Global engineering giant ABB has launched Automation Extended, a new strategic program aimed at helping industrial operators modernize their automation systems without interrupting production. The initiative evolves ABB’s distributed control systems (DCS) portfolio, allowing customers to introduce next-generation capabilities gradually while preserving the integrity of existing operations.

 

Built on ABB’s position as the supplier with the world’s largest installed DCS base, Automation Extended responds to mounting pressure on industrial operations from volatile markets, cybersecurity threats, regulatory demands and a changing workforce. The program is designed to deliver flexibility, scalability and efficiency while minimizing risk and avoiding costly downtime.

 

Automation Extended enables customers to continue operating established platforms such as ABB Ability System 800xA, ABB Ability Symphony Plus and ABB Freelance, while layering in advanced analytics, industrial IoT and digital technologies at their own pace. The approach provides a structured, low-risk pathway to modernization, combining continuity with innovation.

 

“In industries we serve – many operating large and complex infrastructures that deliver essential resources – our customers rely on modernization without disruption,” said Peter Terwiesch, President, ABB's Automation business area. “Automation Extended delivers exactly that: bringing future-ready capabilities into the systems they know and trust, with security and interoperability at the core.”

 

At the heart of the program is a modern, open and modular automation ecosystem built on separation-of-concerns principles. It comprises two securely interconnected environments: a software-defined control environment that delivers deterministic and reliable process control, and a digital environment that enables advanced applications, edge intelligence and real-time analytics. 

 

The digital layer leverages artificial intelligence and machine learning to support decision-making without interfering with core control functions. A unified automation services framework manages and optimizes the full lifecycle of both environments.

 

The architecture is underpinned by an Open Platform Communications Unified Architecture (OPC UA) backbone and a cloud-native approach using containerization, orchestration and modular services. Together, these technologies support a wide range of enhancements, from early detection and correction of process anomalies to continuous condition monitoring for predictive maintenance and more efficient, modular engineering workflows deployable across multiple hardware platforms.

 

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