“AI is a game changer, but not a panacea.“

1. What role does AI play in your sensor and automation solutions?

Artificial intelligence is one of the key technologies of our time and will also fundamentally change industrial automation in the future. For TURCK, AI is not just a tool for increasing efficiency, but a real game changer that opens up completely new possibilities in almost all areas – from product development and system integration to process optimization. AI not only plays an important role in our products and solutions, but also changes the underlying business processes and the working world as a whole.

Despite all this, AI is not a panacea. In many automation applications, it is more economical and faster to process data directly in the field. We use AI where it creates real added value. Our philosophy has always been: smart data instead of big data. Instead of sending all data to the cloud, we rely on intelligent preprocessing at the field level—for example, with our TBEN PLC or logic-capable I/O modules such as ARGEE. We use AI specifically where the complexity of data processing would overwhelm rule-based control systems—for example, in image processing or in the analysis of large amounts of data in the cloud.

2. How does AI support condition monitoring and predictive maintenance?

AI can help identify patterns in sensor data that indicate impending failures – for example, through anomaly detection in time series or through classification of operating states. In our IIoT platform TAS Cloud, we offer AI-supported services for analyzing such data. At the same time, we rely on sensors that already detect and evaluate conditions locally – i.e., without AI. Our vibration sensors are a good example: they analyze data directly on site and report anomalies without the data first having to be transferred to a central control system or the cloud. This saves time and money and increases robustness. AI comes into play when the data situation becomes complex – for example, when classifying error patterns or predicting maintenance intervals. This results in a hybrid approach combining rule-based intelligence and data-driven AI.

3. Are there any practical examples?

A current highlight is our new AI camera TIV (TURCK Intelligent Vision), which we are presenting at the SPS in Nuremberg. The camera is a powerful, AI-based all-in-one vision solution for demanding industrial applications. Its self-learning functions—including difference checking, classification, object recognition, and barcode reading—do not require a separate processing unit. This enables the camera to be quickly and easily commissioned directly at the point of use, and complex visual inspection tasks can be solved without having to transfer large amounts of data to the cloud.

With protection class IP67, the camera is also ideally suited for use in harsh industrial conditions. The AI Cam stands for robust, intelligent, and scalable image processing directly at the edge – making it a central component of our industrial AI strategy.

Another example is our condition monitoring sensors, which evaluate data locally and react based on threshold values or logical links – without AI, but highly efficiently. This rule-based intelligence is often more cost-effective and faster than AI – and completely sufficient for many applications. The combination of decentralized intelligence and AI-supported analysis shows how we at TURCK are making the use of AI pragmatic and application-oriented.

4. How can AI be integrated into IO-Link environments?

IO-Link is an outstanding technology and the ideal basis for smart sensor technology and structured data communication. In combination with edge computing, AI can be integrated very efficiently: The sensors deliver structured data that is pre-processed on edge devices and transferred to the cloud as needed. AI can then be based on aggregated data – for example, for pattern recognition or to optimize maintenance strategies. It is important to note that the AI does not necessarily have to be located in the sensor itself, but can be connected via the IO-Link infrastructure and used intelligently. This creates a flexible system that uses AI where it is really needed.

5. Which data sources are relevant?

Relevant data sources include all sensors that measure physical variables such as temperature, vibration, pressure, current, image data, and much more. It is not only the quantity that is decisive, but also the quality and contextual information. That is why we rely on sensor technology that not only measures but also interprets – and on systems that process data where it is generated. This allows us to avoid unnecessary data overload and create the basis for targeted AI applications.

6. What are the advantages of edge AI?

Edge AI offers several advantages: it reduces data volume, saves bandwidth, and enables fast responses. Instead of sending all data to the cloud, we analyze it directly at the point of origin – for example, with our TIV camera or edge controllers. This is particularly important for time-critical applications where every millisecond counts. Edge AI also increases data security, as sensitive information does not have to be transmitted over external networks. In addition, Edge AI contributes to sustainability: less data traffic means less energy consumption.

7. How do you ensure data security?

Data security is a central element of every TURCK solution – especially in the context of industrial AI. Our cloud solutions meet the highest security standards. We rely on encrypted communication, role-based access controls, and local data processing wherever possible. In addition, we pay attention to the traceability and integrity of the data – every data point must be traceable to its origin and context. This is particularly important for AI applications, as they must be based on reliable and traceable data. We offer our customers full transparency regarding data flows and the option to implement their own security guidelines – both in the cloud and at the edge. At TURCK, security is not an add-on, but an integral part of every solution.

An important milestone in this context is our certification according to IEC 62443-4-1 ("Security for industrial automation and control systems") – an internationally recognized standard for secure development processes in industrial automation. This certification confirms that our products are developed according to a structured and verifiable security process – from risk analysis and architecture to testing and maintenance. This certification is also of great importance in view of the EU's upcoming "Cyber Resilience Act." With IEC 62443-4-1 certification, we are well prepared to continue offering our customers secure and compliant solutions in the future – not only technologically, but also in terms of regulatory compliance.

8. How do you help customers with integration?

We accompany our customers from the initial idea to commissioning. Our solutions are modular in design – from sensor technology to edge devices to the cloud. With tools such as ARGEE, we enable simple logic programming directly in the field without the need for programming knowledge. Our TBEN-PLC with Codesys offers full control functionality in a compact design. In the future, the control software will also offer AI-supported engineering aids – for example, through chatbots or automated code suggestions that take over monotonous tasks and improve the quality of the code. This means that our customers benefit not only technically but also methodologically from AI integration.

9. Which industries benefit most?

Industries with a high degree of automation and complex processes benefit particularly – such as the automotive industry, logistics, mechanical engineering, food production, and the process industry. In these areas, AI can help to ensure quality, avoid downtime, optimize processes, and increase production output. But small and medium-sized companies can also benefit from our scalable solutions – for example, through simple entry-level solutions for condition monitoring or modular cloud offerings. We want to offer our customers solutions that are not only technologically advanced, but also economically viable and easy to integrate.

10. Where is TURCK heading with industrial AI?

We are continuing to develop AI where it brings real benefits – for example, in image processing, in the cloud, or in intelligent data analysis. AI will not only improve individual applications, but will revolutionize the entire end-to-end process from OT to IT – with implications for development, production, maintenance, and business models. For us, the future lies in the combination of intelligent sensor technology, edge computing, and targeted use of AI. That is why we focus on robust, traceable, and scalable AI solutions – always with the aim of offering our customers real added value.