June 3, 2026-AutomationDirect now offers RBS ball screws and nuts to support precise linear motion in both OEM and maintenance replacement applications. 

Designed to convert rotational motion into linear movement, these US-manufactured ball screws are engineered for high positioning accuracy, low friction, and long service life. Utilizing recirculating ball bearings that roll rather than slide, they achieve efficiencies exceeding 90% while minimizing heat generation and wear. With available diameters from 3/8” up to 1”, lengths from 24” to 72”, and multiple lead options, they support applications such as CNC machinery, robotics, packaging equipment, and material handling systems where controlled linear motion is critical.

RBS ball nuts are precision‑matched to their corresponding screws to ensure consistent load distribution and reliable performance. Designed to handle axial loads with minimal backlash, they help maintain accuracy over extended operating cycles and are well‑suited for both high‑speed and high‑load applications. Select models feature safety springs and/or compatibility with wiper kit accessories for tackling tough operating environments. Together, RBS ball screws and nuts provide a dependable solution for applications requiring precise motion control, reduced maintenance, and extended operational life.

About AutomationDirect:

In business since 1994, AutomationDirect is a distributor offering thousands of industrial automation products for electrical control systems, including PLCs, operator interfaces, AC drives, motors, stepper systems, sensors, motor controls, enclosures and more. Their prices are typically well below the list price of more traditional automation companies because of their business model and focus on efficiency, and the majority of their products are stocked for fast shipping. Plus, get free two-day delivery on orders over $49; some limitations apply. For more information and the most current pricing on products contact them at 800-633-0405 or visit https://www.automationdirect.com/

Editorial Contact: Tina Gable
Phone: 678-455-1845
Email: tgable@automationdirect.com
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June 3, 2026 – AutomationDirect has added METEcon multi-wire connectors that simplify complex industrial wiring while improving long-term reliability. Our expanded offering includes more inserts, housing components (including new 32B size), and configuration options without increasing complexity.

With pole configurations from 2 poles plus ground up to 108 poles plus ground, screw or crimp terminations, and support for 26–6 AWG conductors rated 10–80 A, METE connectors adapt easily to control panels, OEM machinery, factory automation, motors and drives, and modular systems. Rugged aluminum or thermoplastic housings, gas-tight crimp contacts, and UL/CE approvals ensure dependable performance in demanding environments, all while reducing wiring time, installation errors, and total system cost.

About AutomationDirect:

In business since 1994, AutomationDirect is a distributor offering thousands of industrial automation products for electrical control systems, including PLCs, operator interfaces, AC drives, motors, stepper systems, sensors, motor controls, enclosures and more. Their prices are typically well below the list price of more traditional automation companies because of their business model and focus on efficiency, and the majority of their products are stocked for fast shipping. Plus, get free two-day delivery on orders over $49; some limitations apply. For more information and the most current pricing on products contact them at 800-633-0405 or visit https://www.automationdirect.com/

Editorial Contact: Tina Gable
Phone: 678-455-1845
Email: tgable@automationdirect.com
Download: High Resolution Image Download
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June 3, 2026 – AutomationDirect now offers Continental hydraulic valves which provide rugged, high‑performance control for industrial hydraulic systems built around NFPA standards. Available in D03 and D05 sizes, these valves support a wide range of circuit requirements while maintaining consistent operation under high pressure and demanding duty cycles.

NFPA D03 solenoid valves deliver reliable, compact directional control for machine tools, automation equipment, and general industrial hydraulics. Available in 4‑way, 2‑ or 3‑position configurations with open, closed, tandem, or float center options, they support both fixed‑displacement and pressure‑compensated pump systems. Cast‑iron construction, manual overrides, and DIN or conduit wiring options make these valves easy to install and service, with operating pressures up to 5,000 psi.

For operator‑controlled applications, NFPA D03 manual valves provide straightforward, dependable directional control without electrical actuation. These compact 4‑way, 3‑position valves are offered with closed or float center configurations and rugged cast‑iron bodies, making them well-suited for industrial environments where simplicity and durability are key.

NFPA D05 solenoid valves expand system capability with higher flow capacity while maintaining standard NFPA mounting. Offered in 4‑way, 2‑ or 3‑position designs with multiple center conditions, these valves feature robust cast‑iron construction, manual overrides, and DIN wiring. Rated up to 4,600 psi, they are ideal for presses, material handling systems, and other demanding hydraulic applications.

About AutomationDirect:

In business since 1994, AutomationDirect is a distributor offering thousands of industrial automation products for electrical control systems, including PLCs, operator interfaces, AC drives, motors, stepper systems, sensors, motor controls, enclosures and more. Their prices are typically well below the list price of more traditional automation companies because of their business model and focus on efficiency, and the majority of their products are stocked for fast shipping. Plus, get free two-day delivery on orders over $49; some limitations apply. For more information and the most current pricing on products contact them at 800-633-0405 or visit https://www.automationdirect.com/

Editorial Contact: Tina Gable
Phone: 678-455-1845
Email: tgable@automationdirect.com
Download: High Resolution Image Download
Download: Web Friendly Image Download

At first, those quick check-ins were seen as an annoyance. People were focused on production targets, deadlines, and getting equipment up and running as fast as possible, and they didn’t want to be bothered. But over time, Bryce’s approach began to shift perspectives. Small oversights—loose guards, worn cables, missing signage—were caught early. Minor fixes prevented bigger problems, and the team began to expect, not resist, those moments of pause.

What seemed like a brief delay became something much more valuable: a shared mindset. Safety wasn’t an afterthought or a box to check—it became part of how work got done. The few minutes spent identifying risks saved hours of downtime, avoided potential injuries, and reinforced accountability across the team.

Safety Month 2026 is the perfect reminder that proactive awareness isn’t a slow-down—it’s a smart investment. Taking the time to assess risks, use the right equipment, and follow proven processes helps ensure that everyone goes home the same way they arrived.

For purchasing safety components, AutomationDirect is your 100% match. AutomationDirect has been selling PLCs and other industrial automation products, including machine safety components, since 1994. We offer FREE shipping and FREE technical support for all products we sell, and offer a 45-day return policy on most products. You can TRUST AutomationDirect to be a reliable supplier for your machine safety products.

Looking for even more safety-related content? Click on the Products menu to see more articles on safety devices!

Automated Robotic Welding Cuts Production Time by Over 90%

A manufacturing company teamed up with a systems integration firm to significantly accelerate an infrastructure project by integrating a robotic welder with precision motion control, intelligent safety systems, and other advanced automation components. Read More –>

Small Theatre’s Rotating Stage Gets VFD Controls Upgrade

After running for decades on its original electro-hydraulic drive, Timber Lake Playhouse’s revolving stage system received significant behind-the-scenes AutomationDirect upgrades in 2007 and 2025. Read More –>

Choosing the Right MOSAIC Safety Controller: M1, M1S, or MZERO from AutomationDirect

Are you looking for a programmable safety controller but not sure which one to choose? When it comes to protecting people and equipment, choosing the right safety controller matters. Today, we’re looking at ReeR MOSAIC safety controllers from AutomationDirect! Watch Now –>

Six Tips to Help You Build a Better, Safer Machine

Safety is an essential aspect of machine design and operation, protecting personnel, guarding against equipment damage, and maximizing productivity.  Read More –>

Beyond Safety Slogans: Cultivating a Workforce Culture to Protect People and Productivity

At AutomationDirect, we’ve seen firsthand how the safety landscape in manufacturing and logistics continues to advance rapidly, creating both new challenges and unprecedented opportunities for protecting our workforce—and supporting our customers in safeguarding theirs. Read More –>

Modern PLCs Support Dependable SCADA Communications
Water and wastewater treatment systems of all sizes are essential and roughly 90% of U.S. systems are considered small (serving 10,000 or fewer people). Though large and small plants often use similar technologies, they operate at very different scales and budgets for automation and staffing. Recognizing this disparity, the team at CoStream set out to build a SCADA system tailored specifically to rural municipal water operations.
Learn more

Motion Control eBook
The Practical Guide to Motion Control offers detailed guidance on building reliable, accurate motion systems for industrial machines. It covers motion control fundamentals, system selection, sizing, tuning, common applications, and key concepts like stepper vs. servo, torque-speed curves, inertia matching, homing, limits, profiling, gearing, camming, interpolation, registration, and synchronization.
Learn more

Now Available

di-soric IO-Link Compatible Ultrasonic Sensors
Starting at $210.00

AchieVe Pressure Switches
Starting at $33.00

Additional CHANNELLOCK Pliers, Cutting Tools, and More
Pliers start at $15.50

More Datalogic Smart-VS Vision Sensors  
Starting at $1,192.00

BLOCK Power Advanced Series Power Supplies with Battery Control / UPS and More
UPS power supplies start at $255.00

AchieVe PSA series NEC Class 2 Power Supplies
Starting at $18.00

RHINO PSR Series Spring Clamp Power Supplies
Starting at $70.00

Laumas Single-Point Load Cells
Starting at $122.00

Penn-Union Split Bolts, Power Bars, Service Post Connectors, and More
Mechanical connectors start at $2.25

What’s Causing Your VFD’s DC Bus Overvoltage Fault
Variable Frequency Drives (VFDs) are a crucial component in industrial automation, providing precise control over a motor’s speed and torque. Numerous built-in protections and fault indications are provided with modern VFDs including the commonly seen DC Bus Overvoltage Fault. This fault has several possible causes and this whitepaper explores each one, offering solutions to ensure proper VFD operation.
Learn More

Small Theatre’s Rotating Stage Gets VFD Controls Upgrade
After running for decades on its original electro-hydraulic drive, Timber Lake Playhouse’s revolving stage system received significant behind-the-scenes AutomationDirect upgrades in 2007 and 2025. While the basic idea of a revolving stage seems fundamental, there has been significant progress in power transmission technology since TLP’s founding over 60 years ago.
Read more

No Screen, No Problem
Traditional factory floors rely on panel-mounted touchscreen HMIs, but modern facilities need more flexible visualization through mobile tablets, large displays, and remote monitoring options. AutomationDirect’s C-more CM5-RHMI headless HMI is the Gold Medal winner in Design World’s 2025 LEAP Award and provides the most adaptable way to deliver visualization anywhere.
Learn more

Monthly Product Giveaway
This month you have a chance to win a Wera Kraftform 2go 100 (11 piece) VDE-insulated screwdriver set. Enter your info for a chance to win. Contest is open for approximately 3 weeks after the newsletter is sent and is open to residents of the U.S. and Canada only. Winner will be contacted via email.
Enter for a chance to WIN!

May 27, 2026 – AutomationDirect now offers more Gladiator GR series DIN rail mounted duplex receptacles that are convenience outlets easily installed within electrical enclosures to provide temporary power for laptop computers, test equipment, and USB powered devices. The new GR-REC2 model consists of two NEMA 5-15 straight blade receptacles, the GR-REC2-GFCI adds GFCI protection, and the GR-REC2-USB-xx receptacles include USB ports in various configurations—one USB A and one USB C port (GR-REC2-USB-AC), two USB C ports (GR-REC2-USB-2C), and two USB A ports (GR-REC2-USB-2A). The GR-USB-4A receptacle consists of four USB A ports only, designed specifically for USB A powered devices. All models are 125 VAC/15A rated, UL recognized, CE marked, and offer a 2-year warranty. 

About AutomationDirect:

In business since 1994, AutomationDirect is a distributor offering thousands of industrial automation products for electrical control systems, including PLCs, operator interfaces, AC drives, motors, stepper systems, sensors, motor controls, enclosures and more. Their prices are typically well below the list price of more traditional automation companies because of their business model and focus on efficiency, and the majority of their products are stocked for fast shipping. Plus, get free two-day delivery on orders over $49; some limitations apply. For more information and the most current pricing on products contact them at 800-633-0405 or visit https://www.automationdirect.com/

Editorial Contact: Tina Gable
Phone: 678-455-1845
Email: tgable@automationdirect.com
Download: High Resolution Image Download
Download: Web Friendly Image Download

Today’s manufacturers are pursuing data analytics, AI-driven optimization, remote support, and enterprise-wide visibility, which means that their operational technology (OT) networks can no longer remain isolated from information technology (IT) systems. In an Industrial Ethernet June 2026 article titled Connecting Operations with IT using Industrial Ethernet Switches, Automation Direct’s Damon Purvis describes a new class of “unmanaged+” industrial edge switches that are helping end users obtain the performance and security they need, with simple plug-and-play options.

A connectivity balancing act

OT teams prioritize determinism, uptime, and simplicity, while IT teams expect segmented, policy-driven networks built on managed switching. Many end user organizations lack the staffing and budgets to deploy and maintain fully managed networking infrastructure end-to-end, yet unmanaged switches alone often provide insufficient security, traffic control, and diagnostic access at the OT/IT boundary between the factory floor and the enterprise.

Industrial edge switches are positioned to close the gap between unmanaged OT hardware and fully managed IT switches. Some devices known as “lightly managed” or “lean” switches still require a degree of software configuration. However, another newer category, called “unmanaged+” switches, delivers friendly OT operation, while adopting the best IT practices for improved segmentation, performance, and visibility. All configuration is performed using simple DIP switches.

Tough and smart

AutomationDirect’s Stride PRO Unmanaged+ Ethernet Switch is purpose-built to help users integrate OT with IT. These switches provide industrial packaging and familiar power requirements: DIN-rail/panel mounting, IP30 metal housings, wide temperature ratings, 24 VDC operation, and enhanced immunity to electrical noise and surges. Some models include redundant power inputs, plus surge, spike, and reverse-polarity protection.

Functionally, unmanaged+ edge switches are purpose-tuned for common industrial Ethernet protocols (EtherNet/IP, PROFINET, Modbus TCP, etc.) and typical traffic patterns, such as high-volume multicasts from remote I/O. Core capabilities include support for Fast/Gigabit Ethernet and mixed media (copper RJ45 and fiber via SFP) to extend distance and reduce susceptibility to EMI. Power over Ethernet (PoE/PoE+/PoE++) simplifies installation of compatible devices by combining power and data on one cable, lowering wiring labor and enabling easier moves/adds/changes.

Performance considerations, such as quality of service (QoS), prioritize sensitive data, while broadcast storm protection prevents runaway traffic from degrading automation response. IGMP snooping is included, and it is especially valuable on control networks because it constrains multicast to only the ports with subscribing devices, reducing unnecessary load on PLCs, drives, and HMIs to improve overall bandwidth utilization.
To align with IT security models without forcing fully managed switch complexity, port-based VLANs provide an easier way than hardwiring multiple physically separate networks to create isolated broadcast domains. For troubleshooting and monitoring, port mirroring provides non-intrusive packet visibility to a laptop or analyzer, and port disconnect alarms accelerate root-cause identification of broken cables, unplugged connectors, or failed devices—potentially integrating with existing OT signaling, such as stack lights or PLC/HMI alarms.

A simple step toward improved OT/IT integration

“Network utopia” can be reached in part by simplifying the OT/IT handoff: IT gains operational visibility, OT gains access to enterprise intelligence, and both benefit from the security and performance that are engineered into the edge, rather than bolted on afterward. Find out more about AutomationDirect networking and communications products.

May 20, 2026-AutomationDirect now offers a wide selection of SIM couplings, along with a new offering of 8M timing pulleys, which has been added to support reliable power transmission in both OEM and MRO applications. Designed for precise motion control, these components help efficiently transmit torque and rotational power between shafts and belt‑driven systems across a wide range of industrial equipment.

SIM couplings are engineered to connect driving and driven shafts while maintaining accurate alignment and consistent torque transfer. Available in multiple bore sizes and configurations, they help reduce vibration, accommodate minor misalignment, and support smooth system operation in compact mechanical assemblies. Newly introduced Advanced Disc Couplings deliver high torsional stiffness and zero‑backlash performance for precision motion systems where accuracy and responsiveness are critical. High Torque Disc Couplings expand the offering further, providing robust torque capacity and reliable power transmission for demanding industrial drives operating under higher load conditions.

SIM timing pulleys transmit rotational power from shafts to timing belts with dependable accuracy and consistent tooth engagement. The newly added pulleys expand the lineup to include 8M sizing. With this addition, designers and maintenance teams can now source fully matched 8M belt‑and‑pulley combinations from a single supplier, supporting synchronized motion in automation, packaging, material handling, and other precision‑driven machinery.

About AutomationDirect:

In business since 1994, AutomationDirect is a distributor offering thousands of industrial automation products for electrical control systems, including PLCs, operator interfaces, AC drives, motors, stepper systems, sensors, motor controls, enclosures and more. Their prices are typically well below the list price of more traditional automation companies because of their business model and focus on efficiency, and the majority of their products are stocked for fast shipping. Plus, get free two-day delivery on orders over $49; some limitations apply. For more information and the most current pricing on products contact them at 800-633-0405 or visit https://www.automationdirect.com/

Editorial Contact: Tina Gable
Phone: 678-455-1845
Email: tgable@automationdirect.com
Download: High Resolution Image Download
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May 20, 2026-AutomationDirect has added Lapp OLFLEX® 190 flexible control cable which provides a new, rugged, versatile option for demanding industrial wiring applications. Designed for machinery, equipment, and control panels, OLFLEX 190 features finely stranded copper conductors with number‑coded insulation and an oil‑, coolant‑, and solvent‑resistant outer jacket for reliable performance in dry, damp, or wet locations. Approved for TC‑ER and PLTC‑ER use, compliant with NFPA 79 machinery wiring standards, and available in sizes from 20 AWG to 6 AWG with up to 41 conductors, OLFLEX cable integrates easily alongside existing tray‑rated control cables while offering excellent flexibility, broad agency approvals, and resistance to harsh industrial and washdown environments.

These flexible control cables can be ordered cut to length in 1-foot increments to avoid unnecessary waste and expense.

About AutomationDirect:

In business since 1994, AutomationDirect is a distributor offering thousands of industrial automation products for electrical control systems, including PLCs, operator interfaces, AC drives, motors, stepper systems, sensors, motor controls, enclosures and more. Their prices are typically well below the list price of more traditional automation companies because of their business model and focus on efficiency, and the majority of their products are stocked for fast shipping. Plus, get free two-day delivery on orders over $49; some limitations apply. For more information and the most current pricing on products contact them at 800-633-0405 or visit https://www.automationdirect.com/

Editorial Contact: Tina Gable
Phone: 678-455-1845
Email: tgable@automationdirect.com
Download: High Resolution Image Download
Download: Web Friendly Image Download

Industry 4.0 is a conceptual framework that applies industrial networking, data-gathering and analytics, and smart devices to cut costs and boost efficiency. It emphasizes improving performance by automating processes and removing humans from the loop. Industry 4.0 led to substantial gains in productivity and profitability. It wasn’t universally applicable, however. Not every process or organization is suitable for automation. Some need humans in the loop. In particular, humans bring key attributes like creativity, problem-solving, and adaptability. Enter next industrial revolution, Industry 5.0.

Industry 5.0 is a new human-centric paradigm that combines the Industry 4.0 foundation with tools like AI and collaborative robots (cobots) to create a “better together” approach (see table). Instead of replacing humans with machines, Industry 5.0 combines the best attributes of each to create an industrial operations model that is flexible, resilient, efficient, and sustainable.

 Industry 4.0 vs. Industry 5.0 in Motion Control

Increasing worker safety and productivity

Modern industrial operations are under pressure. With a labor shortage and the retirement of baby boomers, a skills gap has emerged. Talent is in short supply. To that, add staffing reductions caused by injuries and occupational hazards. With the human-centric shift of Industry 5.0, the goal is to create a “super-worker” who is safer, more comfortable, and more productive when augmented by precision technology.

Wearable Motion Support (Exoskeletons)

Once considered a novelty, exoskeletons are fast transitioning to standard personal protective equipment (PPE). The market for exoskeleton components is projected to reach over $2 billion by 2030, up from $450 million in 2024, for a CAGR of over 29% (source: Markets and Markets). Exoskeletons, sometimes called wearable robotics, augment movement to increase worker productivity while preventing acute injuries and repetitive strain injuries (RSIs). They can be divided into two classes:

Powered Lifting Support

Hard exoskeletons for powered lifting support include exoskeletons that provide back support during a wide variety of tasks ranging from lifting heavy loads to working in stressful postures (see Figure 1). The Exia from German Bionic, for example, combines motion control with physical AI to provide up to 84 lbs (38 kg) of lifting augmentation per movement. The Exia AI model trains on billions of data points gathered across different users and industries. During actual use, the AI model continues to customize its performance for each worker, getting better and better over time.

Soft Exosuits

Rigid exoskeletons can hamper movement or be uncomfortable. Some tasks require greater flexibility or manual dexterity than can be provided by rigid versions. This has led to the emergence of soft fabric-like exosuits (see Figure 2). Exosuits are designed to protect against repetitive stress injuries in workers during tasks like bending, stretching overhead, or holding heavy objects.

Biometric Ergonomic Feedback

Seemingly harmless movements repeated over time can lead to musculoskeletal disorders (MSDs) that can cause pain, lost work hours, and disability. The focus on human-centric design has led to the development of biometric ergonomic feedback devices. These devices help workers move more safely in the workplace and help the workplace better adapt to their needs. It’s a case of the motion control technology developed for Industry 4.0 now being applied in human-centric Industry 5.0.

At-Risk Posture Alerts: 

The combination of Industry 4.0 data gathering and AI makes it possible to use video feeds from pre-existing systems to analyze activities across almost any facility. At the base level, these types of systems can review tasks to identify dangerous postures and dynamics for future education. Once the correct models are built, workers can be monitored in real time and given visual, audible, or haptic (vibrational) alerts when they move or stand in ways that could cause injury over time. An alternative approach involves the use of wearable sensors capable of tracking a worker’s skeleton in 3D space. If the worker reaches at an angle that could lead to an RSI, the system provides haptic feedback to correct the posture.

Dynamic Workstations: 

Good workplace ergonomics are essential to the avoidance of MSDs and RSIs. In the new human-centric workplace, tables, assembly rigs, and pick-and-place stations can be equipped with motion-control systems that support dynamic reconfigure ability. The machine scans the worker’s RFID tag or accesses biometrics upon login. The equipment automatically adjusts for the height and tilt required by the specific individual and the task they’re undertaking.

Robots with agency – AI gets physical

The most common interaction with AI at present is a virtual exchange with a large language model (LLM) through an electronic device. Although misinformation and errors are always possible, risk of real physical harm is minimal. With the increasing adoption of robots with agency―physical AI―the possibility of property damage and even injury to workers is much higher. That’s why a concerted effort is underway to establish methods for safe and efficient interactions between workers and physical AI.

Classic industrial robots were high-mass machines programmed to perform specific motions at high velocity. To protect human workers, these robots were placed in locked cages that could only be opened when the robot was powered down. Fast-forward to the cobots of today. Cobots are designed to operate in close proximity to human beings. Devices feature rounded edges, low speed and low force motion, and safety sensors and programming to ensure safety by design (see Figure 3).

Figure 3 : Classic industrial robots are kept in cages to protect workers from high velocity movements (left). Robots are designed for human interaction, with rounded edges and low-speed, low-force motion (right).

The Cobot-human partnership

As humans and robots with agency increasingly work side-by-side in the industrial environment, engineering teams have reimagined the human machine interface and programming of physical AI robots. Key focuses include safety and ease of use.

Legibility of Intent 

A modern automated warehouse, for example, can contain hundreds to hundreds of thousands of autonomous mobile robots (AMRs) operating in proximity to workers. To prevent injury and maximize efficiency, AMRs need to telegraph their next movements to nearby workers. They can do this through visual and audio cues. Simple approaches like turn signals or wearable haptic proximity sensors that vibrate when robots are near are quick and inexpensive, but can be overlooked in the noisy, often cluttered industrial environment. Designers are exploring more intuitive approaches that mimic human body language, such as reductions in speed/cadence and the use of articulating sensors that can signal intent with an “eye gaze.” Now, an AMR turning toward a bin can signal its intentions by slowing down and “glancing” toward the object, just like a person would.

“Follow-Me” Tugger Trains 

Autonomous tugger trains, which consist of AMRs that pull carts on fixed routes, have become increasingly common in manufacturing and logistics. With the Industry 5.0 focus on human-centric design, tugger trains have also become collaborative robots that can increase human safety. Festooned with sensors―lidar, laser range finders, 3D cameras―these tugger trains have the ability to follow human operators from point to point. During “follow me” operation, the tugger train handles the load while its human partner performs the tasks requiring adaptability. In some cases, follow-me technology can be used to program routes for the train to follow autonomously. The human operator leads the train on the desired path and the system repeats it. The result is a dynamically reconfigurable robotic system with a very low bar to entry.

Improved usability

Controlling a robot by writing code for every single action is time-consuming and complex. Any time any part of the process changes, the code must be rewritten, tested, and debugged. With the assistance of AI, robots are emerging that can be trained almost as easily as a human.

VLA Models 

Robot policy emerged as a solution to programming complexity. A robot policy is a framework that enables the robot to identify its current environment and configuration―its state―then map that state to a set of actions it needs to take to achieve the next objective. Even then, robot policy refinement is challenging. Enter vision-language-action (VLA) models.

VLA models are analogous to the LLMs and vision-language models (VLMs) that power generative AI. VLA models are pre-trained on large, heterogeneous data sets, frequently using VLMs and LLMs as starting points. Motion-specific training for the VLA includes a wide range of scenarios and tasks. Instead of training for a narrow set of tasks, the robot can adapt any of a large set of options to its needs.

During operation, the robot first determines its state by comparing the data it gathers to the generalized VLA data set. Because VLMs can include a variety of types of data such as images, video, and text, a single VLA can be applied to many different scenarios. Next, the VLA’s LLM training set equips the robot to understand audible natural-language commands (“Pick up the blue bracket and hold it here.”) With the aid of the VLA model, the robot can now calculate the trajectory and force needed to assist without any manual programming. If there are any changes to the environment, object, or task, the robot has the resiliency to rapidly adapt. The technology is still in its early days but impressive demonstrations have already been conducted.

Shadowing AI 

Another solution to the programming challenge is programming by demonstration (PbD), also known as imitation learning. An early form of imitation learning was manual guided teaching, in which the user would move the end effector of a cobot through the desired sequence. The robot would then follow that sequence going forward. With the addition of Industry 4.0 instrumentation and AI, projects are now Underway in which the cobot observes as the human operator performs a task, then mimics the process. The information gathering also makes it possible for the cobot to assist the technician with tool orientation or by applying a steadying force.

The human-centric paradigm of Industry 5.0 promises to bring industrial operations into a new era of resiliency, efficiency, and sustainability. Built upon the foundation of Industry 4.0’s focus on connectivity and automation, Industry 5.0 combines the best the machines and humans have to offer. The resultant technologies increase worker safety and productivity while leveraging the unique human traits of creativity, adaptability, and problem solving.