Introduction: The Rise of Smart Manufacturing
The 2025 SPS exhibition in Nuremberg showcased the latest breakthroughs in industrial automation, factory automation, and control systems.
Attendance increased by 9%, reflecting strong interest in digitalized production, IoT-enabled operations, and AI-driven manufacturing.
Experts from IoT Analytics observed key trends across eight major suppliers, highlighting innovation in PLC, DCS, industrial AI, and software-defined automation.
This article summarizes the main takeaways and shares practical insights for industrial decision-makers.
1. Siemens: Driving Digital Transformation and AI Integration
One Unified Strategy
Siemens presented its “One Tech Company” approach to integrate industrial edge computing, cloud services, and shared data policies.
This unified framework enhances scalability for customers and aligns IT and OT systems seamlessly.
Industrial AI Co-Pilots
The Engineering Copilot TIA automates engineering tasks including PLC code programming, HMI design, and hardware configuration.
The Production Insights Hub enables operators to interact with real-time production data using natural language.
Companies like TotalEnergies have scaled AI templates across multiple sites, accelerating operational decisions.
Software-Defined Automation
Siemens emphasized Simatic AX as a platform for IT-driven automation.
New vPLC versions expand flexibility, supporting smaller or cost-sensitive installations without sacrificing performance.
Advanced Hardware and Drives
The Sinamics S220 servo drive reduces size while increasing power density, controlling up to 12 axes per unit.
Simatic S7-1200 G2 offers improved kinematics and OPC UA support, meeting rising automation performance needs.
Zero-Trust Security for OT Networks
SINEC Secure Connect applies zero-trust principles to OT networks, ensuring compliance with regulations like NIS 2.
Products are “hardened ex works” to mitigate cybersecurity risks in industrial control environments.
Sustainability and Circular Economy
Siemens EcoTech labels provide measurable sustainability criteria for products.
Circular Repair Services restore equipment to near-new condition, extending product lifetime and supporting circular manufacturing.
2. Beckhoff Automation: Physical AI and Modular Control Systems
Market Recovery and Growth
After a challenging 2024, Beckhoff projects 7% revenue growth in 2025.
This growth is fueled by demand for modular, flexible automation solutions and AI-enabled control systems.
AI Embedded in the Control Layer
The TwinCAT CoAgent acts as an AI assistant for operators, automating troubleshooting, PLC code generation, and HMI creation.
The TwinCAT 3 Machine Learning Creator supports predictive analytics for signals and time-series data.
Physical AI and Robotics
Beckhoff demonstrated robots that autonomously plan and execute tasks using large language models.
“Physical AI” allows AI agents to interact directly with machinery, increasing efficiency and precision.
EtherCAT Platform and Standards
EtherCAT remains a robust, globally recognized standard for real-time industrial communication.
Beckhoff continues to develop chips and IPCs to support high-performance applications and regulatory compliance.
Next-Generation Control Cabinets
The MX-System integrates drives, I/O, and IPCs on a modular baseplate.
Its flexible, “Lego-like” design simplifies assembly and reduces engineering time for large automation projects.
3. Rockwell Automation: Smart Manufacturing and AI-Enabled Operations
Control Platforms for Scalable Systems
The ControlLogix 5590 PLC improves processing, memory, and functional safety while integrating cybersecurity features.
Unified control systems reduce complexity and support factory automation modernization.
Modular I/O for Dynamic Production
PointMax I/O supports scalable and reconfigurable deployments, allowing plants to adapt to changing operational demands.
Industrial AI Co-Pilots
FactoryTalk Analytics LogixAI predicts quality issues and enhances process reliability.
The AI co-pilot in Design Studio explains ladder logic and aids engineers in documentation tasks.
Digital Twins for Simulation and Validation
Emulate3D software allows virtual testing of machines and control systems before physical commissioning.
This approach shortens design cycles and mitigates operational risks.
4. ABB: Energy Efficiency, Electrification, and AI Innovation
Optimizing Energy Management
ABB showcased solutions like ASKI, InSite, and LV Titanium Variable Speed Motors for efficient energy usage.
These tools help industrial plants reduce costs and comply with energy regulations.
Sustainable Operations
ABB introduced DC network solutions and Solid State Circuit Breakers with high energy efficiency.
Applications in green hydrogen and renewable energy illustrate ABB’s commitment to decarbonization.
AI-Driven Process Optimization
AI tools analyze drive and motor data, automating operations to maximize efficiency.
Cloudworx 3D visualization simplifies commissioning and troubleshooting of industrial equipment.
Advanced Control and Safety
SACE Emax3 breakers and ACS380-E drives combine intelligent protection, cybersecurity, and predictive maintenance capabilities.
5. Schneider Electric: Open Automation and Agentic AI
Software-Defined Automation Ecosystem
EcoStruxure Automation Expert integrates PLC and DCS workflows with open standards.
Aveva Connect and Advanced Analytics enable cloud-based engineering data management.
Agentic AI for Autonomous Engineering
Agentic AI automates control logic creation, digital twin generation, and unit testing.
Engineers retain control by reviewing AI outputs, improving productivity by 50–70%.
6. Advantech: Edge AI and Open Control Platforms
AMAX Platforms for Modern Automation
AMAX IoT Control Platforms provide unified soft PLC, real-time OS, and virtualized controller support.
This architecture overcomes legacy PLC limitations for high-intensity motion and vision tasks.
Edge AI for Real-Time Applications
Containerized AI models can run locally at the edge, reducing cloud dependency and latency.
Industrial AMRs leverage multi-sensor fusion and self-learning during operation.
Open Ecosystem and Federated Learning
Advantech collaborates with NVIDIA, Intel, AWS, and multiple automation partners to enable secure, scalable deployments.
Federated learning protects sensitive data while improving AI performance across multiple machines.
7. Belden: Industrial Connectivity and Edge Intelligence
Reliable Network Infrastructure
Belden introduced deterministic Wi-Fi 7 access points and Single Pair Ethernet solutions for industrial networks.
These technologies support control systems, factory automation, and OT security requirements.
Unified Network Management
The Belden Horizon platform offers cloud-based monitoring and secure remote access.
Edge devices collect real-time sensor data for analytics without interrupting control processes.
AI-Assisted Network Operations
Belden’s “digital coworker” AI prototype supports operators by analyzing network performance and suggesting optimizations.
8. Phoenix Contact: Modular Automation and Open Control
PLCnext Technology for Open Automation
PLCnext provides scalable, hardware-independent control, supporting virtualization and real-time operations.
Three new versions (1000, 2000, 3000) extend flexibility and system redundancy.
No-Code Industrial AI
MLnext allows predictive maintenance and equipment monitoring without requiring data science expertise.
Operators can deploy AI solutions faster while maintaining safety and compliance.
Sustainability and Energy Management
Phoenix Contact supports DC grids and Power-to-X applications, enhancing energy efficiency by up to 8%.
Modular components, including Push-X connectors and Wi-Fi 6E access points, simplify integration and maintenance.
Application Scenarios
1. Modernizing Legacy PLC Systems
Combine Siemens S7-1200 G2, Rockwell Emulate3D, and Beckhoff TwinCAT CoAgent.
The result is faster troubleshooting, automated code generation, and reduced downtime.
2. Flexible Robotic Cell Deployment
Use Beckhoff physical AI, Advantech edge AI, and Phoenix Contact PLCnext.
Robots plan, sense, and act autonomously, reducing manual programming.
3. Energy-Efficient Smart Plant
ABB energy meters, Siemens digital twins, and Schneider EcoStruxure enable optimized energy use and predictive maintenance.