Industrial manufacturers are piloting voxel-based modular automation systems in 2026, aiming to enhance interoperability, scalability, and return on investment. A European initiative, coordinated by Siemens under the aerOS project, links manufacturing cells-including automated guided vehicles (AGVs), robotic arms, and decentralized compute nodes-using standards such as PROFINET, OPC-UA (Open Platform Communications Unified Architecture), ROS2 (Robot Operating System), and MQTT to provide unified data flow and real-time adaptability. This setup integrates SIMATIC Industrial Edge with cloud orchestration to establish modular, cyber-physical production environments. The pilot demonstrates dynamic system reconfiguration in response to changing production demands, highlighting the transformative role of voxel-style modular architectures in automation. The trial is underway in early 2026.
Background
Modular automation architectures-often based on "voxel" concepts of small, interconnectable units-are gaining momentum as manufacturers seek agile reconfiguration and multi-vendor interoperability. These architectures leverage Industry 4.0 and emerging Industry 5.0 frameworks, emphasizing edge computing and artificial intelligence (AI)-enabled connectivity via standardized industrial protocols. The aerOS pilot incorporates both industrial and IT layers, aligning with these trends. By utilizing protocols such as OPC-UA and ROS2, the system bridges operational technology (OT) and information technology (IT) divides, enabling real-time data coordination.
Details
The aerOS pilot features four AGVs, two robotic arms, three Raspberry Pi nodes, and industrial PCs as edge devices, all orchestrated using Siemens's industrial edge platform. This configuration increases flexibility, speeds transitions between production states, and raises throughput through decentralized control and AI-based orchestration. The interoperability framework sustains modular automation across different devices and systems, supporting adaptive, lot-size-one manufacturing. Employing standards such as OPC-UA and ROS2 enables vendor-neutral integration, a core element of voxel-based modularity.
Manufacturers are assessing return on investment by comparing modular edge architectures with traditional monolithic control systems. While definitive ROI data from aerOS is pending, anticipated advantages include lower retooling times, improved machine uptime, and enhanced traceability across variable production runs. AI and edge computing integration is also projected to decrease latency and enable real-time decision making on the shop floor.
Outlook
As pilot deployments progress through 2026, broader adoption across discrete manufacturing and logistics sectors may follow, driven by standards-based industrial ecosystems. Further advances could bring detailed ROI data and standardization of modular control components. Key performance metrics under review include reconfiguration time, uptime, and interoperability effectiveness to evaluate voxel-style system benefits.
