Digitization and automation

Machine safety 2026: Trends in IoT, AI, and cloud solutions

In 2026, manufacturers and operators face the task of integrating new technologies such as industrial IoT, artificial intelligence, and cloud solutions while meeting increasing demands for functional safety and cybersecurity. TÜV SÜD outlines key trends.

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Published January 8, 2026 - 1:04 p.m.

Concrete numbers 2026 stand prominently on dusty ground of an active construction site. A yellow excavator and a safety helmet nearby create a rugged atmosphere under a clear blue sky

(Mila Shnobel - stock.adobe.com)

Modern sensors and industrial IoT solutions enable continuous real-time monitoring of machine conditions. They improve transparency, availability, and maintenance planning. At the same time, increasing connectivity enlarges the attack surface for cyberattacks. Risk assessments must therefore consider not only mechanical and electrical hazards but also new digital threats. Software, firmware, and safety-relevant control components must be specifically protected against manipulation, as these can have direct impacts on machine safety.

Artificial intelligence for process optimization and predictive maintenance

Artificial intelligence is increasingly used to optimize production processes, make machines more flexible, and detect impending failures early. The prerequisite for reliable AI results is the integrity of the underlying data. Since there are currently no harmonized standards for AI in machine safety, requirements and protective measures must be defined with individual risk assessments. If safety-relevant functions are affected, the involvement of a notified body is required. Safety controls are increasingly responding automatically or autonomously to critical operating conditions. The stronger networking of these systems requires robust protective measures against manipulation and system failures. The selection of suitable measures requires sound knowledge of functional safety, safe design procedures, and the evaluation of significant changes to machines. International standards and guidelines such as the IEC-62443 series or IEC TR 63074 provide practical support.

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Collaborative robots with integrated safety

To address the shortage of skilled workers, companies are increasingly relying on collaborative robots (cobots) in combination with artificial intelligence. Traditional safety functions such as force and speed limitation or visual recognition are increasingly being supplemented by digital protection mechanisms. AI-supported cobots do not require protective cages in many applications and can be flexibly used for changing tasks. A prerequisite for safe operation is reliable and interference-free communication between humans, robots, and IT systems.

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Cloud-based security management systems

Cloud technologies enable the cross-location collection and analysis of security-relevant data in real time. At the same time, the responsibility for protecting this data increases - especially with regard to regulatory requirements such as the EU Cyber Resilience Act and the EU Artificial Intelligence Act. Certified cloud services, role-based access concepts, regular audits, and additional technical and organizational measures are necessary to prevent data manipulation and data protection violations.

Holistic machine safety as a key for the future

Machine safety in 2026 goes far beyond protection from physical hazards. It increasingly includes the safeguarding of digital processes and networked systems. This approach is reflected in regulations such as the EU Machinery Regulation and international standards like the IEC-62443 series. Early integration of functional safety and cybersecurity is crucial to creating safe, efficient, and future-proof production environments.

Source: TÜV Süd

FAQs on trends in machine safety 2026

1. Why is machine safety considered a holistic concept in 2026?

Machine safety no longer only includes protection against mechanical or electrical hazards. Through digitalization, networking, and the use of software and AI, cybersecurity risks are gaining importance. Functional safety and IT/OT security must therefore be considered together.

2. What role does industrial IoT play in machine safety?

Industrial IoT solutions enable continuous real-time monitoring of machines and improve maintenance and availability. At the same time, they increase the attack surface for cyberattacks, which is why risk assessments and protective measures need to be adjusted.

3. How does artificial intelligence influence the safety of machines?

AI can optimize processes and detect failures early. For AI to work reliably, the underlying data must be protected from manipulation. Since there are no uniform standards yet, individual risk assessments and measures are required.

4. When is a notified body necessary for AI applications?

As soon as AI influences functions that are safety-relevant or become part of a safety function, the involvement of a notified body is required. This ensures that legal and normative requirements are met.

5. What challenges arise with automated safety controls?

Automated and autonomous safety controls must reliably respond to critical situations. However, their networking increases the risk of manipulation or system failures. Appropriate protective measures require sound knowledge of functional safety and relevant standards.

6. Are collaborative robots safe to use without protective cages?

Yes, provided they have suitable safety functions such as force and speed limitation and digital protective mechanisms. Reliable communication between humans, robots, and IT systems, as well as careful risk assessment, is crucial.

7. What significance do cloud solutions have for machine safety?

Cloud-based safety management systems enable the central analysis of safety-relevant data across multiple locations. At the same time, high requirements for data protection and data security must be met, especially regarding regulatory requirements such as the EU Cyber Resilience Act and the EU AI Act.