Control Intelligence

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Welcome to Control Intelligence, a ControlDesign.com podcast that goes deep inside the automation and technology that machine builders, system integrators and end users rely on to keep production humming efficiently

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24 episodes
weekly
Avg 22 min
English

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#163
Tuesday · 55 min
A technical Q&A with industry expert Brian Romano
In this episode of Control Intelligence, Mike Bacidore is joined by Brian Romano, director of technology development at Arthur G. Russell Co., executive board member of ISA and long-time collaborator with Control Design. They take a technical deep dive into some of the controls industries' hottest topics.
#162
August 31 · 28 min
A3's Jeff Burnstein talks physical AI, humanoid robots and more
In this episode of Control Intelligence, Mike Bacidore is joined by Jeff Burnstein, President of the Association for Advancing Automation (A3), the North American trade group representing almost 1,500 companies involved in robotics, artificial intelligence, machine vision, motion control and related automation technologies. Burnstein joined the association in 1983 and has held a variety of senior positions, culminating in his promotion to President in 2007. He is a frequent commentator on automation issues to the news media, policy makers and the public, and regularly speaks at global conferences on topics such the latest automation trends, the impact of automation on jobs and the future of automation beyond the factory floor. In 2023, he received the Engelberger Robotics Award for Leadership.
#161
August 24 · 50 min
AMT’s Doug Woods: What’s in store at IMTS
In this episode of Control Intelligence, editor in chief Mike Bacidore spoke with Doug Woods, president of the Association for Manufacturing Technology, which hosts the International Manufacturing Technology Show (IMTS) September 14-19 at Chicago's McCormick Place. In this interview, Woods explains the missions of the association and the exhibition, which is the western hemisphere's largest manufacturing trade show, as well as expectations of what the 2026 IMTS has in store and how to navigate the massive event.
#160
August 17 · 1 hr
The future of system integration: CSIA CEO Adrienne Meyer shares a vision based on learning
In this episode of Control Intelligence, editor in chief Mike Bacidore spoke to Adrienne Meyer, CEO of the Control System Integrators Association, about the experience she brings from the Open DeviceNet Vendors Association and her MBA studies at the University of Michigan. In this interview, Meyer shares what she’s learned over the course of more than a year at the helm of CSIA, most of which she’s spent visiting and speaking with system integrators from around the world.
#159
August 10 · 20 min
Top 20 practices for securing PLCs from cyberthreats
In this episode of Control Intelligence, editor in chief Mike Bacidore spoke to Jagannathan Raghunathan, director of cyberphysical security services at Bureau Veritas, about the recent CISA alert. Raghunathan is also co-chair of the PLC Security Top 20 List. In this interview, he outlines how the PLC Security Top 20 List addresses programmable logic controller (PLC) vulnerabilities by offering practical, engineering-focused guidance across the hardware lifecycle.
#158
August 6 · 21 min
What happened with the CISA wastewater cybersecurity alert?
The Cybersecurity & Infrastructure Security Agency (CISA) issued an alert on July 30 regarding a significant increase in cyber threat actors targeting programmable logic controllers (PLCs) in the water/wastewater sector. In this episode of Control Intelligence, Control Design’s longest standing columnist, automation industry veteran Jeremy Pollard, spoke with Mike Bacidore about the vulnerabilities of PLCs; the evolution of their connectivity to the Internet; the use of virtual private networks (VPNs) and gateways; and what machine builders can learn from this to keep industrial equipment secure.
#157
August 3 · 6 min
What can terminal blocks do for you?
A terminal block is a place to connect a wire to another wire and create a junction point. Picture a terminal block as an intersection on a two-way or four-way highway. In this episode of Control Intelligence, written by contributing editor Tobey Strauch, editor in chief Mike Bacidore discusses terminal blocks.
#156
July 13 · 6 min
Uses for industrial PCs vs. PLCs
Hardware independence is what PC-based control promised back in the 1990s. You can run any software on any hardware you choose. In this episode of Control Intelligence, written by contributing editor Jeremy Pollard, editor in chief Mike Bacidore compares the uses of PLCs and industrial PCs.
#155
July 6 · 5 min
The role of transducers in wireless networks
Factory OT uses wireless networks regularly to interface the physical world and the digital world. Transducers make this connection possible. A transducer is a component that converts one form of energy to another. Industrial controls capitalize on this device by utilizing the convenience of wireless in safety, remote and environmentally challenged environments. In this episode of Control Intelligence, written by contributing editor Tobey Strauch, editor in chief Mike Bacidore explains the role of transducers in wireless networks.
#154
June 16 · 7 min
How to use variable frequency drives as predictive maintenance tools
Using vibrational analysis tools that can sense wear, imbalance, noise or harmonics can help identify machinery issues prior to failure. This allows for correcting those issues at a more convenient time, such as scheduled downtime, and avoid costly catastrophic failure. In this episode of Control Intelligence, editor in chief Mike Bacidore shares how variable-frequency drives can be used for physical-asset condition monitoring.
#153
June 8 · 7 min
Running a motor at 175% load: should you do it?
Sometimes motors can run at 175% of their rated load continuously, but the conditions should be specified within boundaries of the system. When we talk about running a motor at 175% continuously, it means the expected current load or the torque will be at roughly 175% of its rated full load Amps. In this episode of Control Intelligence, written by contributing editor Tobey Strauch, Mike Bacidore explains when a motor should be allowed to run in an overload condition.
#152
June 2 · 30 min
Beckhoff USA’s Jeff Johnson explains how mechatronic forces make waves
Beckhoff’s XTS linear transport system, No Cable Technology and EcoLine motor modules are part of the Beckhoff mechatronics portfolio, which is under the supervision of Jeff Johnson, mechatronics product manager at Beckhoff USA.
#151
May 26 · 44 min
Brian Romano discusses PLC coding, IT/OT convergence and more
In this episode of Control Intelligence, Mike Bacidore is rejoined by Dr. Brian Romano, director of technology development at Arthur G. Russell Company. With more than four decades of experience in industrial automation and control systems engineering, Romano's career has centered around innovation, leadership and a forward-looking commitment to advanced technology in manufacturing. His work includes control systems architecture, enterprise connectivity, digital transformation and predictive analytics, even combining them to offer production-as-a-service capabilities by leveraging remote monitoring capabilities. Beyond his industry leadership, Romano brings a passion for developing the next generation of engineers, serving as adjunct faculty at both Central Connecticut State University and the University of Hartford. His academic achievements, including a Ph.D. in Technology and Innovation, an MBA in Business and Data Analytics, and multiple national honor societies, complement his work as an entrepreneur, a published researcher and the 2022 Division Leader of Year with the International Society of Automation. He is also an ISA fellow.
#150
May 15 · 7 min
The reliability and accuracy of machine vision systems
Machine vision has long been used in factory automation for quality inspections, the final checkpoint separating acceptable parts from the rework pile or the scrap bin. Today, vision systems are no longer just inspectors. They are becoming adaptive, data-driven participants in the manufacturing process, capable of influencing outcomes rather than simply recording them. In this episode of Control Intelligence, written by contributing editor Joey Stubbs, editor in chief Mike Bacidore discusses how artificial intelligence has impacted the reliability and accuracy of vision systems.
#149
May 11 · 6 min
Uniting engineering principles with 3D tools
There is a growing trend to use laser scanning to create 3D images of the plant floor, of machine locations and of intricate areas that are congested with plant infrastructure to allow integrators to visualize how they can install new equipment or modify old equipment. In this episode of Control Intelligence, written by contributing editor Tobey Strauch, editor in chief Mike Bacidore discusses how to combine 3D tools with engineering principles.
#148
May 4 · 43 min
2026 Joseph F. Engelberger Robotics Award application winner Robert Little tells all
In this episode of Control Intelligence, editor in chief Mike Bacidore spoke to Robert Little, founder and executive advisor of Robert Little Robotics in Raleigh, North Carolina, and the 2026 application winner of the Joseph F. Engelberger Robotics Award. He will be recognized at the awards dinner during the Automate Show in Chicago the week of June 22. With more than 40 years of experience in robotics, automation and manufacturing, Little serves as a Robotics Technology Strategy board member of the Association for Advancing Automation. He co-founded ATI Industrial Automation in 1989 and helped grow the company from approximately $1 million to more than $100 million in revenue. Under his leadership, ATI became a global leader in robotic tool changers, force/torque sensing and other end-effector technologies that expanded the practical use of robots in manufacturing. Following the acquisition of ATI by Novanta in 2021, Little served as president of Novanta’s ATI business group and later as chief of robotics strategy. He now supports the robotics industry through his advisory firm, Robert Little Robotics, where he advises companies on business strategy focused on robotics and automation markets.
#147
April 20 · 7 min
Inductive, capacitive and passive IR sensors: what’s the difference?
Whether they’re used for position detection on gantries, for detecting parts for assembly or for innumerable other cases, the use of non-contact presence sensors has been a mainstay of industrial controls since the development of the first versions in the 1950s. In this episode of Control Intelligence, written by contributing editor Joey Stubbs, editor in chief Mike Bacidore discusses non-contact presence sensing technologies.
#146
April 6 · 50 min
Brian Romano's 45 years of industry leadership
In this episode of Control Intelligence, editor in chief Mike Bacidore is joined by an important figure in the controls and automation world, Dr. Brian Romano, director of technology development at Arthur G. Russell Company. With more than four decades of experience in industrial automation and control systems engineering, Romano’s career has centered around innovation, leadership and a forward-looking commitment to advanced technology in manufacturing. He’s played a central role in aligning machine-building with data-enabled systems before Industry 4.0 was a thing. His work includes control systems architecture, enterprise connectivity, digital transformation and predictive analytics, even combining them to offer production-as-a-service capabilities by leveraging remote monitoring capabilities. Beyond his industry leadership, Romano brings a passion for developing the next generation of engineers, serving as adjunct faculty at both Central Connecticut State University and the University of Hartford. His academic achievements, including a Ph.D. in Technology and Innovation, an MBA in Business and Data Analytics, and multiple national honor societies, complement his work as an entrepreneur, a published researcher and the 2022 Division Leader of Year with the International Society of Automation. He is also an ISA fellow.
#145
March 27 · 36 min
Drive technology: servo motors, inverters and more
Control Design editor in chief Mike Bacidore spoke Mark Arisman, manager of business development for control products at Nord Drivesystems, about Nord's advancements in drive technology and the digital twin.
#144
March 16 · 6 min
Balancing safety and throughput
The space shuttle had three computers and needed a two-of-three voting system to determine if a sensed variable was real or phantom. This would be a good thing regarding a leaking door seal on the capsule. Safety sensing isn’t a new technology, but it seems that understanding what a safety system function is might be lacking a bit. In this episode of Control Intelligence, written by contributing editor Jeremy Pollard, editor in chief Mike Bacidore talks about safety systems.

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