Smart Measurement, Smarter Manufacturing

HBK’s digiBOX Edge Amplifier transforms how manufacturers use data to increase precision and automation

From underground trains to advanced assembly lines, the need for smarter, real-time data in industrial environments has never been greater. Hottinger Brüel & Kjær (HBK), a global leader in test and measurement solutions, has answered that call with its award-winning digiBOX Edge Amplifier – the 2025 winner of Most Innovative IoT Solution in the Manufacturing Supplier Innovation Awards UK 2025.

As manufacturers grapple with the complex demands of Industry 4.0 – data integration, predictive maintenance, and automation at scale – HBK’s digiBOX offers a decisive edge. By delivering seamless IT/OT integration, intelligent diagnostics, and robust performance, it provides a modern solution for legacy challenges.

“We’re proud to win the Manufacturing Innovation Award,” said Michael Guckes, Product Manager for Industrial Electronics at HBK. “This solution represents our deep commitment to driving smarter, more flexible, and more efficient production systems.”

Bridging the gap between IT and OT

The digiBOX Edge Amplifier is designed to enhance both measurement accuracy and data intelligence at the edge of the network. Unlike traditional amplifiers, digiBOX doesn’t just transmit data – it interprets it, using built-in smart functions to perform real-time diagnostics and pre-calculations. This relieves the machine’s control unit from extra load, allowing it to focus solely on running the process.

“Our solution allows control systems to receive health status data from machines directly,” Guckes explained. “This improves safety, reduces downtime, and makes the entire process more efficient.”

In short, digiBOX doesn’t just measure – it thinks. For manufacturers, this means gaining deeper insight into equipment performance while streamlining production logic and enhancing system responsiveness.

Designed for Industry 4.0 from the ground up

HBK’s innovation was purpose-built for today’s smart factory environments. Key features of the digiBOX Edge Amplifier include:

• Simultaneous IT/OT communication: It talks to both PLCs and cloud-based systems without interruption.
• Modern protocol support: Built with MQTT and openDAQ for easy cloud and analytics integration.
• Industrial-grade durability: IP67-rated, ruggedized to handle harsh conditions.
• Application versatility: Suitable for everything from precision weighing to large-scale industrial operations.

“Measurement technology is a strategic enabler of smart production,” Guckes added. “You can’t fully embrace Industry 4.0 without amplifiers and sensors that can keep up.”

This approach ensures HBK’s solution aligns with evolving needs in automation, predictive quality control, and flexible manufacturing.

Built from real-world testing needs

The development of digiBOX didn’t happen in a vacuum. HBK’s roots in test and measurement provided critical insight into the challenges manufacturers face – especially around validating products in fast-paced development cycles.

With shorter product lifecycles and increasing customization, manufacturers need the ability to simulate years of wear and environmental conditions in a controlled environment. HBK’s technology is designed to make that possible.

“Despite all the digital simulation tools available, you still need real-life testing with prototypes,” Guckes explained. “That’s where advanced measurement systems like digiBOX come in – they help bridge the gap between product development and production reality.”

Tangible results in the field

One HBK customer is using digiBOX to enable collision detection in driverless trains operating in mining environments – a high-stakes use case where system reliability and real-time diagnostics are critical. But this is just one example of its broad applicability.

In a more general sense, manufacturers using digiBOX have seen improvements in:

• Efficiency
• Cost-effectiveness
• Fault detection
• Automation of manual processes

Guckes likens the transition to adopting digiBOX to the way cloud-based navigation apps have transformed the way we travel – more visibility, more control, and smarter decision-making.

Looking ahead: from smart sensors to AI integration

The team at HBK isn’t stopping at edge-level intelligence. Their roadmap includes even more compact and cost-efficient amplifiers, with a focus on advancing digital capabilities and embedding smart algorithms.

Future HBK offerings will emphasize:

• AI-powered analytics
• Cloud-based data platforms
• Easier integration for operators at all levels of technical skill

“Our goal is to simplify the complexity of smart manufacturing,” said Guckes. “Whether it’s enabling condition-based maintenance or streamlining commissioning, we want to make it easy for our customers to use intelligence at every level.”

Advice for manufacturers new to IoT

For companies exploring IoT adoption, Guckes has clear advice: focus on increasing automation and flexibility by investing in sensors and amplifiers with built-in intelligence and communication memory.

“Look for components that can store fault histories, communicate with both machine control and cloud platforms, and be easily swapped out by minimally trained staff,” he said. “That’s where the real value lies – not just in data, but in what you do with it.”

HBK’s digiBOX proves that great innovation isn’t just about creating new products – it’s about redefining how manufacturing works. As industries evolve, tools like digiBOX will be critical to enabling a smarter, more sustainable future.

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