In the ever-evolving industrial world, the future belongs to those who innovate at the convergence of sustainability, safety, and digital transformation.
EKSO, a cutting-edge company in trenchless pipes maintenance and smart pipe technologies, is doing just that with its participation in the XR5.0 project, funded under Horizon Europe and in collaboration with 24 partners of excellence.
As part of the XR5.0 pilot for Operator 5.0 training, EKSO is demonstrating how Extended Reality (XR), in combination with AI and real-time sensor data from equipped pipelines, can revolutionize the way operators monitor and maintain water infrastructure.
Why Smart Pipes Matter
EKSO’s smart pipe system, equipped with embedded sensors and AI-enabled analytics, detects early signs of damage and supports predictive maintenance strategies.
But technology alone is not enough. That’s where XR5.0 enters the picture.
XR Meets Predictive Maintenance
As the XR5.0 pilot continues, EKSO is now in a critical stage whereby the fusion of Extended Reality (XR) with predictive maintenance technologies is being tested in real-world settings.
Initial field tests demonstrate how XR complements EKSO’s intelligent pipe systems by delivering real-time information and diagnostics to operators. The pilot uses sensorized composite pipes to track key parameters such as pressure and temperature. AI-powered predictive models offer early detection of possible problems, including micro-leaks and structural stress, before visible failure.
What’s being experimented now is the way in which this intelligence can be made more available to operators in a form that is intuitive and actionable. With XR devices like AR headsets and smart tablets, technicians are beginning to see how digital overlays, and real-time alerts can lead them directly to areas of concern.
Rather than referring to independent dashboards or depending on occasional inspections, operators now have the pipeline’s health represented visually on site, in real time.
EKSO and its technical partners are considering adding a digital twin—a virtual representation of the pipeline that mirrors its present state based on sensor information. The model enables operators to run fault scenarios, examine past trends, and more effectively comprehend system alerts. Early feedback indicates it supports faster, smarter interventions, particularly when combined with personalized XR guidance.
Most exciting, perhaps, is how XR is facilitating a more collaborative maintenance experience. In the trials, the experts have already been able to participate in live XR sessions, providing guidance, confirming observations, and solving technical problems together—in real time, without ever leaving the office. This developing capability promises to cut downtime, travel expenses, and response times dramatically. While the pilot continues, EKSO is already starting to envision how XR can transform predictive maintenance from a data-driven to a human-centered model, one in which operators are not simply alerted but actually empowered. These initial trials are informing a new operating model in which AI, XR, and field know-how are combined in concert to safeguard critical water infrastructure and the ecosystems they support.
Training Operator 5.0: A New Era of Workforce Empowerment
In EKSO’s XR5.0 pilot, Operator 5.0 is not just a label—it’s a vision for a new generation of field technicians who are empowered by technology, driven by data, and trained through immersive learning experiences. Using Extended Reality (XR), the pilot is transforming traditional operator training into a dynamic, responsive, more secure and highly personalized process.
Here’s how:
- Immersive Diagnostics Training: Operators visualize internal states of smart pipes—such as temperature changes and pressure fluctuations—through XR overlays and digital twins, gaining real-time insights via AR glasses.
- Scenario-Based Simulation and Decision-Making: Training modules simulate scenarios like saltwater leaks or pipe corrosion, allowing workers to practice decision-making and emergency responses in a safe XR environment, enhancing preparedness and reducing stress.
- Guided Maintenance and Task Automation: Operators receive interactive AR instructions for maintenance tasks, making complex procedures easier for less experienced workers to navigate.
- Real-Time Collaboration with Remote Experts: The pilot features XR-enabled remote assistance, allowing operators to connect with experts for real-time problem-solving through live video and shared XR annotations, minimizing downtime and errors.
- Performance Monitoring and Personalized Learning Paths: Training data informs AI-powered analytics dashboards, offering tailored feedback and improvement recommendations to support continuous learning and adaptability.
Through these innovations, EKSO’s Operator 5.0 training pilot is redefining how water infrastructure professionals are prepared—not only to operate today’s smart pipelines, but to lead tomorrow’s sustainable systems with confidence and skill.
Expanding XR with Image Detection Capabilities
Beyond predictive maintenance, EKSO is now testing AI-based image detection capabilities across multiple real-world scenarios-broadening the reach of XR technology in field operations.
In Use Case 1, XR guides operators in real time while working on sensorized pipes, enhancing spatial awareness and safety.
In Use Case 2, the company integrates AI image analysis into robotic video inspection workflows, enabling more efficient and accurate identification of anomalies captured via CCTV footage.
Finally, Use Case 3 explores new forms of field training and operator assistance, where AI-powered computer vision supports real-time learning and decision-making.
These applications represent a crucial step forward in EKSO’s mission to embed intelligent automation into daily operations-turning video, voice, and sensory data into actionable insight for field professionals.
The Broader Vision
EKSO’s pilot is not an isolated success—it’s part of a broader XR5.0 mission to shape the future of Industry 5.0 through AI-powered, XR-enhanced, and worker-centric solutions. With its smart water pilot, EKSO exemplifies how small enterprises can lead big transformations—bringing European-made XR technology into critical infrastructure domains where impact matters most.
