Sometimes, perfect timing is everything, and if it's off, the consequences can be greater than you initially thought. For example, imagine a vehicle braking hard at the wrong moment on the highway in heavy traffic. The effect can snowball until a traffic jam forms. The obstruction arises practically out of nowhere, and those who suffer the consequences cannot identify the cause. There is no apparent reason for it, such as an accident, roadworks, or other disruptions. Similar effects can occur in production, especially when cycle times are short, buffers are small, and partially or fully automated lines are increasingly interconnected with AGVs and mobile transport robots. To prevent these scenarios from occurring, all elements involved must be synchronized down to the hundredth of a second. The article on page 24 illustrates how this can be achieved with a high degree of robustness and accuracy.
Digital File Requirements available at: www.ien.eu/technical-guidelines/
The factory of the future is becoming increasingly digital and electric. Read the article on page 8 to find out how to select motors that will meet the requirements for an energy-efficient future, ensuring the most sustainable and cost-effective production runs possible.
I hope you enjoy reading!
KayPetermann
Editor IEN Europe
Energy Efficient Motors & Drives
Meeting Tomorrow's Industry Demands Today
Energy Efficient Motors & Drives:
Smart Gearboxes for the Digital Transformation Digitalization is opening up new possibilities in robotics and mechanical engineering. Networked ecosystems, intelligent components and smart services are the key to unlocking huge potential. Gearboxes play a special role in this.
Energy Efficient Motors & Drives How Electromechanical Actuation is Making Electric Flight a Reality
To improve efficiency of its stamping processes for future production runs, Ford Mexico explored the possibility of using a machine learning and predictive analytics solution to support business oblectives.
Robotics & Automation: Precision Timing: The Pulse That Powers Smarter Robotics
Exclusive Interview:
Elevating Data through the Power of Context
IEN Europe interviewed Norman Hartmann, co-founder and CEO of Workerbase GmbH, who introduces the benefits of the Connected Worker Platform concept.
ADI and NVIDIA Deepen Joint Effort to Advance Physical Intelligence in Humanoid Robotics
NVIDIA announced the GA of Jetson Thor, and Analog Devices, Inc. (ADI) is spotlighted for its role in accelerating the development of humanoids. Humanoid robots are moving closer to real-world deployment, and their progress depends on physical intelligence and real-time reasoning. ADI enables "physical intelligence," a trend where AI systems perceive, reason, and act in the physical world with high fidelity and efficiency. The company’s expertise in edge sensing, precision motion control, power integrity, and deterministic connectivity, together with Jetson Thor's advanced compute capabilities, can make this possible. ADI & NVIDIA are accelerating the development of reasoning-enabled robots by integrating ADI's high-fidelity signal chains with NVIDIA's Holoscan Sensor Bridge and Isaac Sim. By embedding robotics foundation models into the ADI development stack, ADI closes the Sim2Real gap so the company’s hardware behaves in Isaac Sim as it will in the real world. The news builds on ADI’s broader work with NVIDIA, including an MOU, to drive innovation in AI and robotics. ADI's play a critical role in enabling physical intelligence within AI models.
Heading to the Finals
Endress+Hauser is once again among the three finalists for this year’s German Sustainability Award (GSA) in the measurement and control technology sector. “The fact that we are once again among the finalists for the GSA confirms our consistent path toward sustainable transformation – both in our own actions and in what we implement together with our customers. This recognition motivates us to continue actively shaping our responsibility,” shares Julia Schempp, Corporate Sustainability Officer of the Endress+Hauser Group. Being a partner to the industry, Endress+Hauser approaches sustainability holistically: products, solutions and services in measurement and automation technology support customers worldwide in using resources efficiently, reducing emissions and making processes safer and more environmentally friendly. As a family-owned company, Endress+Hauser’s sustainable approach to its own processes is at the core of its long-term thinking, throughout generations. The company’s greenhouse gas targets, including its commitment to reaching net-zero greenhouse gas emissions across the value chain by 2050, have been validated by the Science Based Targets initiative – one of many declared targets in its sustainability strategy. This year’s award winner will be announced at the German Sustainability Day on 5 December 2025 in Düsseldorf.
IFR Publication on Humanoid Robots: “Vision and Reality”
Old Batteries from Electric Vehicles: Too Valuable to Shred
Humanoids are considered to be the next big thing in robotics: China has set out specific targets for its plans to mass-produce humanoids, tech companies in the US and Europe are announcing significant funding. The vision is to create general-purpose robots based on human motion mechanics. The International Federation of Robotics has released a new positioning paper that provides valuable insights about trends, opportunities, and potential limitations of humanoids. “Futuristic humanoids working in homes, businesses, and public spaces fuel people's interest," says Takayuki Ito, President of the International Federation of Robotics. “Since our environment is optimized for the human body, the idea of a quick, universal helper to maintain manufacturing and services is evident. If and when a mass adoption of humanoids will take place remains uncertain. In any case, humanoids are not expected to replace the types of robots currently on the market in the future. Instead, they will complement and expand upon existing technology.” The position paper takes a closer look at humanoid robots und tries to separate vision and reality, taking a glance also on the regional differences of technology adoption. On the IFR website the position paper is available for free download.
After years of use, many traction batteries still have a residual capacity of between 70 and 80 percent. While this may be too little for further use in vehicles, some cells could still serve well in large storage systems for households, businesses, or utility providers. Cells that have been specifically refurbished and repurposed for new applications can be ready for long-term use again. Dr. Rico Schmerler and his team at Fraunhofer IWU, in collaboration with EDAG Production Solutions, are investigating how components and cells from traction batteries can be extracted efficiently and cost-effectively in a new project. The future pilot plant in Chemnitz is a response to the rapidly growing demand for efficient solutions within the circular economy. Fraunhofer IWU is currently working with EDAG Production Solutions to build a highly innovative, automated dismantling plant for active (functional) traction batteries at the Chemnitz location. The facility focuses on variant-flexible, AI-supported dismantling to ensure economical and safe handling of various high-voltage storage systems. An integrated system to analyze the "state of health" (SoH) of modules and cells ensures that only reusable components are reintroduced into service. Completely intact units can even be used in new traction batteries.
David Hawley, ABB’s Global Head of Sales for IEC Low Voltage Motors, notes that while superior performance, reliability, and efficiency are essential factors influencing electric motor selection, availability is also key to achieving ambitious energy goals.
The EU Clean Industrial Deal is a significant opportunity to enhance Europe's global competitiveness. It aims to generate jobs, strengthen the manufacturing sector, and improve energy security, all while progressing us toward the goal of becoming the first climate-neutral continent by 2050.
A key step in reaching this target is the gradual adoption of energy-efficient industrial motors. According to EU estimates, this transition could save 106 terawatt-hours of electricity by 2030 — roughly equal to the Netherlands’ yearly energy usage — and prevent 40 million tons of CO2 emissions annually.
While much attention is given to realizing the technologies of the future, achieving the EU Clean Industrial Deal’s ambitious energy goals will also rely on upgrading the every-
day motors powering industries today. General Performance motors offer a ready-made solution to drive energy efficiency across key industrial applications like pumps, fans, and compressors.
With up to IE5 Ultra-Premium efficiency, these motors ensure immediate reductions in both emissions and electricity costs. Every inefficient motor left in operation is a lost opportunity, but widely available, high-efficiency motors make it easier than ever for industries to start saving now.
Engineering for today’s industrial environment
In facilities around the world, the demands placed on motors are evolving. Beyond energy efficiency, organizations seek motors that
are robust and adaptable to a range of applications and operating environments. Each engineering choice must respond directly to these requirements. General Performance motors feature rugged cast-iron construction (up to frame size 355) and high-strength steel shafts. This makes them well-suited for challenging installations, from manufacturing lines to remote pumping stations, where reliability under stress is crucial. Design decisions must also consider serviceability. For instance, these motors use high-quality Series 62 or 63 bearings. Smaller models incorporate sealed-for-life bearings, catering to customers who favor maintenance-free operation. For larger units, re-greasing points are included, allowing for upkeep without system shutdowns, helping
David Hawley, ABB’s Global Head of Sales for IEC Low Voltage Motors. Picture: ABB
Combination of variable speed drive and motor for the best possible performance and efficiency. Picture: ABB
operations reduce unplanned downtime.
Bearings are mounted with precise clearance to handle thermal movement under load. This addresses a problem often seen in continuous-run equipment: increasing internal temperatures can cause expansion, leading to vibration, wear, and eventual failure. Driveend axial locking also eliminates unwanted shaft play, improving system integrity even in high-duty-cycle use.
Built to handle electrical and environmental stress
In industrial operations, motors are often subject to voltage fluctuations and overloads. That’s why these motors are built with Class F insulation and Class B temperature rise, offering thermal margins that provide a safety buffer while enhancing overload capacity. Operators benefit from longer insulation life, especially in variable speed or on/off-duty situations. Environmental adaptability is also key.
A resilient Class C3 paint finish allows the motors to serve reliably across geographies, including coastal, chemical, or humid conditions, which reduces the chance of corrosion or premature surface wear.
Designing flexibility into form
One core challenge faced by OEMs and end users is the need for motors that adapt to diverse applications and installation standards across global markets. To meet this need, General Performance motors are engineered for rapid configurability. While standard motors can often be delivered from inventory, many include optional add-ons available within one to two days to meet specific operating requirements.
The motors specifically meet heightened energy efficiency demands and help customers reduce carbon dioxide emissions. Induction motor ranges are available with up to IE4 Super-Premium efficiency or IE5 Ultra-Premium efficiency as permanent magnet motors. For optimal performance and even greater efficiency, motors rated up to 500V can be paired with variable speed drives (VSDs). Customers can benefit from a convenient “one-stop shop” solution if they buy optimally matched motor-drive solutions from one supplier.
Global success stories from diverse industries
The real-world successes of General Performance motors underscore their value across global markets:
Saneago Water Company, Brazil
As the primary water utility serving the state of Goiás, Saneago treats and supplies drinking water for more than 5.7 million people and thousands of industrial and agricultural users. The utility aimed to reduce energy consumption and boost system reliability at its pumping stations.
After installing 15 General Performance high-efficiency motors and 15 drives across four pumping stations, Saneago achieved a remarkable 25 percent reduction in energy consumption. The utility also wanted to enhance the overall reliability and resilience of its water operations. To achieve this, ABB Ability™ Smart Sensors were fitted to the pumping station’s pumps and motors, while NETA-21 devices were added to the drives to enable the company to identify and address potential issues before breakdowns occur, improving operator safety and extending equipment life.
PRO-DO-MIX, Italy
Padua-based PRO-DO-MIX specializes in the manufacture of vertical agitators and dry feeders. It recently experienced rapid export
growth, specifically in the Middle East, Australia, and South America. ABB’s General Performance motors (sizes 71 to 180) were the ideal motor choice due to their compliance with the certification requirements of those countries, including voltage, frequency, and sea altitude.
Meeting these stringent requirements while offering a compact footprint, reliability, easy maintenance, and high performance positioned ABB motors as an indispensable component in PRO-DO-MIX’s growing global business.
A comprehensive motor solution
In several industrial applications, immediate access to the right motor will be the deciding factor between commercial success and failure. General Performance motors are specifically designed to meet this critical demand, as well as meet the expectations of efficient growth in European markets. Customers benefit from outstanding performance, reliability, extended service life, low maintenance, energy efficiency, and the option to select either induction or permanent magnet (PM) motor technologies – all features complemented by exceptional product flexibility and availability.
66077 at www.ien.eu
For industrial applications, immediate access to the right motor can be the deciding factor between commercial success and failure. Picture: ABB
Smart Gearboxes for the Digital Transformation
Digitalization is opening up new possibilities in robotics and mechanical engineering. Networked ecosystems, intelligent components and smart services are the key to unlocking huge potential in terms of productivity, efficiency, process reliability, maintenance and availability. Gearboxes play a special role in this. Nabtesco, the world's largest manufacturer of precision gearboxes, knows the challenges and offers unique solutions for the digital transformation of industry.
In today's age of digitalization, the successful interaction of hardware and software is increasingly becoming a decisive competitive factor. Intelligent components, smart sensor technology, digitally networked systems and automated production processes are dominating innovation and setting the course for success. No digitalization, no future. “The digital transformation is one of the key challenges of our time. Anyone who misses the boat here will sooner or later fall by the wayside. Modern IIoT technologies and data-based solutions support companies in optimizing their processes and make them fit for the future”, says Daniel Obladen, Director Sales & Marketing at Nabtesco Precision Europe GmbH, and makes it clear: "Precision gearboxes such as the cycloidal gears and strain wave gears from Nabtesco Precision Europe make a valuable
contribution. They are an essential component in the drive train of robots and production machines and make a significant contribution to increasing productivity and efficiency in digital automation environments, improving machine and system availability, reducing downtimes and cutting costs.”
Focus on the digitalization of gearboxes
Nabtesco, one of the leading specialists for precision gearboxes and world market leader in the field of robotic gearboxes, brings together a unique combination of outstanding gearbox expertise, innovative electronics and software development, many years of experience and mechatronic system competence within the corporate family. This concentrated know-how forms the basis for new innovations and for-
Innovative plug-and-play solution for intelligent automation: the digital strain wave gear is smart, backlash-free and installation space-neutral.
Picture: Nabtesco Precision Europe GmbH / stock.adobe.com/Inna, Number 386234689 / stock.adobe.com/MH, Number 196608236
ward-looking solutions. One of the current main points is the digitalization of gearboxes. Hybridization, digital gear twins, machine learning, big data and artificial intelligence (AI) are the buzzwords.
Analyzing data
Data is the fuel of digital transformation and opens the door to new possibilities such as condition monitoring and predictive maintenance. Operating and process parameters can be recorded directly via real sensors or indirectly via virtual sensors. The art lies in analyzing and processing the data. Experience, expertise and an understanding of the application-specific characteristics are essential for this, as a high quality of the underlying data and a well-founded, detailed and high-quality evaluation are of im-
Strain wave gearboxes offer absolute freedom from backlash, exceptional transmission accuracy and high torsional rigidity. Bild: Nabtesco Precision Europe GmbH / stock.adobe.com/MH, Nummer 196608236
mense importance for the quality of the results. Nabtesco Precision Europe is a decisive step ahead here. Whether digital gearbox models, sensorized strain wave gearboxes or hybridized cycloidal gears: the technology leader's solutions combine know-how and expertise from more than 35 years and provide convincing answers to current questions.
No additional space required
The digital strain wave gear developed and produced in Limburg an der Lahn (Ovalo GmbH site) integrates smart sensor technology with the same dimensions as a standard gearbox and therefore offers a space-neutral solution for intelligent automation. This is unique on the market and a major advantage for users. Sensors determine torque, temperature and vibration. Together with empirical values from practical experience, reliable conclusions can be drawn about the condition of the gearbox. The integrated Electronic Evaluation Unit (EEU) evaluates the data and sends it directly to the higher-level control system via the bus system. The operator receives recommendations for action and can react to changing parameters at an early stage and initiate appropriate measures. “With our sensorized strain wave gear, we are expanding our range of digital solutions and taking drive technology into the future. Our plug-and-play product combines high-precision, backlash-free technology with smart sensor technology and artificial intelligence without any change in size. This solves key problems for our customers and helps to increase efficiency, optimize performance, conserve resources and improve cost-effectiveness”, says Daniel Obladen, summing up the benefits.
Cycloidal gears and the digital gear twin Nabtesco is taking a different, equally innovative approach to cycloidal gears. The company is the first gearbox manufacturer in robotics to open up the black box gearbox and provide robot manufacturers with gearbox-specific data and characteristics using a Nabtesco add-on for the robot controller. The goal: a digital replica of the haptic gearbox with its relevant properties. The digital gearbox twin becomes reality. It will work with values that are already available. The speed and torque curve, combined with a pool of statistical data from over 35 years of transmission development, allows detailed conclusions to be drawn about
With
permanent monitoring, the actual operating behaviour can be observed and the level of wear can be calculated in real time.
Picture: Nabtesco Precision Europe GmbH /
the condition of the transmission and thus its remaining service life. “Not all data can be recorded using external sensors. This applies, for example, to rigidity and, of course, the empirical values from development. We carry out extensive tests before a gearbox is launched on the market and therefore know exactly how the gearbox behaves when it wears out or what influence temperature and lubricant have. All these parameters are incorporated into the robot control system”, explains Daniel Obladen.
Seizing opportunities, exploiting potential Digitalization requires a radical rethink. Technologies, products, processes - everything has to be put to the test. At the same time, it opens up incredible opportunities. Whether calculating the real gearbox service life, determining the gearbox fault or detecting overload, wear, loss of efficiency, unsuitable operating points and cases of misuse: Digital gearbox solutions make it possible to track the real operating behavior and the specific load on each individual axis of machines and robots in real time. This allows immediate countermeasures to be taken in the event of irregularities or signs of wear. The result: reduced maintenance costs, predictable service calls, less downtime, maximized machine, system and robot availability,
significant increases in efficiency and performance and lower overall operating costs. All in all, this results in potential savings in the double-digit percentage range.
The gearbox of the future is digital And digitalization can do much more. It revolutionizes production processes, opens up growth potential and paves the way for completely new business models, applications and services. Gearboxes are the heart of machines and robots and are therefore an important cornerstone of digitalization in the manufacturing industry. They transmit and convert torques, speeds, directions of rotation and forces and set the pace or the beat. If precision is required, cycloidal gears and strain wave gears from Nabtesco Precision Europe are the first choice. The technologies cover a torque range from 7 to 70,000 Nm, meet the highest requirements in terms of precision, torque capacity and torque density and are ready for the digital age thanks to technological innovations. “In order to always be at the cutting edge of technology, we are continuously developing our products and services with the requirements of the digital factory in mind”, emphasizes Daniel Obladen.
66078 at www.ien.eu
How Electromechanical Actuation is Making Electric Flight a Reality
Whether you’re talking about hybrid regional jets to next-generation air taxis it’s increasingly clear that the future of flight is electric, and electromechanical (EM) actuation is playing a central role in making this a reality.
As aircraft systems move away from hydraulics and pneumatics in favour of all-electric architectures, EM actuation is enabling lighter, more modular designs that promise greater efficiency, simplified maintenance, and a clearer path to certification.
Regal Rexnord Aerospace Solutions is helping to advance the adoption of electro-mechanical actuation by delivering integrated subsystems that combine high-performance motors, gearing, brakes, and control systems. Drawing on the industry expertise of its brands, including Rexnord Aerospace, Kollmorgen™, Portescap™, Nook™, and Delavan™, Formsprag Clutch, Thomson, the company is helping to support a wide range of aerospace applications through a unified, system-level approach.
The shift to all-electric
For decades, hydraulic systems have delivered the motion needed for flight control, landing gear, and high-lift systems. But as new aerospace platforms emerge, the drawbacks of hydraulics, such as complex plumbing, weight penalties, and intensive maintenance, are becoming more apparent.
That’s where EM Actuation comes in. By replacing traditional hydraulic systems with compact, electrically driven actuators, aircraft designers can reduce weight, simplify architectures, and increase system flexibility. The result is faster assembly, superior control, and improved reliability.
"We’re seeing a clear shift toward fully electric fly-by-wire systems, particularly in emerging platforms like eVTOLs and uncrewed aircraft," explains John Meyer, Senior Director Marketing at Regal Rexnord. "EM
Actuation offers a streamlined alternative with real benefits in integration, efficiency, and performance."
Unlocking the aircraft of tomorrow
Modern EM Actuation systems are far more than a simple motor and gearbox. To meet aerospace demands, they must be precision engineered for high reliability, minimal weight, and exceptional control responsiveness. This calls for a coordinated approach where every element – motors, gearing, sensors, and brakes – is designed to work together as a complete system.
“In most of the programs we support, the actuator isn't something pulled directly from a catalogue,” notes Julian Del Campo, Senior Business Development Manager at Regal Rexnord. “It’s a tightly integrated system that tailors proven designs to the envelope, load,
and responsiveness required for that airframe. That’s where the value of early engineering collaboration really shines.”
This is exactly why EM actuation suppliers should be deeply involved with design projects from day one, helping OEMs and system designers explore trade-offs between actuator size, power consumption, and redundancy strategies. A collaborative process like this accelerates development and supports a smooth path to compliance – both key factors as aerospace innovation accelerates and compresses timelines.
Programs that once spanned a decade now aim for certification in a fraction of that time. The emerging advanced air mobility (AAM) sector is a clear example, with developers working to deliver electric aircraft to market on ambitious schedules. That’s adding extreme emphasis on agility and scalability, as
Aircraft systems move away from hydraulics and pneumatics in favour of all-electric architectures. Picture: Regal Rexnord
EM actuation systems must not only meet performance targets but do so within short, iterative development cycles. Suppliers need to offer rapid prototyping, customizable solutions, and deep familiarity with aerospace standards.
“Being able to take a proven aerospace motor or resolver design and adapt it quickly to a new platform is a huge advantage,” says Julian. “It reduces risk and shortens the path to flight qualification. That’s critical when every moment counts.”
From innovation to integration
As the boundaries of EM Actuation expand, the technology is reaching into new areas of the aircraft. In the future, electric actuation is expected to play a role not just in secondary
functions but also in primary flight controls, landing systems, and high-lift devices, even in large commercial aircraft.
This evolution is already underway, and it underscores the need for systems that are not only robust but also easy to integrate.
COMPACTBRUSHLESSDCSERVOMOTOR
High-powered48Vmotorformobileapplications
Advancing electric flight with precision electromechanical actuation.
EM Actuation solutions must deliver precision control, environmental durability, and fault tolerance, all while fitting into the tight weight and space constraints of modern aircraft. At the same time, developers are seeking out partners who can support them with more than just components. Regal Rexnord’s motion control brands offer decades of aerospace experience, along with a proven track record of collaboration across a broad spectrum of air and defense platforms.
Digitalization in Hazardous Areas: Complete Solutions with Ethernet-APL Unfold Their Full Potential
19 Efficient and Safe Operations with Advanced Diagnostics
SENSOR TECHNOLOGY: Transmitter with Cearamic Diaphragm
19
18 MAINTENANCE: ATEX-certified Acoustic Camera
automation&communication
Digitalization in Hazardous Areas: Complete Solutions with EthernetAPL Unfold Their Full Potential
Ethernet-APL enables fast, standardized Ethernet communication down to field level, even in hazardous areas. While the technology simplifies engineering, commissioning, and diagnostics, the real value lies in integrated solutions. With engineered, certified systems tailored to customer needs, operators benefit from reduced complexity, faster deployment, and higher system availability.
A fundamental change is imminent in the process industry: With Ethernet-APL (Advanced Physical Layer, APL for short), endto-end Ethernet communication down to the field level will be possible for the first time, even in explosion-hazardous areas. The technology is based on the proven Ethernet and enables data transmission at 10 Mbit/s over distances of up to 1000 meters. Ethernet-APL therefore not only provides the foundation for a new era of system communication, but also considerably simplifies engineering, commissioning, and maintenance. Real-time data from the field is available without detours, diagnostic information can be used in a targeted manner, and standardized interfaces facilitate system integration.
Plug&Go Makes the Difference
Ethernet-APL offers plant operators a technological basis for sustainably modernizing communication in process automation, including in explosion-hazardous areas. However, while the physical interface and device compatibility are precisely defined in standards, project implementation is anything but standardized. Each process environment has its own specific requirements: existing sensors, industry-specific or regional regulations, operating conditions, maintenance concepts, or maintenance cycles. This is precisely where it is decided whether an APL project delivers the expected added value or falls short of its potential.
A central problem: operators who plan and
implement their APL infrastructure themselves are confronted with a multitude of tasks that go beyond the mere selection of components. The selection of suitable APL field switches, the design of explosion-protected enclosure solutions, the interaction with existing sensors (4–20 mA/HART, discrete, analog), integration into existing control systems, ATEX or IECEx-compliant certification, EMC-compliant cabling—all of this must be coordinated. What's more: Not every field device is APL-ready, not every cable is suitable, and not every combination is permitted.
A solution provider that integrates, thinks and delivers all these aspects relieves the operator of this complexity. This eliminates a large number of interfaces from the design phase through to commissioning. Project costs can be better calculated, coordination is centralized, and the solution works straight away – tested, documented, and ready for acceptance. This not only saves time, but also reduces the project risk, especially in safety-critical applications
Structured Project Processes with Technical Know-How
A successful APL project begins long before the first components are delivered – it starts with an understanding of the processes, framework conditions, and objectives of the system. This is why professional providers such as Pepperl+Fuchs rely on structured project processes that systematically map all phases from requirements analysis to commissioning.
The first step is to take a technical inventory: Which signals need to be transmitted?
Which devices are already available? In which Ex zones are the components located?
Which standards, for example IECEx, NEC, or regional regulations such as CCC or INMETRO, need to be taken into account? This results in a technical specification that forms the basis for the solution concept.
A suitable infrastructure is then developed consisting of stainless-steel enclosures for Zone 1/21 or Zone 2/22, with multi-input/ output (MIO) for discrete or temperature input modules (TM-I) for analog signals, as well as APL field switches with integrated physical layer diagnosis, which provide information about the quality of the installation. A central element is engineering, assembly, and system testing in Pepperl+Fuchs’ own Solution Engineering Centers (SECs). This is where the solutions are designed, the enclosures are machined, components are installed and wired, electrical tests are carried out, and the Ex-certification is prepared. The customer receives a tested system including complete documentation: wiring diagrams, certificates, declarations of conformity, and operating instructions. On request, packaging is also carried out according to transport
specifications, for example for direct delivery to construction sites.
Fixed contact persons, project managers, and technical specialists are constantly available throughout the course of the project – an aspect that is particularly important for multi-stage projects in complex systems. This means that adjustments can be introduced and coordinated at an early stage.
Digitalization of a Tank Farm with Ethernet-APL
The example of an international operator in the waste management sector who wanted to modernize the control technology of its tank farm shows what this approach looks like in practice. The existing PROFIBUS PA installation was technically outdated, fieldbus junction boxes made of aluminum were getting on in years with recurring failures due to moisture ingress, and many components were no longer classified for Zone 2 in accordance with standards.
As part of a turnaround, the operator opted for a complete solution based on Ethernet-APL from Pepperl+Fuchs. Explosion-protected and durable stainless-steel field
junction boxes were used, pre-assembled and certified according to ATEX and IECEx, equipped with MIO or TM-I modules for connecting existing sensors. The central component of the solution was an APL rail field switch with comprehensive diagnostic functionality and easy integration into the existing infrastructure. The commissioning was carried out digitally throughout, with automatic device recognition and minimal configuration effort.
The result: significantly increased plant availability, reduced maintenance costs, and a future-oriented communication concept –without the need for extensive rewiring. The operator can now evaluate all field signals digitally and has end-to-end asset management right down to the individual temperature sensor.
From Technology to Solution: A Holistic Approach to Ethernet-APL
Ethernet-APL opens up completely new possibilities in process automation, especially in hazardous areas. However, the real innovation does not lie in the technology alone, but in its systematic implementation. Only those who understand APL as part of a wellthought-out overall solution can take full advantage of the benefits for efficiency, safety, and availability. Complete solutions from a single source reduce interfaces, accelerate projects, and offer security –technically, organizationally, and economically. They are the key to a successful migration to a fully digital system.
With its specialized Solution Engineering Centers, Pepperl+Fuchs makes it possible to handle the entire project, including certification and quality control, from a single source. The solution is pre-assembled, tested, documented, and packaged in-house, as a "plug-and-go" system that can be installed directly at the customer's premises. This represents real added value for customers.
66089 at www.pcne.eu
Complete APL enclosure solution in a pharmaceutical environment. Picture: Pepperl+Fuchs SE
According to the International Society of Automation, factories worldwide lose 5-20% of their productive capacity to unplanned downtime. With supply chain disruptions increasing, Mitsubishi Electric's predictive maintenance solutions help manufacturers identify equipment failures before they occur, maintaining operational continuity.
Research from Arimo shows the average plant loses 15 hours weekly to downtime, with production lines facing approximately 20,000 interruptions annually. According to Resilinc, manufacturing disruptions increased by 30% in the first half of 2024 compared to last year, with factory-specific issues rising by 40%.
Higher transport costs and worker shortages have amplified the impact of each stoppage. In this environment, predicting maintenance needs gives companies a significant advantage. Mainly due to the early indication of a fault, allowing it to be fixed during the next maintenance period, which means longer machine uptime.
AI-Maintenance In Figures
"When we can spot equipment failures weeks before they happen, the whole supply chain benefits," explains Daniel Sperlich, Strategic Product Manager Controllers at Mitsubishi Electric Europe. "We can order spare parts for repair that can be stored until the next planned maintenance phase. And, we allow the production line to continuously run, without any interruptions - including those caused by a lack of spare parts when these are needed ‘here and now’. " As Rafi Ezra, Managing Partner US Industrial Market at IBM Services states: "AI-powered maintenance solutions can cut downtime by up to 50%, reduce breakdowns by 70%, and lower overall costs by 25%."
Industry Response
to The Needs
Mitsubishi Electric has developed several predictive maintenance systems. Their MELFA FR series robots with Smart Plus cards
track performance and identify potential issues early. The company's MELSERVO-J5 servo amplifiers use AI to detect wear in critical mechanical parts by analysing vibration patterns, tension changes or backlash. Additionally, the FR-E800 Series inverters feature Corrosion Alert System and Life Diagnostics Function to monitor component conditions. "Today, implementing predictive maintenance tools is no longer just an advantage but a necessity for companies that want to stay competitive," emphasises Daniel Sperlich, Strategic Product Manager Controllers from Mitsubishi Electric. "Our solutions help manufacturers address problems before they affect their production lines. We ‘put intel-
ligence’ where it is required most, directly into our equipment, close to the mechanics."
Real-World Impact
At Mitsubishi HiTec Paper Europe GmbH, a monitoring system for cooling fans in a paper machine paid for itself in just one hour of production time. With daily production exceeding 300,000 kg, preventing even brief stoppages brings significant financial benefits. "Supply chain reliability starts on the factory floor," says Daniel Sperlich. "When a machine can self-diagnose before breaking down, it prevents the chain reaction of missed deliveries that can disrupt downstream operations."
The Predictive Future
The global predictive maintenance market, valued at $7.85 billion in 2022, is expected to grow at 29.5% yearly through 2030(https:// www.grandviewresearch.com/industry-analysis/predictive-maintenance-market). “There is growing interest in implementing new maintenance systems step by step to optimise productivity. The idea here is that improvements can start at the machine level as well as the
whole line or factory level so that automation is perfectly tailored to meet the specific needs of a particular production facility” - adds Daniel Sperlich. “In this way, the return on investment is also much easier to calculate and fully understand. At Mitsubishi Electric we call it the Smart Manufacturing Kaizen Level (SMKL) approach”. The dynamic growth of the predictive maintenance market reflects the increasing need of manufacturing companies to shift from re-
active to proactive strategies, enhancing performance whilst stabilising supply chains in uncertain times. A key driver is the ability to implement these solutions in a scalable manner—from individual devices to entire production facilities—without requiring significant initial capital investment and with clear and easy ROI calculation.
To improve efficiency of its stamping processes for future production runs, Ford Mexico worked with Altair to explore the possibility of using Altair's machine learning and predictive analytics solution to support its business objectives.
Authors: John Fisher, Senior Sales Director EMEA, Altair & Alberto Ochoa Frías, D&R and Stamping Process Engineer, Ford
Today’s automotive manufacturers face increasing pressure to innovate rapidly while optimizing their development processes and material usage, making efficient production essential for maintaining an edge in a highly competitive market. In this context, Ford Mexico, headquartered in Mexico City, saw the need to streamline its stamping process, and – being a long-time customer – turned to the Altair team to solve this challenge.
Sheet metal forming in the automotive industry
Sheet metal stamping is fundamental to the automotive manufacturing industry. A wide range of different tool, die, and process combinations are employed to create an equally diverse array of components. Traditionally, determining the optimal stamping process for a specific part design has been a time-consuming and labour-intensive task, heavily dependent on the stamping engineer’s expertise and experience. To address this issue, Ford Mexico began documenting successful metal stamping production runs over a 5-year period. Management’s goal was to capture in-house domain knowledge and
Determining the optimal stamping process for a specific part design has been a time-consuming and labour-intensive task, heavily dependent on the stamping engineer’s expertise and experience.
Picture: Pavel L Photo and Video//Shutterstock
best-practices to explore ways to speed the selection of the best stamping process for future production runs to enable business benefits including increased plant efficiency and part quality, reduction of scrap material, and the ability to rapidly train new personnel.
Finding the right process
In many production facilities, there are multiple sheet metal stamping processes available to form nested and individual parts, including progressive, transfer, and tandem press lines. For a specific part design, numerous factors come into play to identify the optimal or most efficient stamping process, such as the material type, thickness, part width, and desired surface finish. The success or failure in selecting the right process depends significantly on the experience and expertise of the manufacturing process engineer. However, increasing design complexity, non-conventional material types, and a multitude of process combinations can pose challenges even for the most seasoned process engineers, necessitating a labour and material-intensive trial-and-error prove-out process.
Cutting material waste
Material utilization is a particularly critical benchmark. Most automotive plants expect around 60% material utilization in their stamping mills while the remaining 40% is wasted. Ford aimed to improve these metrics while also improving the accuracy of selecting the optimal stamping process on the first attempt and increasing First Time Through (FTT) rates.
To achieve these goals, Ford Mexico started documenting and accumulating a valuable asset: large amounts of clean data associated with their successful production runs.
Spanning a 5-year period, process engineers recorded successful stamping processes for thousands of parts. Captured in this historical data were valuable insights but the question now was how they could use this information to help automate and guide the selection of best stamping process for a given part design.
Handling the data with Altair
First learning of Altair® Knowledge Studio® through an Altair tech-
Knowledge Studio streamlined the selection of the optimal stamping process for new sheet metal formed parts. Picture: Ford)
nology briefing, Ford Mexico approached Altair to explore the possi bility of applying Altair’s machine learning and predictive analytics solution to support their business objectives.
Leveraging the data Ford collected for over 3,000 stamping process es identified as being representative of future requirements, Ford’s stamping domain experts and Altair’s solution architects collabo rated to develop an accurate, reliable machine learning model with Knowledge Studio.
Knowledge Studio offers 15 different machine learning models al lowing users to explore, select and train the model that best fits their data. Using subsets of the data, the team ran a series of tests to determine which was most effective. With an accuracy rate of over 90%, the decision tree model produced the most consistent results. In the process, a surprising – and valuable – discovery was made. In terms of selecting the optimal stamping process, the most important factors are the overall dimensions and thickness of the finished part. Individually, these factors are insufficient for making a final decision. However, when combined with all other data points, Knowledge Stu dio’s machine learning algorithm provided Ford with results that are nearly 100% accurate.
Improved processes and training
designs further enhancing production efficiency and business value. Overall, projected throughput increased threefold, while improvements in FTT rates led to reduced rework time – all accomplished without the need for additional resources.
Additionally, the Knowledge Studio machine learning model successfully captured the company's in-house domain knowledge. This supported a faster learning curve for training new personnel, ensuring that valuable expertise was efficiently passed on to new employees. By using this technology, the company has enhanced its training processes and maintained a knowledgeable workforce.
The machine learning predictive capabilities of Knowledge Studio demonstrated high accuracy and effectively automated much of the stamping process selection. By minimizing manual trial-and error process validations and rework, more time was available for stamping process engineers to address the most difficult and complex part
Precision Timing: The Pulse That Powers Smarter Robotics
The deployment of robots in factories worldwide reached and passed 4 million last year, representing a doubling of robot density over the past seven years.
Author: Amy Taylor,
Director, Marketing – Industrial, SiTime
Used to augment the human workforce, collaborative robots demand flexibility and customizability, being easily reprogrammed for new tasks and hyperconnected to Internet of Things (IoT) networks and AI architecture. There are also the performance criteria of high pose accuracy and repeatability. To satisfy these requirements, modern industrial robotics rely not just on mechanics and software, but on highly accurate and stable timing systems. This article will explore how Precision Timing is paving the way for a new generation of smarter robotics.
The role of Precision Timing in robotic coordination
Exact timing is essential to coordinate multi-axis robotic arms, autonomous guided
vehicles (AGVs), and collaborative robots (cobots). Time-sensitive networks and synchronized operations are crucial for robotic systems in manufacturing and automotive lines.
We have witnessed a shift from loose timing tolerances to sub-microsecond synchronization using Precision Time Protocol (PTP), an industry-recognized default behaviour that synchronizes clocks across networks and makes robotics and factory systems efficient and able to perform new tasks safely. With a new, higher level of synchronization and accuracy being required by the time-sensitive networks supporting robotics, the latest microelectromechanical system (MEMS) oscillators have enabled the required stable reference frequencies needed.
MEMS oscillators vs quartz: Why silicon wins in harsh environments
For guaranteed timing accuracy in factories using robots, stability and accuracy are non-negotiable. A clear advantage of silicon MEMS devices over their quartz crystal predecessors is much greater resistance to shock and vibration; characteristics of industrial settings where there is frequent mechanical stress. MEMS devices can survive up to 20,000g of shock and are vibration resistant. Traditional quartz devices are more likely to succumb to these stressors and falter because they are far more sensitive to mechanical g-forces.
Temperature cycling - that is, the exposure of timing devices to extreme temperature fluctuations - is another reality of factory environments. MEMS-based timing devices are able to avoid frequency drift - with a best-inclass short-term stability of ±0.1 ppm (-40°C to 105°C) - making them ideal for industrial automation.
Precision Timing is also increasingly required in the mission-critical sectors of aerospace and defence - where reliable performance in high-intensity environments is paramount - in applications such as tactical radios, unmanned aerial vehicles, satellite communication systems and radar systems.
Enabling AI-driven quality control
A recent McKinsey report predicted that AI factories could absorb 60-70% of the human workload by automating tasks. This potential is reflected in the way that AI and machine learning are transforming quality inspection
in industrial processes. Smart machine vision teaches itself to automatically detect defects using AI-powered image processing.
These automated defect sorting systems use multispectral and 3D cameras to identify faults on the surface, and in the structure, of products. Low-latency, high-precision timing is central to this technology, providing synchronization for image capture and data processing. The result is improved fault detection, reduced false negatives, and faster sorting.
Real-time monitoring and industrial IoT integration
The smart sensors used in IoT networks can track parameters from energy consumption to temperature and pressure, reducing the risk of equipment failure with the reliable detection of irregularities. It is the synchronization provided by precision timing that is a backbone of this real-time processing and failure detection.
Research by authors Mandakini Gupta and Ashutosh Ahuja has shown that IoT-based predictive maintenance results in significant operational benefits: Up to 50% reductions in unplanned downtime and 10–40% reductions in maintenance costs, with asset availability rising by 5–15%. In aggregated case studies, downtime dropped by 30–40%, while maintenance costs fell by 20–30%.
Synchronisation of industrial IoT sensors with edge computing systems for on-site data processing is required for them to be effective. They must be synchronized with cloud systems that allow remote monitoring and predictive analysis (the basis of predictive maintenance) to be performed. Precision Timing also facilitates the timestamping of errors, which deepens the understanding of how the mistakes that caused the defects were made.
Functional safety and human-robot collaboration
Timing impacts functional safety in environments where robots and humans collaborate, with fail-safe timing systems having an important role in safety-critical responses.
MEMS-based timing devices provide functional safety that wasn’t possible with traditional quartz timing. Thanks to Precision Timing, cobots have a reliable clocking system that self-detects failures. This means that when something unexpected occurs, they react in a predictable way.
Reference standards and requirements are similar to those used in the automotive industry for autonomous systems. In automotive, these functional safety integrations are used by advanced driver assistance systems and autonomous driving systems.
Precision Timing is also a building block in the relationship between speed and accuracy. Robotics applications in factories must successfully synchronized in order to achieve speed and accuracy needed. For collaboration between humans and robotics be safe and effective, and between robots themselves, the optimization of task execution relies on Precision Timing’s synchronization of activities. In this respect, Precision Timing minimizes latency and optimizes tasks performed by cobots, robotic arms, and automated guided vehicles.
Timing
as the backbone of robotics evolution
As robotics systems grow more complex and
interconnected in the Industry 4.0 era - due to the widespread employment of AI, IoT, and cloud technologies - timing remains the common denominator enabling these advancements. Real-time communication protocols are required by modern robotics systems to execute increasingly complex tasks with autonomy and flexibility. Collaborative tasks and predictive analytics rely on a unified timing framework that spans from the sensor level to cloud-based AI engines. With these requirements, there is a need for accurate, deterministic timing with sub-microsecond accuracy to maintain system-wide coherence and performance. Timing drift, however small, can lead to process instability and data misalignment - especially in environments demanding millisecond or microsecond-level responsiveness.
Looking ahead, the trajectory of robotics innovation will be shaped by how effectively systems can maintain synchrony under dynamic, often-harsh, real-world conditions. Precision Timing will continue to define the performance ceiling of robotics in Industry 4.0, operating as the invisible infrastructure that supports reliability and safety.
66095 at www.ien.eu
Silicon MEMS devices offer stability and accuracy for networks, where time is of the essence.
Picture: SiTime
exclusive interview
Elevating Data through the Power of Context
IEN Europe interviewed Norman Hartmann, co-founder and CEO of Workerbase GmbH, who introduces the benefits of the Connected Worker Platform concept.
IEN Europe: Not all our readers are familiar with the term “Connected Worker-Platform”. Could you please describe the idea behind it?
Hartmann: A Connected Worker Platform is a digital tool set that empowers frontline workers in industrial environments. While most digital transformation efforts have historically focused on machines and automation, human workers have remained on the sidelines in terms of digital integration. The concept of a Connected Worker Platform changes that by providing shop floor employees with the right information at the right time, directly at the point of activity. It enables them to perform their jobs more efficiently, avoid mistakes and collaborate better with other departments. The integration of machines, people and materials in a unified digital ecosystem bridges the gap between humans and industrial IT systems. Beyond task management, it enables teams to document work in real time, access contextual data and benefit from AI-supported assistance. It’s about creating a closed feedback loop. Workers not only receive instructions but also generate valuable data that improves future processes.
IEN Europe: What is the software and hardware needed for implementation? Which role does the “Industrial Smartwatch” play in this concept?
Hartmann: We started out with the industrial smartwatch because experienced workers usually know how to do their jobs. They just need to know what to do next. A smartwatch is hands-free, always on the wrist, and doesn’t interfere with manual tasks. It was ideal for quick task dispatching, alerts
and confirmations. It also helped us communicate the concept in a very tangible way during our early days. However, today the Workerbase platform is device-agnostic. It runs on smartwatches, smartphones, tablets, laptops and desktop PCs. A smartwatch is still very useful for specific use cases, but not a requirement. This flexibility means our solution can scale with the needs and preferences of each customer site. Whether it’s maintenance, logistics or quality assurance. Each role can use the device that best fits their tasks.
IEN Europe: AI is a term that is hard to avoid in the industrial landscape at the moment, no matter where you look. How would you rate the current situation regarding the use of AI in production? What is your opinion on how things will develop in the near future?
Hartmann: We’re definitely in the early stages of AI adoption in manufacturing. There’s a lot of experimentation happening. Some of it quite promising, some of it still struggling with real-world applicability. The big challenge is that AI alone isn’t useful without context. That's why we’ve designed our platform to act as an AI enabler. Companies can integrate their preferred AI engines, whether it’s OpenAI, Gemini, or an in-house model. What we do is provide the infrastructure: contextual data from the shop floor, user input, task flows and historical performance. With this, the AI can do meaningful things, like helping workers make better decisions based on past events, summarizing procedures or generating documentation automatically. Conversely, once AI helps produce structured documentation, it can then
Norman Hartmann, co-founder and CEO of Workerbase. Picture: Workerbase
analyze it to surface patterns and opportunities. This two-way interaction between human activity and artificial intelligence is what unlocks real value, and we make that accessible.
IEN Europe: What skills are needed in a company and how many specialists are needed to prepare and implement a Worker Platform project?
Hartmann: One of the most powerful aspects of a Connected Worker Platform is its simplicity. Most tasks, like building workflows or digitizing checklists, can be done with no IT background. It’s designed to be as intuitive as
writing a Word document. This allows companies to start small, experiment and scale at their own pace. For more advanced use cases, we offer the ability to integrate custom code. This is optional and only needed if a company has very specific requirements. At that point, collaboration between domain experts and IT teams can unlock even more potential. In practice, each factory site usually has at least one key user, someone who acts as the local expert. In larger organizations, we sometimes have hundreds of key users across regions. These teams create new applications and continuously refine the system. It’s a very decentralized and dynamic approach to digital transformation.
IEN Europe: What industries and sectors customers come from? What are the typical benefits and what period of time can be expected for the return of invest?
Hartmann:We originally started in discrete manufacturing, but today our customers come from virtually every industry: automotive, electronics, consumer goods, food & beverage — you name it. The challenges we solve are universal: bringing the right information to workers, documenting their actions, coordinating across teams and accelerating onboarding. The return on investment is typically seen within a few months. We’ve seen companies save millions of eu-
The communication of the type and possible cause of a problem simplifies the targeted response by the employee, thereby enabling a more efficient resolution. Picture:
ros by preventing errors, reducing downtime and streamlining processes. The platform improves traceability, compliance and efficiency, all of which contribute to a significantly more agile and responsive production environment. Because the software integrates seamlessly with existing systems like ERP and MES, it doesn’t require customers to rip and replace. Instead, it extends their digital capabilities directly to the frontline, creating immediate and measurable value.
IEN Europe: Can you give us an example of challenges you solved for customers Hartmann: One of the most impactful cases was with Gazelle, a leading bicycle manufacturer. They were struggling with frequent and unexplained assembly line stops. Previously, when a stop occurred, it was simply recorded as a binary event, “stop” or “go”, with no context. Our system changed this by capturing additional data directly from the workers. Now we also record the reasons behind each stop, such as workers not knowing how to proceed or missing materials. This approach allows us to provide a different level of support. For instance, if a worker doesn't know how to solve a problem, the system can route the task to the appropriate person to offer guidance. If missing materials are the issue, the system can automatically notify logistics or the supply chain team to deliver the resources. By adding context and traceability, we were able to reduce downtime by 35%, significantly improving production efficiency. Furthermore, by capturing detailed reasons for each interruption, we’re able to identify recurring problems and implement measures to prevent them.
IEN Europe: Thank you for these insights! 65946 at www.ien.eu
Depending on requirements, notifications or alarms can be received via an industrial smartwatch or other mobile device. Picture: Workerbase
Workerbase
AI Camera for Collision Warning in Industrial Environments
Enhanced driving safety with AI camera for person detection
On construction sites with blind spots, a construction machine equipped with the O3M AI 2D/3D intelligent sensor system can reverse more quickly. A municipal vehicle can stop reliably, even if the person crossing is difficult to detect. At airports or container terminals, the sensor system guides the positioning of a passenger boarding bridge or a container to within centimetres without risk of collision. The combination of the two technologies virtually eliminates the annoying false triggers that are almost inevitable with conventional 3D systems.
Improved results in a radius up to 25 meters
Such is achieved through the unique combination of a 3D PMD sensor and 2D AI camera in an embedded area monitoring system. System reliability is greatly enhanced by fusing data from two different types of sensors on a fully integrated and calibrated platform. AI analysis of the 2D camera data improves the quality of object detection, enabling it to distinguish between people and other obstacles. The new collision warning system works much better and more accurately than conventional solutions.
The O3M AI smart sensor
system uses the data from the 2D and 3D cameras to generate a video that displays the surroundings and simultaneously overlays information on the exact distances to all objects and people within a radius of up to 25 metres onto the image. The O3M AI can always tell whether emergency braking, a controlled stop or deceleration would be appropriate in a given situation.
The high-resolution digital Ethernet camera is equipped with a powerful processor with AI accelerator (NPU).
This enables ultra-fast processing of the AI algorithms for person detection directly in the system. In addition to the Ethernet camera, a 3D PMD camera is integrated. It provides an accurate distance measurement to the object in every single pixel based on the PMD time-of-flight principle. Depth mapping from the 3D system and video from the Ethernet camera can be combined or used on their own, depending on the application.
Trained for industrial environments
The O3M AI’s person and obstacle detection has been optimised for mobile machines. The collision warning system can accurately distinguish between a distant obstacle and a person in close proximity, even if that person is ly -
ing on the ground, is wearing dark clothing or is difficult for conventional systems to detect due to larger tools or unusual posture. It works in both bright sunlight and twilight and has a maximum range of 25 metres with an accuracy of 10 centimetres. The AI, hardware and software have been developed in Germany by ifm. A wide variety of people, equipment and work positions from the typical mobile machine work environment are included in the AI training examples.
The result is a far greater gradation of possible alarms and warnings from the system. When it comes to striking the right balance between efficiency and safety, this is an important criterion.
DataHub software puts OT data on a DMZ using only outbound connections which keeps all inbound firewalls ports closed and requires no VPNs. On the DMZ, connected DataHub software provides secure, bidirectional data flow to and from any cloud service to support real-time Industrial AI.
