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Precision Measurement Enters the Digital Control Plane
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Applied Technology Review | Friday, February 20, 2026
Industrial automation leaders are confronting a quiet yet persistent problem within modern production lines: measurement accuracy degrades long before mechanical systems reach their physical limits. Electrical noise, aging analog infrastructure, and skills gaps around calibration undermine confidence in data that increasingly drives closed-loop control and quality assurance. As factories modernize, the weakest link is often the last meter between the physical measurement point and the digital control system. Addressing that gap now defines the difference between incremental improvement and sustained precision.
Measurement solutions that still depend on long analog signal paths expose plants to interference from welding robots, drives, and power electronics. Shielded cabling, amplifier cards, and manual tuning can mitigate risk, yet these measures add cost and complexity while remaining vulnerable to drift and human error. Digital communication alone does not resolve this issue if the analog-to-digital conversion occurs too far from the measurement point. Precision depends on where that conversion happens and how tightly calibration is controlled across the entire signal chain.
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A second pressure comes from workforce change. Expertise in configuring analog measurement systems is retiring faster than it is replaced. Maintenance teams increasingly favor systems that integrate directly into existing PLC environments, behave consistently across sensor variants, and reduce dependence on specialist intervention. Measurement technologies that preserve mechanical investments while modernizing data interfaces offer a practical path forward, particularly in plants running fixtures designed decades ago.
These realities point toward a clear direction. Reliable measurement today depends on integrating signal conditioning as close as possible to the probe, converting data to digital form before noise can distort it, and transmitting that data through an open industrial communication layer that aligns with modern automation architectures. Open standards matter because they protect buyers from vendor lock-in and allow sensors to participate fully in broader data flows, whether feeding PLC logic or higher-level monitoring systems through standard gateways.
Mechanical integrity remains equally decisive. Digital output cannot compensate for play, friction, or inconsistent guidance at the measurement interface. Precision hinges on repeatability, which in turn depends on bearing design, surface quality, and assembly discipline. Solutions that combine rolling linear guidance with play-free construction deliver consistent positional data over long service lives, supporting both accuracy and reparability. Longevity is no longer a secondary concern. Buyers increasingly value equipment that can be serviced and returned to specification rather than discarded.
Within this landscape, Peter Hirt presents a compelling reference point for organizations evaluating advanced digital displacement measurement. Its approach centers on embedding miniature signal conditioning electronics directly within the probe assembly, converting the analog measurement signal to digital form at the source. This architecture sharply reduces sensitivity to electrical noise and removes the need for complex external conditioning hardware. Digital transmission via IO-Link then carries calibrated measurement data up to ten meters without degradation, after which standard industrial networks extend reach further.
The decision to adopt IO-Link as an open interface shapes the broader value proposition. Integration into PLC environments follows established patterns familiar to automation teams, while access to IO-Link gateways enables straightforward data acquisition and edge connectivity through protocols such as OPC UA and MQTT. Parameterization and diagnostics flow through the same channel, simplifying setup and maintenance across diverse applications.
Mechanical design reinforces this digital foundation. Ballbearing guidance without axial play delivers high repeatability across both short and long stroke probes, while a standardized eight-millimeter form factor allows direct substitution into existing fixtures. Consistent output scaling ensures that probe replacement does not introduce configuration errors, even during off-shift maintenance. Reparability extends product life and supports sustainability goals without compromising measurement integrity.
For executives responsible for precision measurement investments, Peter Hirt stands out as a disciplined choice. It aligns digital communication, calibration control, and mechanical accuracy into a coherent system that reduces risk at the point where measurement matters most. In environments where data quality underpins automation performance, this combination represents a measured and credible benchmark.
In the ever-evolving industrial landscape, the advent of digital twins is a testament to human ingenuity and the unwavering pursuit of efficiency. This transformative technology is reshaping the manufacturing sector and redefining the essence of production and design.
The Essence of Digital Twins
A digital twin is a vigorous, virtual model of a physical object or system. It's a mirror image in the digital realm, reflecting the real-world entity in real time. From a single screw to an entire assembly line, digital twins capture the intricacies of their physical counterparts with astonishing precision.
Revolutionizing Design and Production
The impact of digital twins on design and production is profound. They enable engineers to experiment and optimize without the constraints of the physical world. Accelerated product development, reduced defects, and significantly decreased manufacturing costs. Digital twins are not just tools but the new architects of innovation.
Predictive Maintenance: A Proactive Approach
One of the most compelling applications of digital twins is in predictive maintenance. By mirroring the real-time equipment status, digital twins allow for anticipating failures before they occur. This foresight is invaluable, leading to increased uptime and a drastic reduction in unplanned downtime. Digital twins enhance maintenance schedules, operational efficiency, and proactive problem identification, saving time and resources by analyzing historical data and trends.
The Sustainability Edge
In today's world, where sustainability is paramount, digital twins offer a beacon of hope. They provide a pathway to more sustainable manufacturing practices by optimizing resource usage and reducing waste. Production's environmental footprint can be minimized, paving the way for a greener future. Digital twins allow real-time monitoring and analysis of operations, enabling companies to make data-driven decisions that contribute to sustainability goals, revolutionizing industries' approach to environmental responsibility.
As we embrace the digital revolution, it's essential to remember that technology is a tool, and its value lies in how we wield it. Digital twins, with all their complexity, are ultimately about enhancing human potential. They reflect our creations and aspirations to build a smarter, more efficient, and more sustainable world. ...Read more
Steven is a strategic technology leader with 25 years of global experience driving innovation, transformation, and growth. At Pepper Money he leads the digital, data and technology functions, combining digital thinking, data-driven insights, commercial acumen, and executional discipline to deliver meaningful outcomes for both customers and the bottom line. His work spans digital strategy and delivery, enterprise transformation, M&A integration, and business operations, always with a focus on innovation, practical impact, and sustainable change.
As CIO of Pepper Money, I oversee our entire digital, data and technology ecosystem. My role involves aligning technology strategy with business goals, driving innovation and ensuring secure, efficient operations across the business. I focus on initiatives that transform how we operate and go to market— modernizing lending processes, enhancing digital experiences, unlocking data insights and exploring emerging technologies like AI.
Building Secure, Compliant Innovation From The Ground Up
Balancing innovation with compliance and cybersecurity is critical. We embed governance into every initiative through three key strategies:
1. Innovation with Guardrails: We pilot new technologies in controlled environments. For example, new machine learning models are tested in parallel with existing systems before scaling. We maintain transparency with the Executive Committee and Board, especially for high-risk innovations like AI.
2. Balanced Investment Portfolio: Using a structured prioritization framework and quarterly planning, we allocate resources across “run,” “change” and “transform” initiatives.
We track human capital investment ratios to ensure alignment with business value and operational sustainability, with full support from Executive Leadership and Board.
3. Compliance and Security by Design: Our legal, risk, cybersecurity and compliance teams are integral to the design phase of new initiatives.
By integrating regulatory requirements into product development, applying secure coding practices, conducting early threat modelling, and investing in modern controls, we achieve innovation with confidence.
Balancing Customer Experience With Platform Agility
We leverage modern technology to deliver seamless, personalized experiences and scalable systems:
1. Frictionless Value Chain: Using human-centred design and process mining, we optimize digital journeys. Brokers can complete online enquiries in under two minutes with real-time product fit and serviceability advice. Customers apply digitally, verify identity biometrically, upload documents securely and sign electronically. Underwriting is supported by automated workflows, document processing and real-time decisioning using machine learning. Fraud detection tools analyze data for tampering and asset finance disbursements enable same-day vehicle delivery. These innovations have led to above-average NPS scores, industry-leading mortgage turnaround times, and high auto-approval rates.
2. Agile, Integrated Architecture: Our microservices and low-code architecture supports rapid deployment and seamless integration across platforms. Systems communicate via APIs, enabling features like resuming paused applications in real-time. This architecture is scalable, reliable and minimizes downtime.
3. Cloud-First Infrastructure: With 90 percent of systems in public cloud or SaaS, we ensure performance, uptime and agility. This allows us to scale quickly during demand spikes or market expansion, maintaining fast uninterrupted service.
Key Advice For Aspiring Leaders
Driving digital innovation in a regulated environment is challenging but rewarding. My advice to fellow CIOs:
• Stay Customer-Centric and Business-Focused: Technology should serve customers and business goals. Be a business leader first, align initiatives with strategy and customer needs to gain executive support and deliver real value.
• Empower Talent and Collaborate: Innovation comes from people, so build diverse, skilled teams and give them space to grow. Share the vision, define boundaries and encourage safe experimentation. Foster cross-functional collaboration and lead by example.
• Capture Business Value: Move beyond IT dashboards to use data intelligently to tell compelling stories, quantify cost avoidance, efficiency gains or speed improvements in business terms. This builds trust and connects technology to outcomes.
• Continuously Reinvent Yourself: The tech landscape evolves rapidly. Stay informed on trends, regulations, and best practices. Be ready to pivot strategies and adapt your leadership style because adaptability as a CIO is essential for today’s uncertain, fast-paced environment.
Pepper Money is a leading non-bank lender founded on a mission to help people succeed. For over 25 years, Pepper Money has helped over half a million customers with a wide range of really helpful loan options including home loans, car loans, novated leases, personal loans, asset finance, commercial real estate and SMSF loans. Operating across Australia and New Zealand, Pepper Money works through trusted broker partners, white label solutions and direct channels—always guided by the question: “How can we be more helpful?”. ...Read more
Drones are an emerging technology in various industries, including the military, law enforcement, rescue operations, entertainment, and mining. This essay will address the issues that the mining industry faces as the use of drones grows.
Data Processing and Analysis
The modern mine is a data-intensive industrial ecosystem. Millions of data points are generated during everyday operations, ranging from weather and ambient conditions to asset mobility, geography, geology, and other elements specific to particular working settings.
Drones must consequently be capable of collecting, processing, and analyzing data utilizing powerful software and analytical tools. Furthermore, central data processing hubs, to which drones transmit information in real-time, must be robust and capable of efficiently analyzing the data collected in mines.
Safety and Security
Drones can pose a risk if not appropriately operated by trained workers. They may endanger air traffic and personnel in underground mines' restricted confines. Sensors, cameras, and GPS positioning can reduce collision chances while adhering to local rules can prevent more significant difficulties.
Security is another major worry in the drone industry as a whole. If strong security protocols are not in place, drones can be hacked and hijacked. This can result in the loss of sensitive data and, in the worst-case scenario, a backdoor into crucial systems, disrupting mining efforts and posing a threat to life.
The importance of cybersecurity has grown to the point where the US government restricted the export of drones by a significant manufacturer last year, citing concerns about national security and foreign policy. Concerns concerning GPS spoofing, downlink intercepts, and data mining are fast increasing in the drone industry.
Technical Limitations of Drones
Despite breakthroughs in sensor technology, artificial intelligence, machine learning, and other critical components of current drones, several technical limits remain.
Flight time, range, cargo capacity, and battery life can all impact the effectiveness of mining drones. Furthermore, integrating drones with other devices and legacy systems might take much work. However, technological progress can overcome these obstacles.
For example, hybrid power systems may overcome battery restrictions, which makes them more appealing to mining businesses. Innovation, like any other technology, produces increasingly sophisticated drone systems that can be used for mission-critical tasks. ...Read more
By offering touch-based feedback, AI-based haptic systems improve human-machine interaction and increase their dependability and usability. Because they close the gap between humans and artificial intelligence, foster openness, and uphold public confidence in these applications, they are essential in sectors including healthcare, robotics, virtual reality, and driverless cars.
Haptic technology builds trust by making AI systems feel more interactive and responsive. Through tactile feedback, users gain control and clarity over AI-driven processes. For instance, in robotic-assisted surgeries, haptic feedback allows surgeons to feel the pressure and texture of tissues, even when operating remotely. The level of interaction enhances precision and instills confidence in the AI-powered robotic system, as surgeons can directly experience the system's functionality.
Haptic technology also strengthens trust in autonomous systems, such as self-driving cars. Vehicles can communicate critical information to drivers or passengers through haptic interfaces like vibrating steering wheels or seat feedback. For example, a gentle vibration can alert users to potential obstacles or changes in driving conditions, ensuring they remain informed about the AI's decision-making process. This real-time feedback fosters collaboration between humans and AI, reducing anxiety and increasing acceptance of autonomous technologies.
The healthcare sector benefits significantly from haptic-enhanced AI systems. Devices with haptic feedback enable medical professionals to perform diagnostics, administer treatments, and conduct training confidently. For instance, AI-driven prosthetics incorporating haptic technology allow users to feel textures and pressure, restoring a sense of touch and improving their quality of life. Similarly, rehabilitation systems with haptic feedback help patients regain motor skills more effectively, as the tactile input reinforces their trust in the system's ability to aid recovery.
Despite its transformative potential, the integration of haptic technology with AI faces challenges. High development costs, the need for advanced hardware, and compatibility with diverse AI systems can hinder widespread adoption. Designing haptic interfaces that effectively convey complex information without overwhelming users requires careful planning and innovation. Addressing these challenges demands collaboration between AI developers, haptic technology experts, and end-users to create functional and user-friendly systems.
As research advances, haptic technology becomes more accessible and sophisticated, paving the way for broader industry applications. The development of lightweight, cost-effective, and wireless haptic devices ensures that these solutions can reach a wider audience. Integrating machine learning with haptic feedback promises even greater personalization as AI systems adapt to users' preferences and behaviors over time, enhancing functionality and trust. ...Read more