial Automation

ABB has launched Automation Extended, a next-generation automation architecture designed to help industries modernize control systems without costly shutdowns. Unlike traditional “rip-and-replace” upgrades, this approach allows operators to gradually adopt digital technologies while maintaining mission-critical operations.

Building on Proven DCS Platforms

Automation Extended leverages ABB’s established distributed control systems (DCS), including System 800xA, Symphony Plus, and Freelance. Operators can continue using these trusted platforms while introducing new digital capabilities over time. This structured path ensures continuity and minimizes risk in industries such as energy, chemicals, mining, and utilities.

Addressing Industry Pressures

Industrial sectors face challenges from volatile markets, cybersecurity threats, regulatory demands, and workforce transitions. ABB’s solution provides resilience by separating modernization into manageable steps. As a result, companies can strengthen competitiveness without jeopardizing reliability.

Separating Control from Digital Innovation

At the core of Automation Extended is a dual-domain architecture. The control domain maintains deterministic performance for essential processes, while the digital domain hosts AI, machine learning, and analytics applications. This separation reduces operational risk and ensures that proven control structures remain untouched.

Open and Modular Framework

ABB designed Automation Extended around open standards and modular services. Technologies such as OPC UA and containerized cloud infrastructure enable interoperability across diverse industrial systems. This architecture supports advanced functions like anomaly detection, predictive maintenance, and optimized engineering workflows.

Lifecycle Services for Long-Term Value

Beyond technology, ABB offers a unified lifecycle service model to support deployment, management, and system performance. This ensures that modernization efforts remain sustainable and cost-effective over the long term.

Expert Commentary on Industry Trends

The move toward modular, open automation reflects a broader industry trend: balancing reliability with digital innovation. In my view, ABB’s separation of control and digital domains is a practical response to operator concerns about downtime. Moreover, the emphasis on interoperability aligns with global standards, making Automation Extended a forward-looking solution for industrial automation.

Application Scenarios and Solutions

• Energy: Gradual integration of AI-driven optimization into power generation systems.

• Chemicals: Enhanced condition monitoring for critical assets without disrupting production.

• Mining: Predictive maintenance tools deployed alongside existing DCS infrastructure.

• Utilities: Secure IoT connectivity layered on top of legacy control systems.