All About Circuits

Ep. 94 | Sensing at the Control Level: Leveraging Data for Both Safety and Analytics

The episode wraps a three‑part Control Automation Day series, focusing on how modern sensors are evolving from simple on/off devices into smart, networked components that serve both safety and analytics functions. Host David Peterson and Rockwell Automation’s Kate Sokniki discuss recent breakthroughs such as Olink integration, NFC configuration, and affordable vision systems. Sokniki explains that Rockwell has been embedding the open‑source Olink serial protocol in virtually all its sensors, allowing real‑time process data and device health information to travel over the same field bus without an upcharge. She also highlights the rise of NFC and other wireless links that let technicians program sensors from a nearby smartphone, and the commoditization of low‑cost cameras that can feed AI‑driven inspection to edge or cloud platforms. A key theme is the dual‑purpose nature of these devices: they provide immediate control‑loop feedback—such as diverting a product on a conveyor—while simultaneously reporting diagnostics like remaining useful life. Sokniki notes that without proper metadata, AI models can produce meaningless results, so Rockwell standardizes data models across devices to simplify analytics for both data‑science teams and plant operators. For manufacturers, the convergence of safety, connectivity, and analytics means reduced downtime, lower capital expense for vision systems, and a clearer path to leveraging AI without extensive custom integration. The move toward standardized, cost‑free smart sensors accelerates digital transformation across the factory floor.