42 n AUTOMATION October 2025 www.drivesncontrols.com Sensing the shift: trends in industrial automation Over the past few years, the industrial automation market has experienced significant growth. There is increasing demand for productivity, uptime and additional output. Machines need to be turned on more quickly and for longer. Scaling operations must be done even more rapidly, and introducing new lines has to happen even faster than it would have done in previous years. All of this accelerates the industry's need for smarter industrial automation, from vision and sensing to connectivity to the cloud, access to data, and the ability to manage factories remotely. At DigiKey, we are excited by the growing demand and technological innovation we are seeing on factory floors around the world. Cutting-edge robotics, sensors, edge computing, IoT and more are at the forefront of smarter manufacturing, bringing together the technology, infrastructure and innovation that power modern automation. In an automation environment, robots improve repetitive tasks, precision, consistency and uptime across processes. They remove inconsistent movements and improve safety in hazardous environments. Robots and cobots also elevate the workforce, allowing skilled labour to shift into roles that enable manufacturers to scale and adjust outputs. Whether in maintenance and repairing, or programming and configuring machines, automation also plays an important role in tackling labour shortages. As demand grows faster than the workforce, automation enables manufacturers to scale without depending on labour availability. That does not mean manufacturers rely completely on robots without skilled labour, because robotic systems still need maintenance. Nothing is completely autonomous. Manufacturers still need people working alongside machines, but in a re-envisioned way that supports consistent output and a reduced training overhead. Robotic cells – enclosed workstations that combine robots and other tools – allow manufacturers to build safer and more efficient systems. One of the most important advantages they offer, whether in assembly, welding, inspection or material handling, is precision around repetitive tasks. These cells also improve manufacturing consistency. For example, if a process error occurs and a batch is incorrect, reviewing the data and tracing it back to a specific lot, robot or time of day, can pinpoint what changed in the environment. Tracing back errors, identifying what changed in the data and preventing it from happening in the future, allows for added efficiencies and visibility. Advanced Sensing The latest advances in sensor technologies, data acquisition systems and communication protocols are also shaping the future of smart automation. As the pace of innovation accelerates, understanding these emerging technologies is crucial for manufacturers to stay ahead. Advanced sensing options, whether they are optical, infrared, inductive, LiDAR or ultrasonic, are game-changers in allowing manufacturers to better understand the factory floor environment in real time. Manufacturers are mixing solutions that measure and monitor performance, accuracy and range to capture everything happening instantaneously. Leading suppliers are developing smart sensors and vision systems that are flexible and traceable, especially in high-speed and collaborative environments. Safety sensing technologies – such as light curtains, emergency stops, and safe motion controls – help production personnel to interact with the equipment and the surrounding environment. For example, the ability to establish warning zones to alert workers approaching a hazardous area before they get too close can be a significant benefit. It prevents workers from accidentally entering the hazardous area, tripping a safety device and turning off a machine. Key Trends As we look to the future of smarter industrial automation, we are keeping our eyes on some exciting trends. The future of industrial automation is not just smart, but is agile and safe. Connor Doherty, director of industrial automation at the distributor DigiKey, examines some of the latest trends driving the sector. Robots allow manufacturers to build safer and more efficient systems, and provide precision for repetitive tasks
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