34 n CONTROLS AND SOFTWARE November/December 2025 www.drivesncontrols.com I/O systems get smart for the digital age Industrial businesses are using digital transformation to unlock new levels of efficiency. The main focus is often on bigticket items such as AI, next-generation automation, or advanced machines. However, these all rely on devices at the edge of the network, where the data originates. Intelligent edge devices positioned close to sensors, actuators and assets, can enable real-time decision-making and empower operators to solve issues before they lead to costly downtime. Until recently, data was never connected to the cloud so, for example, I/O systems were not designed with built-cybersecurity functions. However, today’s networks are widely connected and handle much higher levels of network traffic, while integrating complex analytics and many types of devices. This has driven the development of a new generation of I/Os that improve resilience, reduce latency and enable real-time responsiveness. Intelligent I/O is not just a data pathway; it is also an enabler of performance and control. Modern I/O systems are capable of filtering, formatting, securing and, in some cases, preprocessing data. This forms a foundation for intelligent edge devices to offer the most value by ensuring that only valuable and actionable insights are sent upstream. The latest generation of I/O has been developed to reduce downtime, while improving flexibility and ease-of-use for system integrators, helping to keep project costs under control. Cybersecurity No discussion of data in industrial settings is complete without considering cybersecurity. This is especially true for intelligent edge devices, where every deployment is a potential entry into the network. Resilience of the whole system is non-negotiable. Businesses can protect and future-proof their data network by using modern I/O systems that comply with the IEC 62443-4-2 cybersecurity standard. This covers aspects such as: secure boot and firmware integrity checks; event-logging and intrusion detection; and role-based access to ensure that any data transfer is securely accessed to protect operations, including data originating from intelligent edge devices. The latest I/O technologies are no longer passive components, but are essential enablers of digital transformation and cybersecurity. In the digitalisation era, as new edge devices are added, they will not be isolated in silos; instead all data will contribute to the overall digital transformation effort to improve operations. Today’s I/O technologies need to integrate multiple slices per island – such as digital and analogue inputs and outputs, motion control, and fieldbus connections. This provides flexibility and futureproofing. An important aspect of the latest technologies is physical robustness, resulting in high availability and reducing unplanned downtime. Unrestricted hot-swap capabilities also help to cut downtime. They allow operators to switch modules without losing valuable production time while powering down the system. This was not possible in the past, when previous generations of I/O were limited in terms of the number and proximity of modules that could be removed at one time. Systems integrators are benefiting from compact, modular and scalable platforms that are easy to use. These features save time in design, procurement and installation. They also offer flexibility and scalability for integration in standalone machines or largescale distributed systems. Modern I/O platforms use interchangeable slices, which allow a scalable building block approach. New functions or process changes can be accommodated with minimal interruption, so I/O platforms do not need a complete overhauls as edge devices are added or more data is produced. This flexibility is particularly valuable in sectors where customer needs shift quickly, such as food and beverage, CPG or batch manufacturing. Intelligent I/O platforms are allowing plant operators to cut the engineering effort for new production lines, machines or compliance changes. Together, these features make I/O a strategic enabler of digital transformation, rather than merely a supporting component. As businesses invest in intelligent edge devices, they also need to optimise the infrastructure that supports them. The latest I/O platforms – such as Schneider Electric’s Modicon Edge I/O NTS – are a crucial element ensuring that data can be effectively harnessed, secured, and acted upon. n The convergence of OT (operational technology) and IT is now a reality, but for industry to benefit fully, edge devices, including the I/O modules that handle streams of data, need to operate autonomously and to offer cybersecurity. Ursula Barr, offer manager for PAC and software at Schneider Electric, explains. I/O is now a strategic enabler of digital transformation, rather than merely being a supporting component.
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