“AI is a game changer, but not a cure-all.“

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 specific real-world examples of AI being used in industrial applications at TURCK?

A current highlight is our new AI camera, TIV (TURCK Intelligent Vision), which we are showcasing at SPS in Nuremberg. The camera is a high-performance, 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 allows for quick and easy commissioning 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 an IP67 protection rating, the camera is ideally suited for use in harsh industrial environments. The AI Cam delivers robust, intelligent, and scalable image processing directly at the edge—making it a key component of our industrial AI strategy.

Another example is our condition-monitoring sensors, which evaluate data locally and respond based on thresholds or logical operators—without any AI, yet highly efficiently. This rule-based intelligence is often more cost-effective and faster than AI—and entirely sufficient for many applications. The combination of decentralized intelligence and AI-supported analysis demonstrates how we at TURCK approach the use of AI in a pragmatic and application-oriented way.

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

IO-Link is an outstanding technology and the ideal foundation for smart sensor systems and structured data communication. When combined with edge computing, AI can be integrated very efficiently: The sensors deliver structured data, which is preprocessed on edge devices and transmitted to the cloud as needed. AI can then be applied to aggregated data—for example, for pattern recognition or to optimize maintenance strategies. Importantly, the AI does not necessarily have to be located within the sensor itself; instead, it can be connected via the IO-Link infrastructure and utilized intelligently. This creates a flexible system that deploys AI exactly where it is truly needed.

5. Which data sources are particularly relevant for AI applications in industrial sensor technology and automation?

Relevant data sources include all sensors that measure physical quantities—temperature, vibration, pressure, current, image data, and much more. What matters is not just the quantity, but also the quality and contextual information. That’s why we rely on sensor technology that not only measures but also interprets—and on systems that process data right where it’s generated. This allows us to avoid an unnecessary flood of data and lay the foundation for targeted AI applications.

6. What are the benefits of Edge AI?

Edge AI offers several advantages: It reduces data volume, saves bandwidth, and enables rapid responses. Instead of sending all data to the cloud, we analyze it right where it’s generated—for example, using our TIV camera or edge controllers. This is particularly important for time-critical applications where every millisecond counts. Edge AI also enhances data security, since sensitive information does not have to be transmitted over external networks. Furthermore, Edge AI contributes to sustainability: less data traffic means lower energy consumption.

7. How do you ensure data security?

For TURCK, data security is a central element of every 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 ensure the traceability and integrity of 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 ability to implement their own security policies—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 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 through to testing and maintenance. This certification is also of great significance in light 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 from a technological standpoint, but also from a regulatory one.

8. How do you help customers integrate AI into their automation and production environments?

We support our customers from the initial idea through to commissioning. Our solutions are modular in design—ranging from sensors to edge devices to the cloud. With tools like ARGEE, we enable simple logic programming directly in the field, without requiring any 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—such as chatbots or automated code suggestions—that take over repetitive tasks and improve code quality. This way, our customers benefit from AI integration not only technically but also methodologically.

9. Which industries benefit most from the use of AI in industrial automation?

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

10. Where is TURCK headed with Industrial AI?

We continue to develop AI in areas where it delivers real value—such as image processing, the cloud, and intelligent data analysis. AI will not only improve individual applications but also 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 AI deployment. That’s why we focus on robust, transparent, and scalable AI solutions—always with the goal of providing our customers with real added value.