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Humanoids step onto the factory floor
Hannover Messe preview Hannover Messe 2026 examines how advanced automation and manufacturing is supporting defence ambition
Reinventing the factory grid Phoenix Contact demonstrates how DC power and storage create a highly efficient, all- electric industrial future
When robots get hacked Rising connectivity brings new vulnerabilities, forcing industry to confront the security risks at the heart of modern robotic systems
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FOOD PROCESSING Advanced valve control: tailored to help keep it clean When it comes to food processing, maintaining the highest hygiene standards is essential to ensure both product safety and reliable production outcomes. ROBOTICS Cybersecurity for robotics Manoj Rajashekaraiah, Principal Engineer at Analog Devices, explores security risks and effective security measures in robotic control systems. DIGITAL NETWORK Digital network maintenance: this year’s biggest industry trend? Electricity networks are being pushed into unfamiliar territory. 3D PRINTING Redefining electronics manufacturing: the impact of high-precision 3D printing from prototype to production With electronics becoming smaller, more WOMEN IN ENGINEERING Water, automation, and the power of a different voice Sophie Borgne, Schneider’s Electric’s Water & Environment Segment President, is making the case that industry is shaping our future, and the teams that support this change need to look very different. tightly packaged, and subjected to demanding conditions, 3D printing technology is proving a viable alternative to traditional manufacturing.
EDITOR’S NOTE The robots are here: physical AI and the new industrial frontier “Robots rule the world, and the humans are dead.” At least, that was the tongue-in-cheek warning in a cult song by New Zealand-based pop duo Flight of the Conchords. NEWS This issue’s latest updates In this issue’s News Analysis we look at Mitsubishi Electric’s new AI system, Hyundai’s plans to deploy Atlas humanoid robots, OpenAI and SoftBank’s $1 billion investment in AI data centres, Microsoft’s UK renewable-powered facility, and warnings that the UK’s slow robotics adoption could put national security at risk. HANNOVER MESSE PREVIEW Hannover Messe 2026: industrial innovation meets strategic security Hannover Messe, the world’s largest industrial trade fair, returns for its 77th edition at the Hannover Exhibition Centre from 24–28th April 2026. INSIDE THE FACTORY Inside the Factory: Phoenix Contact’s DC-powered vision in Blomberg On its sprawling campus outside the small German town of Blomberg, electrical components manufacturer Phoenix Contact is quietly rethinking one of the most fundamental assumptions of modern industry: how factories are powered. HUMANOIDS Robots on the line At the Ford Innovation Centre in Cologne, Germany, safety barriers cordon off a section of the factory floor.
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Editor: Lucy Barnard
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“As electronics shrink and functional demands grow, micro-scale 3D printing is becoming a catalyst for innovation.”
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The robots are here: physical AI and the new industrial frontier
looking backwards to move forwards. Also in this edition, we hear how components manufacturer Phoenix Contact’s new factory incorporates both direct current (DC) and alternating current (AC) power systems (p14). AC has dominated industrial and commercial power since the late 19th century, winning the so-called War of the Currents between Thomas Edison and Nikola Tesla. Edison, reluctant to lose royalties on his DC patents, launched a campaign to discredit AC, even publicly electrocuting animals to prove it dangerous. While AC triumphed for long-distance transmission, Phoenix Contact is betting that, within a controlled factory environment, DC offers compelling advantages: efficiency, precision, and compatibility with modern electronics and energy storage. It is a vivid example of how innovation in 2026 can feel “back to the future” – reviving old ideas with new technology to tackle contemporary challenges. This theme of revisiting the past while innovating for the future is echoed in the UK’s electricity networks. As Jonathan Lewin, Head of HV Monitoring at EA Technology, explains, the country’s ageing grid is being pushed to its limits by the energy transition and climate impacts (p20).
Operators are rethinking how they monitor, manage, and protect the network, with digital maintenance and monitoring set to be a game-changer. Over the next 12 months, Lewin anticipates accelerated grid modernisation, driven by resilience, efficiency, and adaptability. Here again, old infrastructure is revitalised through digital innovation, just as factories integrate DC power and AI-driven robotics. Yet the human dimension remains as crucial as the machines themselves. Sophie Borgne, Schneider Electric’s Water & Environment Segment President, illustrates how automation and AI are transforming even the most unexpected sectors, from water treatment to energy management. Smart systems optimise efficiency, reduce carbon footprints, and manage complex operations – yet their potential depends on the people behind them. Borgne’s advocacy for diverse voices in STEM underscores a wider lesson for industry: innovation thrives when teams bring different perspectives, curiosity, and courage to the table. In 2026, the factories, grids, and water networks being reshaped by AI and robotics are only as effective as the humans guiding them. Launching Automation
News in print at Hannover Messe captures this pivotal moment – where fascination meets responsibility. The first edition spotlights pioneering firms, explores pressing issues like cybersecurity, digital grid management, and power systems, and examines the promises and limits of humanoid technology. Our aim is to provide readers with insight into the machines, systems, and strategies shaping industry today, and the approaches needed to harness them safely, effectively, and ethically. So yes, while we remain very much human, the metaphorical idea of robots ruling the world is no longer science fiction. Physical AI is our present, quietly but profoundly changing production, logistics, and the way we collaborate with machines. Combined with a renewed look at ideas from the past – DC power in factories, digital grid monitoring, and smarter water systems – 2026 feels like a crossroads: a place where old and new intersect to redefine what is possible. And while there may be more than one kind of dance on the factory floor – call it the Robot, the Robo-Boogie, or something else entirely – it is clear that humans remain central to the choreography, even as robots increasingly set the rhythm of industry.
“Robots rule the world, and the humans are dead.” At least, that was the tongue- in-cheek warning in a cult song by New Zealand-based pop duo Flight of the Conchords.
W alk the Hannover Messe press preview in 2026, however, and the joke feels strangely prescient – not literally, of course, but metaphorically. Physical AI is everywhere. Humanoids are no longer the stuff of science fiction; they are appearing on factory floors (albeit still in proof- of-concept form) across Europe, the US, and Asia. The dystopian future imagined in song has arrived in fragments, and it is fascinating, exciting, and, yes, a little unnerving. Take Humanoid (p30), a UK-based firm trialling wheeled humanoids with Ford in Germany. Its robots have been ‘working’ autonomously: lugging 8kg loads, dextrously selecting car body parts from storage, and moving them securely across the facility to a kitting table. Yet the trials also highlight the gaps: voice instructions for new tasks are hit-and-miss, safety protocols demand constant vigilance, and integration with human teams remains an iterative
process. Manufacturers readily admit that physical AI is powerful, but far from perfect. Exhibitors at Hannover Messe illustrate the breadth of this industrial shift (p10). Agile One is demonstrating a humanoid capable of complex industrial tasks, while igus presents Iggy Rob, designed for flexible, collaborative material handling. These machines signal a move from experimental prototypes to operational partners in industry. Yet they also raise pressing questions: how can reliability be ensured, accidents prevented, and trust maintained between human and machine? The answers are still evolving. Cybersecurity is another critical frontier. In this edition, Manoj Rajashekaraiah, Principal Engineer at Analog Devices,
Written by Lucy Barnard, Editor, Automation News
examines the industrial security standards shaping the safe deployment of physical AI (p24). As humanoids generate data and connect to networked systems, robust safeguards are essential. Operational excellence now goes hand in hand with digital resilience, and any lapse can have real-world consequences on the factory floor. While armies of robot workers are still emerging, manufacturers are also
“While armies of robot workers are still emerging, manufacturers are also looking backwards to move forwards.”
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Hyundai to deploy humanoid robots in car factories from 2028 Hyundai Motor Group has announced it plans to introduce Atlas humanoid robots into its car factories from 2028. Hyundai said that it had agreed to acquire the entire 2026 supply of Atlas robots produced by Boston Dynamics, the US robotics firm in which it owns a controlling stake. The Korean conglomerate plans to build a new factory capable of producing 30,000 humanoid robots annually, marking the company’s entry into robot manufacturing in earnest. The Korean conglomerate said that it plans to introduce Atlas robots across plants including its HMGMA plant in Georgia, USA, from 2028, initially handling simple tasks such as parts sequencing. But, it said that by 2030 it expected to extend Atlas’ workload to include to car assembly and other complex operations.
News In this issue’s News Analysis we look at Mitsubishi Electric’s new AI system where agents argue to sharpen industrial decision-making, Hyundai’s plans to deploy Atlas humanoid robots from 2028, OpenAI and SoftBank’s $1 billion investment in next-generation AI data centres, Microsoft’s UK renewable-powered facility, and warnings that the UK’s slow robotics adoption could put national security at risk.
Mitsubishi Electric unveils adversarial AI system to sharpen industrial decision- making Mitsubishi Electric has developed a system in which AI agents, rather than co-operating, actively challenge one another and argue. The company said that the technology, developed under the company’s Maisart AI programme, is the first in the manufacturing sector to use an ‘argumentation framework’ to stage automated adversarial debates among expert AI agents, mirroring human debate to improve complex decision-making. “This technology enables deep insights through adversarial debate and evidence-based decision- making, which are difficult with conventional cooperative multi-agent AI systems,” the company said in a press statement. “Mitsubishi Electric’s solution allows AI to be deployed in highly specialised decision-making involving complex trade-offs, such as security analysis, production planning, and risk assessment, contributing to operational efficiency.”
OpenAI and SoftBank to spend $1Bn on next gen AI data centres Japanese banking giant SoftBank and OpenAI, the company behind ChatGPT, are pushing ahead with ambitious plans to invest $1 billion into next gen AI data centres. The pair agreed to each contribute $500 million in SoftBank power subsidiary SB Energy as part of President Donald Trump’s $500 billion Stargate initiative. Under the agreement, SB Energy will design, build,
and operate OpenAI’s planned 1.2-gigawatt data centre in Milam County, Texas, a facility which broke ground in September 2025 and is expected to be completed this year. The project is intended
to support the massive computing needs of OpenAI’s models and the automated systems they power. It will include advanced energy management and server monitoring systems.
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Inside Microsoft’s new ‘zero generator’ data centre Microsoft has said it is pushing the boundaries of data centre construction in the UK with its newest facility in Acton, west London, designed to operate entirely without backup diesel generators. Manufacturers warn UK’s lag on robotics risks national security Industry experts are warning that a failure to invest in automation in the UK could compromise national security. “If we don’t adopt robotics at scale, we risk being unable to meet domestic production needs for critical sectors, including defence,” said Sam Reid, Head of Business Operations at Cyber- Weld, speaking at the Southern Manufacturing Show. “Without sufficient automation, the UK could be forced to send sensitive
unique for a data centre of this scale,” said Éanna McDarby, Principal Program Manager, UK Data Centre Construction at Microsoft. “From initial site due diligence to commissioning, we’re focused on integrating design and operational efficiency in a way that hasn’t been done before in the UK.”
The five-storey site, currently under
construction, will run fully on renewable energy and forms part of a £330M UK expansion programme, which also includes centres in Leeds and Wales, all scheduled for completion between 2027 and 2029. “We’re talking about a facility that is completely
equipment abroad for production or welding.” According to the International Federation of Robotics, UK companies on average employ 111 robots per 10,000 employees, significantly below the global average of 141.
“Without scaling up robotics, the UK risks being unable to deliver critical products reliably, from defence systems to high-value industrial components,” added Peter Williamson, Policy Director at Automate UK.
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Hannover Messe 2026: industrial innovation meets strategic security Hannover Messe, the world’s largest industrial trade fair, returns for its 77th edition at the Hannover Exhibition Centre from 24–28th April 2026. A gainst a backdrop of rising European military spending and shifting geopolitical priorities, the fair will
and policymakers from around the world. Key themes include automation, sustainability, energy transition, and defence technology, highlighting how industrial advancements are increasingly entwined with geopolitical strategy. Hall 26 alone will host the Defence Production Arena, with around 50 exhibitors providing demonstrations, matchmaking opportunities, and guidance for entering
Messe, from hydrogen fuel cells and digital twins to smart factories and sustainable production solutions. Automation News visited some of the most exciting exhibitors to find out what they planned to showcase. Classiq Technologies: accelerating quantum software Classiq Technologies, a pioneer in quantum software design automation, is showcasing how quantum computing can move from experimental labs into industrial practice. for industrial applications
spotlight the intersection of industrial innovation and
defence technology. Dr Jochen Köckler,
Chairman of the Managing Board of Deutsche Messe, stressed the growing strategic dimension of this year’s event. “Not only the industrial turning point but also the new geopolitical situation requires rapid defence technology development,” he said. Political participation at Hannover Messe 2026 reflects this shift. German Chancellor Friedrich Merz is confirmed to open the fair alongside Brazilian President Luiz Inácio Lula da Silva. Their presence underscores Hannover Messe’s dual role as a showcase for industrial innovation and a forum for global economic and security dialogue. Spanning 27 halls and hosting over 1,500 exhibitors, the fair will bring together industrial leaders, innovators,
A six-year-old Israel- based company’s platform acts as an AI copilot for programming quantum computers, even though quantum computers themselves are not yet ready for widespread commercial use. This, says Classiq, enables engineers to jump ahead, developing algorithms for optimisation, material simulation, and manufacturing efficiency. “You can already start working on it now… and once the quantum computers really provide that advantage, they can immediately run their code and benefit from it,” said Nikolai Strah, Commercial Director DACH. Quantum computing promises performance far beyond classical systems, particularly
for complex supply chain, manufacturing, or engineering simulations, while integrating with classical computing workflows. Classiq already counts over 40 commercial clients, including BMW, Mitsubishi Chemical, and Comcast, all using the platform to build “quantum ready” software and IP. Using a quantum simulation achievable on a classic computer, Classiq enables engineers to design quantum algorithms without the need for in-depth quantum coding expertise, allowing rapid prototyping and optimisation for tasks such as logistics, materials simulation, and predictive maintenance. “Our focus is enabling industrial engineers to explore quantum computing benefits in a practical
way, bridging the gap between abstract theory and operational value,” said Strah. Agile Robots: Germany’s Agile One humanoid looks to boost industrial and defence production Another company to look out for at this year’s show is Agile Robot, a European leader in industrial automation solutions, which will be presenting its first European humanoid, Agile One. Agile is currently in the process of setting up the first production lines for Agile One in Germany and is hoping to offer the machine to manufacturers as part of a wider robotics solution.
the defence sector, including dual-use considerations.
Alongside global leaders such as Siemens, ABB, Bosch Rexroth, and Mitsubishi Electric, European and UK firms will highlight their latest products at Hannover
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engines in heavy-duty applications. Joachim Ladra, Head of Sales, Marketing & Communication, explained the company’s focus: “Our mission is to make fuel cells a technically and commercially viable alternative for trucks, buses, and off-highway vehicles, without being limited to our owners’ fleets.” Ladra said that visitors to the Cellcentric stand can explore demonstrations of the company’s fuel cell technology, which achieves efficiency levels above 60%, offering parity with diesel in both payload and driving range. Cellcentric is also highlighting stationary power generation solutions, such as containerised Gensets, which convert hydrogen into electricity for factories, data centres,
present advantage lies in immediate productivity gains. Current adopters span industries from quality control in watchmaking to worm farming, illustrating that automation is not sector specific. For the foreseeable future, igus believes the greatest impact will be in low-skill, repetitive tasks, with truly flexible humanoid robots still five to 10 years away from practical deployment. Cellcentric: pioneering hydrogen fuel cells for heavy- duty decarbonisation Also at the show, Cellcentric, a 50/50 joint venture between Daimler Truck and the Volvo Group, is showcasing its advanced hydrogen fuel cell systems designed to replace diesel
of high-end, expensive robotics. igus offers a marketplace for “low-cost automation,” combining verified components from multiple manufacturers to ensure reliability. Potential buyers can test applications with their own parts before committing to investment, a model designed to eliminate the risk often associated with cheaper imports. While humanoid robots capture the imagination, igus emphasises that for most industrial tasks, specialised arms such as Cobot, SCARA, or Delta robots are more practical. These are configured for specific pick-and-place, gluing, or palletising tasks, fully integrated and delivered at a fixed price without recurring software fees. “Everyone with a base understanding of mathematics would probably say, why pay a few thousand a month when you can pay once and have it work for years?” said Johannes Erdinger, International PR Manager at igus. Prices for humanoids such as the company’s Iggy Rob start at €14,000 and can rise to €86,000 depending on size, payload, and speed. igus anticipates costs will gradually fall as technology matures, though the company stresses the
“Agile One will be a German produced robot,” says Sven Parusel, the company’s Head of Research Partnerships. “We’re not targeting for it as a standalone product. So you will not be able to buy Agile One. It will be included in industrial environments, working together with the humans and other robotic or industrial automation solutions.” Parusel says that humanoids are becoming adept in being able to take on certain tasks on factory floors. But, he adds, there’s a long way to go before the machines are able to take on the sort of tasks currently entrusted to human workers. “So, what we train the robot for, of course, is industrial tasks,” he adds. “Picking up objects, placing objects, putting things together, using tools, machine tending. These kinds of basic ideas are trained into the foundation models that we develop, that we train. So, if it’s in that realm, of course, there’s a good chance that our model already can do some of these things for you. If it’s something completely different, you might start from scratch and collect a lot of new data for that. We’re nowhere close to a generic robot brain, and not just us, nobody really. So, I think humanoids are just doing what you tell them.”
At Hannover Messe, Agile is also demonstrating how its collaborative robotic systems, combined with AI-driven production scheduling, can maximise throughput while reducing waste and energy consumption. The company offers digital twin simulations that allow operators to model production lines virtually, anticipating bottlenecks and testing layout changes before committing to physical implementation. “Our systems are being evaluated not only in automotive and electronics manufacturing but also for defence production, where flexible assembly lines and precision robotics are essential,” Parusel said. Agile’s approach underscores the convergence of industrial efficiency and strategic readiness, illustrating how adaptable automation can serve both commercial and security imperatives. igus brings low- cost automation to SMEs with Iggy Rob humanoid and robotic arms At this year’s show, igus is showcasing a portfolio aimed squarely at small and medium-sized enterprises seeking affordable automation solutions. The company’s philosophy is simple: automation should not be the preserve
and marine applications. These systems allow decarbonisation in contexts where battery-electric solutions may be limited by grid constraints. Yet, despite the tech advances, Ladra admits that take up has been slower than many had hoped. Fleet owners and manufacturers have been reluctant to invest in the technology due to a lack of infrastructure while few fuelling stations have been built due to a shortage of hydrogen trucks. To get round this impasse, Ladra says Cellcentric is actively collaborating with partners across the Global Hydrogen Mobility Alliance to develop hydrogen refuelling networks in Europe. “Technology alone is not enough. We need the full ecosystem – fuel, infrastructure, and operational reliability – to make hydrogen a sustainable alternative,” he said. “Our next-generation fuel cell systems, launching this year, are designed to be ready for that transition.”
Written by Lucy Barnard, Editor, Automation News
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can be fed directly back into the system. “In logistics, you’re lifting loads up and lowering them down at the same time,” Wetter says. “If designed correctly, it becomes almost a zero-sum game.” Peak load management is another key benefit. In some applications, Phoenix Contact estimates that DC systems can reduce peak demand by as much as 60- 80%, easing strain on both internal infrastructure and the external grid. Yet these advantages come with technical challenges. Unlike AC systems, which pass through zero voltage 50 times per second in Europe, DC maintains a constant voltage. This makes faults more dangerous and requires extremely fast protection systems. “I have been a big enemy of DC systems for many years. That’s because if you cut a live 40-volt AC wire there is a big flash of light and a loud noise. If you do the same on a 650-volt DC line, you are dead. It fries you,” said the company’s Chief Operating Officer Ulrich Leidecker. “AC naturally goes to zero voltage every few milliseconds, but DC does not. You need protection that turns off in microseconds, not milliseconds. This is something we’ve built and
On its sprawling campus outside the small German town of Blomberg, electrical components manufacturer Phoenix Contact is quietly rethinking one of the most fundamental assumptions of modern industry: how factories are powered. Inside the Factory: Phoenix Contact’s DC-powered vision in Blomberg
A t its new €35 million “all-electric society factory” building, the company is piloting a direct current (DC) energy system designed to integrate renewables, storage, and industrial loads into a single, highly efficient network. Known as Building 60, the 18,500 square metre site houses around 400 employees and serves as both a production facility and a live demonstration of how Phoenix Contact thinks future industrial energy will work. At the heart of this vision is a shift away from alternating current, which has dominated power systems since the late 19th century following the War of the Currents between Thomas Edison and Nikola Tesla. While AC won out due to its ease of transmission over long distances, Phoenix Contact is betting that, within the confines of a factory, DC offers compelling advantages. “From my point of view,
excess solar power, and production processes can draw from multiple sources depending on demand. The efficiency gains are not just theoretical. According to Wetter, switching from AC to DC in factory environments can deliver energy savings of 8-12%, largely by eliminating repeated conversion losses. Material savings are also significant, with copper usage reduced by up to 50% due to lower cabling requirements, and electronic components cut by around 25%. Perhaps more importantly, DC systems enable new forms of energy recovery. In industrial environments where loads are constantly accelerating and decelerating – such as robotics or logistics systems – energy generated during braking
DC is a real key enabler for the all-electric society,” said Martin Wetter, Executive Vice President for Innovation at Phoenix Contact at a press tour of the facility. Inside Building 60, those ideas are already being put into practice. The facility combines a conventional AC supply with a 650- volt DC grid, fed by bi- directional converters, photovoltaic systems, and battery storage. Around 110 kilowatts of solar capacity is connected directly into the DC network, while additional generation feeds into the AC side due to regulatory constraints. Wetter says that this hybrid architecture allows energy to move flexibly across the system. Electric vehicles can be charged during the day and discharged at night, batteries store
are introducing into the industry.” To manage stability, the factory relies on voltage- based control rather than frequency – a fundamental shift from traditional grid management. Phoenix Contact has implemented both local device-level controls and a centralised master controller, enabling intelligent energy management across the site. This software-driven approach allows the system to prioritise renewable energy, optimise charging cycles, and dynamically balance loads. “You can implement anything you like in this control unit,” Wetter
said. “It’s very flexible, and very intelligent.” Flexible and intelligent it may be, but Phoenix Contact continues to take a cautious approach when rolling out the changes. On the factory tour, Automation News noted that only one of the 12 or so huge strip lights illuminating the factory runs on direct current. The company says that gaining regulatory approval for DC powered facilities within the factory continues to be challenging. Nonetheless, energy integration at the site extends beyond electricity. One of the more unusual features is a large-scale ice
“It’s fascinating technology,” Wetter said. “Freezing water releases a huge amount of energy without changing temperature.”
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storage system used for heating and cooling. Beneath the factory sits a 19-metre-wide tank containing 1.5 million litres of water. By freezing the water in winter, the system extracts thermal energy for heating; in warmer months, the stored ice enables highly efficient cooling. “It’s fascinating technology,” Wetter said. “Freezing water releases a huge amount of energy without changing temperature.” Alongside heat pumps and a campus-wide heat network, the system forms part of a broader effort to reduce the company’s carbon footprint. Separately on its Blomberg campus, the company has also built a showroom highlighting the various technologies
onto rails and marking them using laser systems can produce components rapidly and with minimal error, using data directly from digital design tools. “Digitalisation is key – without a digital twin of the product, even the best physical component is only half as valuable in production,” Schreiber adds. New connection technologies are also being introduced to streamline assembly. Phoenix Contact’s push-in wiring systems, for example, eliminate the need for screws or ferrules, allowing wires to be inserted quickly and securely, and reducing both labour time and complexity. Together, these initiatives point to a broader transformation. The factory is not just demonstrating new energy infrastructure, but also new ways of designing, building, and operating the electrical systems that underpin modern industry. “DC is a real key enabler for the all-electric society,” adds Wetter. “Here at Blomberg, we are showing that it’s not just a vision – it can work in daily industrial operations, efficiently, sustainably, and safely.”
“We’ve designed specialised workstations that guide workers step by step, using digital data from engineering.”
manufacturers are using to transition from fossil fuels which is open to visitors and school parties. But Phoenix Contact’s ambitions at Blomberg are not limited to energy systems. Part of the factory has been dedicated to rethinking another bottleneck in industrial electrification: the production of control cabinets. As electrification accelerates globally – with millions of wind turbines, solar installations, and kilometres of grid infrastructure required – the demand for control
cabinets is rising sharply. These systems, which house the components that control electrical processes, are becoming increasingly critical. To address this, the company has created an application centre – an industrial “shop floor” environment within Building 60, where customers can work alongside Phoenix Contact engineers to develop and test solutions. Looking a bit like an Ikea Kitchen Design Station, Phoenix Contracts new division can provide anything from assisted manual workstations to
that nearly 90% of control cabinet builders see labour shortages as a major constraint, even as demand continues to grow. The company’s response is to embed digitalisation directly into the production process. Worker assistance systems guide operators step-by-step using data from engineering software, enabling even less experienced staff to contribute effectively. At the same time, automation is being deployed where standardisation allows. Machines capable of assembling terminal blocks
fully automated production systems, all linked by digital workflows. “We’ve designed specialised workstations that guide workers step by step, using digital data from engineering. This allows even semi-skilled staff to assemble control cabinets efficiently and accurately,” says Andreas Schreiber, the company’s Vice President for Industrial Cabinet Solutions. One of the key challenges identified by Phoenix Contact is a shortage of skilled workers. Internal research conducted with industry partners found
Written by Lucy Barnard, Editor, Automation News
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HUMANOIDS
Robots on the line
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At the Ford Innovation Centre in Cologne, Germany, safety barriers cordon off a section of the factory floor. Inside this area a solitary figure dressed in a Ford t-shirt, lifts plastic containers and car parts, picking them up from one bench only to travel a few feet and set them down on a different bench.
S o far, so ordinary. is a humanoid robot, comprising a shiny black head, human style-torso and a hinged base where its legs should be, set on a swivel pedestal and a base the size of a small coffee table. The machine, which recently completed a Proof of Concept (POC) trial inside one of Europe’s most advanced automotive facilities offers a glimpse into what the near future of manufacturing could look like. Unlike most humanoid The only difference? the figure in question
trials, which tend to focus on controlled, repetitive processes in a lab environment, the robot, Alpha HMND 01, developed by UK-based robotics startup Humanoid, was set the challenge by Ford to complete real- world workflows – the sort of thing that real people actually do on its assembly lines – and to do them on a real factory floor (albeit a roped off area of one). Artem Sokolov, Humanoid’s Russian born founder, explains the challenges: “Even though a POC isn’t a full deployment yet, it’s already very different from a lab – there’s more
variability, more movement, more unpredictability,” he tells Automation News . “Some elements were adapted for the demo, for example, navigation was tuned to that specific environment. To scale this to a full plant, we would need much more advanced mapping and safety validation,” he adds. “Energy is another practical challenge: we demonstrated around 60 minutes of operation, but for real industrial use, longer endurance is required, so battery scaling or swap/charging strategies become important.”
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The trial took place over six weeks at the start of the year, taking place both in the Humanoid Lab and later at the Cologne plant. The robot was given two core tasks: autonomously moving filled totes weighing 8kg between workstations and finding and manipulating a large, sheet metal car body component and moving it to a kitting table. Both tasks are commonplace in vehicle manufacturing, yet notoriously difficult to automate due to variability in objects, environments, Humanoid reported that in the first task, the robot operated continuously for a full hour, double the initial target, while achieving 97% reliability in autonomous pick-and-place operations. Productivity also surpassed projections, with the robot completing 83 picks per hour compared to the anticipated 50, a 60% improvement. The second workflow pushed the robot into even more complex territory. Here, Alpha demonstrated dual-arm manipulation, handling a thin sheet-metal car body component, an object that is both flexible and sensitive to improper handling. The robot successfully navigated to the storage location, and movement requirements.
identified and localised the part, lifted it securely, and placed it onto a kitting table. The key enabler, Sokolov adds, was the robot’s AI: “The system is built around task-level understanding, which allows the robot to adapt much faster. It combines perception, decision-making, and motion in real time, meaning we don’t need heavy re-engineering every time the robot encounters a new environment,” he says. Humanoid says technology from NVIDIA played a significant role in enabling this rapid development cycle. The project used operational digital twins, virtual replicas of real- world environments that allow teams to simulate, test, and refine robotic behaviour before physical deployment. What makes the tools such as NVIDIA Omniverse to create achievement more striking is the minimal time required to prepare the system. According to the company, just one hour of on-robot data collection was needed to fine-tune the AI model for the task. This rapid deployment was made possible by training the system on extensive datasets gathered across varied environments, allowing it to generalise
quickly to new conditions. “Because our models are trained on large, diverse datasets beforehand, we don’t need massive amounts of on-site data to deploy,” Sokolov says. “About an hour was enough to get a high-performing system. Simulation using tools like digital twins allows us to train and test the system before deployment, and minimal fine-tuning on-site makes the approach scalable across factories and industries.” And Humanoid’s work for Ford is just one of a number of collaborations taking place between humanoid robotics companies and automotive manufacturers at the moment. Elon Musk’s Tesla has said that it plans to get its Optimus robot models to help in its car plants from this year while Tesla has committed to converting space in its Freemont factory, previous used for Model S and X production to mass produce humanoids. Hyundai too has said it will deploy Atlas humanoid robots in its factories from 2028 following its investment in the robotics company behind Atlas – Boston Dynamics – in 2021. Not to be outdone, in February BMW announced a pilot to deploy humanoid
robots at its Leipzig plant in Germany in partnership with Hexagon Robotics following a previous demonstration at its Spartanburg plant in the USA in collaboration with tech firm Figure AI. “What differentiates us is speed and commercial focus. On the hardware side, we’re moving very fast. Our wheeled robot was built in about seven months, and our bipedal robot was developed even faster, in around five months. This level of speed is unprecedented for the industry,” Sokolov says. “But more importantly, we focus very early on real- world use cases. While most humanoid robotics companies focus more on impressive prototypes, we want to create robots that the market and different industries really need. That’s why we started testing with commercial
partners even at very early stages. In less than two years, we’ve already completed seven POCs, which gives us real feedback from the field. And then on the AI side, we recently introduced KinetIQ, our proprietary ‘AI brain’. It’s a four-layer framework that orchestrates entire robot fleets across industrial, service, and home environments, and a foundation of what we call a capability factory. “Our goal is very clear: to become a leading general- purpose humanoid robotics company for industrial applications in the next two years.” And beyond hardware and AI, Sokolov is also focused on the broader vision for humanoid robots in industrial environments. “We anticipate that in the near term, humanoid robots
will have the biggest impact in industrial environments. They will take on physically demanding, repetitive, or hazardous tasks, which will naturally increase productivity. Because robots don’t need rest or sleep, operations can run 24/7, unlocking a completely new level of efficiency,” he explains. “At a larger scale, thousands of robots working across factories and warehouses could free people from tasks that are repetitive or undesirable. It will open the door to much bigger opportunities, from continuous research to large-scale innovation, and eventually even areas like space exploration. At the core, it’s about shifting human effort toward higher-value work, while machines handle the rest.”
Written by Lucy Barnard, Editor, Automation News
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FOOD PROCESSING
Advanced valve control: tailored to help keep it clean
VM10 valve island was integrated into the system to achieve this. The valve island enables centralised management of all pinch and ball valves, simplifying operation while improving responsiveness and ensuring that each ingredient is delivered accurately and in the correct sequence. Pressure control is equally critical in such systems. Inconsistent pressure can lead to irregular flow rates and inaccurate mixing, which could compromise cleaning effectiveness. To address this, IMI Norgren Excelon Plus Pressure Regulators were incorporated, providing precise and reliable pressure management for the valve island and associated piping. The combination of high- performance pinch valves, diverter valves, and controlled pressure regulation creates a fully integrated system where each component functions seamlessly with the others. From a systems engineering perspective, this project demonstrates the value of cross-
sector collaboration within IMI. By combining Membracon’s expertise in food processing machinery with IMI’s advanced pneumatic and valve technologies, we were able to deliver a solution that meets stringent hygiene standards while optimising operational efficiency. Every component, from chemically resistant pinch valves to the centralised valve island and precision pressure regulators, was selected and integrated with durability, reliability, and safety in mind. The resulting cleaning system provides significant benefits to the food processing operator. On- site disinfectant production reduces dependency on external chemical supplies and ensures freshly prepared disinfectant is always available. The pneumatic pinch valves protect mechanical components from exposure to aggressive chemicals, minimising wear and
maintenance requirements. Centralised control simplifies operation and monitoring, allowing staff to manage the cleaning process with confidence and precision. This project exemplifies
how the integration of specialised valve technologies and pneumatic control can address complex challenges in food
When it comes to food processing, maintaining the highest hygiene standards is essential to ensure both product safety and reliable production outcomes. Contamination risks in this industry can have serious consequences, making cleaning processes a critical aspect of operational management.
processing. By focusing on chemical resistance, operational precision, and safety, it is possible to design a cleaning system capable of sustaining rigorous hygiene standards without compromising reliability. Such systems play a critical role in maintaining compliance, protecting consumers, and ensuring production lines operate efficiently and safely, shift after shift.
T hese processes must not only be thorough but also consistent, efficient, and capable of handling the aggressive disinfectants commonly used in modern facilities. Developing systems that meet these demands requires careful engineering to balance safety, durability, and precise control. Recently, for IMI’s Industrial Automation sector collaborated with Membracon, an original equipment manufacturer, it was asked to design and implement a bespoke machine cleaning system for a food processing customer. The primary goal was to create a reliable on-site disinfectant production capability, enabling equipment to be cleaned efficiently after each production shift. This project demonstrated the importance of
integrating advanced valve technologies, pneumatic control, and precise pressure regulation to achieve a robust and effective solution. The challenge presented by the customer was twofold. Firstly, the system needed to generate sufficient volumes of disinfectant on-site. The disinfectant is composed of four highly reactive chemical ingredients, each stored in separate barrels, which must be accurately mixed into a single-use batch. Secondly, the chemical properties of these ingredients are highly aggressive, necessitating equipment that could withstand corrosive media without compromising operational safety or performance. Conventional valves and control systems are often unable to tolerate such chemicals, leading to rapid wear or potential failure.
To address this, Membracon developed a dedicated mixing machine that utilised IMI PBM pinch valve technology to manage the flow of the chemical components. Pinch valves are ideal for this application because the process media never comes into direct contact with the valve body. Instead, a flexible tube carries the media, and the valve operates by pneumatically pinching the tube to control flow. This design provides high chemical resistance, consistent performance, and reduced wear, making it particularly suitable for handling aggressive disinfectants safely and reliably. In addition to the pinch valves, precise and centralised control of multiple valve operations was required to maintain accurate dosing and mixing. An IMI Norgren
Written by Lourens Derksen, Sales Manager for IMI’s Industrial Automation sector
Author biography: Lourens Derksen is a Sales Manager for IMI’s industrial automation sector. Responsible for the BENELUX region, Lourens leads the team across various industries, including general industry and food & beverage. With more than two decades of engineering expertise, Lourens is passionate about solving customer challenges, improving processes, and ensuring their success through innovative solutions and dedicated support.
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ROBOTICS
control systems, protect critical assets, and many others. Figure 2 shows the IEC 62443 is a comprehensive security standard. While some parts of the standard focus on processes and procedures, IEC 62443-4-1 and IEC 62443-4-2 specifically address component security. According to IEC 62443-4- 2, component types include software applications, host devices, embedded devices, and network devices. The standard defines the capability security level (SL) for each component type based on the component requirement (CR) and requirement enhancement (RE) they meet. It defines four security levels (SL) SL0 to SL3. The SL2 and SL3 levels specifically require hardware-based security. What capabilities and technologies are necessary when developing robotic security system solutions? To build secure robotic control systems, we need to address the risks highlighted in the Security Risks in Robotic Control Systems section. Key technical capabilities and technologies needed include:
Written by Manoj Rajashekaraiah, Principal Engineer, Analog Devices
Cybersecurity for robotics Manoj Rajashekaraiah, Principal Engineer at Analog Devices, explores security risks and effective security measures in robotic control systems. He looks at the industrial security standards currently in place in the sector and analyses the essential requirements to meet
Figure 2
Regulations and acts for the industrial and robotics sectors promote cyber resilience and safeguarding operations The cybersecurity landscape is rapidly evolving, and there are a growing number of regulations as well as acts that target the industrial and robotics sector. Among the many, some of the acts that target cybersecurity are the EU Cybersecurity Act, the EU Cyber Resilience Act, and the US Cyber Incident Reporting for Critical Infrastructures Act. There are regulations and acts evolving in China and India as well. The NIST Guide to Operation Technology (OT) Security and Standards
like IEC 62443 provide us with guidance, enable us to take the secure-by-design approach and design, and develop our control systems to be resilient against cybersecurity attacks. IEC 62443 requirements for industrial automation and control systems security (IACS) IEC 62443 is security for industrial automation and control systems security [2] . It is a widely adopted standard for developing industrial automation control systems, and most regulations recommend it and recognise its importance. It enables us to be compliant with relevant regulations, mitigate potential cybersecurity risks in control systems, address security gaps in
these standards. Security risks in robotic control systems Factory automation is at the centre of Industry 4.0 and industrial robots, autonomous mobile robots (AMR), and collaborative robots play a crucial role in enabling the implementation of modern Industry 4.0. Robots are becoming smarter, more collaborative, and better positioned to handle complex tasks with and without human intervention. Higher levels of automation and higher use of robots also drive the demand for higher safety and security of robotic control systems. [1]
Figure 1
used on factory floors but now robots are used in different domains like medical, military, logistics, and agriculture. The need for safety and security is of much more importance than it was a decade back. Accidents are bound to
occur, but the ones caused by malicious attacks are critical. Malicious hijacking and control of robots can cause serious economic and financial losses. Figure 1 shows typical security risks that can lead to malicious attacks on robotic control systems
Robots were initially mostly
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