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More benefits of having a bus coupler module in your remote I/O system: enjoy streamlined installation and long-term savings with the IDEC SX8R

Faster, smoother installation saves time on every system building project Many of the SX8R’s clever features contribute to cutting installation and wiring times: Modular architecture : install what you need at the time, and nothing more. Over 40 remote I/O modules to choose from : find and quickly combine modules with digital and analog inputs and outputs for the ideal setup. Easy addition of expansion I/O modules : various expansion modules can be easily added to the bus coupler module, with no base plate required. Expansion interface module : easy to increase the number of digital and analog I/Os as needed. Push-in terminals : wiring takes roughly half the time, compared to using screw terminals. These advantages could have a significant impact on how quickly you can get your system up and running. SX8R features that help to minimize downtime: Flexible scalability and system expansion : add modules as and when without rewiring the entire system. Quicker wiring : as push-in terminals speed up the process, you can restore full system functionality even sooner. Support for multiple network protocols : take advantage of the SX8R’s compatibility with EtherNet/IP, Modbus TCP and CC-Link IE Field Basic for reliable communication between devices. Dedicated software : use SX8R Configurator for easy ‘drag-and-drop’ module configuration and communication settings. Operating temperature range : the wide -25°C to +65°C range keeps the SX8R running optimally in hot and cold operating environments. Equipment maintenance : every machine will need maintenance at some point. To get the most use and efficiency out of your equipment, you need to optimize your maintenance processes. This involves knowing the current state of machinery and when/how to maintain it – in other words, you need the latest device data. In systems where devices are installed further away from each other, visiting all of them in person to record data read-outs is impractical and time-consuming. However, a lack of real-time information can throw off your maintenance schedule. Remote I/O systems are designed to reduce and optimize maintenance, using IoT connectivity to efficiently collate data. Having the latest information in one place creates the opportunity for predictive maintenance – spot issues before they happen, replace parts before they break, and prevent unnecessary work. We’ve previously looked at how the IDEC SX8R bus coupler module (for remote I/O systems) can improve the reliability and efficiency of your automated systems . The other main considerations for industrial systems designers are – naturally – speed and the costs of implementation and maintenance. The SX8R can also act as an effective solution for customers prioritizing these needs. How and where do bus coupler modules fit into an industrial automation system? In some ways, it’s more than just part of the system: a bus coupler module is what makes remote I/O systems possible.In medium- to large-scale systems, various control and safety devices may be installed in different locations. Depending on the size of the system, ‘different locations’ could mean anything from separate rooms to opposite ends of a warehouse. Smart, efficient features that save time and money over equipment lifecycles When calculating the long-term costs of running a remote I/O system, there are 2 inevitable factors you must consider: downtime , and maintenance . Unplanned and/or extended downtime : all control systems evolve over time. You may want to change the number of devices, or decide that the latest version of a device better meets your needs. Depending on how the system is arranged, adding or removing a device may mean temporarily putting everything else on hold. You can always plan ahead to minimize the downtime involved with control system upgrades – but if the work takes longer than expected, cost and productivity losses will continue to rise by the hour. In a well-designed remote I/O system, changes have a minimal effect on the rest of the existing setup. Lower disruption also means a lower chance of errors and equipment failure, further preventing unexpected downtime. Built for adaptability across different industries Remote I/O systems – and the SX8R bus coupler module as part of a system – have features and functions that lend themselves to a wide variety of industrial applications. For example: Machine tools : efficiency is key, in terms of both installation space and work processes – achieve system downsizing and improve machine uptime with the SX8R and a remote I/O system in combination. Automotive : downtime losses in the automotive industry are measured by the minute – the SX8R in remote I/O systems helps keep downtime to a minimum. Food and packaging : accurate data is essential to maintain product quality and hygiene levels – use remote I/O modules to collect real-time information on temperatures, weights, process timing, etc. Automated production lines : different lines and process stages require a variety of different devices – pick out the I/O modules to support each device type and AC/DC inputs and outputs. Construction : depending on the work site, data monitoring in the field may be too difficult – IIoT connectivity is a game-changer for construction projects, enabling reliable remote monitoring. Logistics : in large warehouses and storage facilities, devices may be placed far away from both each other and the controller – in remote I/O systems, more distance between devices isn’t a barrier to data transfer. Physically connecting control devices with wires and cables becomes extremely difficult – and taking manual data readings becomes highly impractical. A bus coupler acts as the dedicated communication module for connected remote I/O modules to share data, via commonly used network protocols. Each remote module collects information from control devices out in the field and sends it to the bus coupler, which then forwards it to the PLC. The SX8R fits into these systems with ease, thanks to its compact design and mounting hooks. No wires are needed to connect the bus coupler and I/O modules – they simply click together. Added convenience, from system implementation to ongoing maintenance Whether you’re weighing up changes to your remote I/O system or making plans to design a new one from scratch, the IDEC SX8R can make things simpler. The SX8R bus coupler module is available in all of our global regions. Review the specifications here on the website, then reach out to your local IDEC team to further discuss your needs. SX8R features that help to simplify maintenance: Simpler installation of sensors : if your system needs added sensors for predictive maintenance, these can also be installed with minimal wiring. Increased data visibility : having system information in one place significantly lowers the risk of unforeseen issues. Easy debugging of configurations : view the data from each I/O module remotely, including ON/OFF status, current values, set values, and error information (for analog modules). Self-diagnostic software function : SX8R Configurator can display the specific location of a fault (e.g. which I/O module has the error).

Full control in long-distance & high-interference environments

Wireless instability, operator safety, and long-distance machine control are major challenges in heavy-duty welding environments. This month, discover how the HT4P IDEC Safety Commander™ helped a custom metal fabrication customer deploy a reliable 20-meter wired control solution while preserving the flexibility of their Android-based welding interface.

Empowering autonomous mobility with HMI-X: IDEC and ez-Wheel’s integrated approach (part 2)

HMI applications – and the HMIs themselves – are evolving in harmony In this HMI-X system, the definition of ‘HMI’ has started to change. The ‘interface’ aspect of ‘human machine interfaces’ is even more interactive. The balance is shifting – before, users (humans) actively used interfaces by pressing buttons and touching displays. Now, the ‘machine’ element of HMIs plays a stronger part, with passive technologies that sense humans and automatically act to keep them safe. Together, the devices and technologies that make up HMI-X systems create working environments where machines and humans can safely coexist. Transformation: calling it simply a corporate ‘buzzword’ plays down the real, constant changes and evolutions in technologies and how people work. Many manufacturers and other companies are aiming for ‘transformation’ in their industry. They could just say ‘change’, but transformation takes more effort and dedication. It involves rethinking how they do business from the ground up. You may see ‘X’ used to represent transformation in a business context. Take DX (digital transformation) as one common example. At IDEC, we plan to transform human-machine interfaces (HMIs) through the HMI-X concept. Industry 4.0 will naturally be followed by further stages of technological advancements, and we’ll continue working to redefine HMIs and what they’re capable of. In part 1 of this series , we explained the HMI-X concept and several IDEC products born from new initiatives. This time, we’ll go into more detail on other products that demonstrate our progress so far and the ongoing potential of HMI-X. In this article: Building on the HMI-X concept: Safety Wheel Drive HMIs and their applications evolving in harmony Transforming workplace safety with HMI-X and automation Transforming workplace safety with HMI-X and automation solutions Combined with IDEC’s SE2L Advanced safety laser scanner, the motorized Safety Wheel Drive system addresses the functional needs of driverless industrial trucks. It also does so in full compliance with international standards for AGVs, and with ISO3691-4. Safety Wheel Drive is currently on sale in many regions, including Japan, Europe, the USA and Canada. The SE2L Advanced safety laser scanner is available globally. These advances in HMI-X solutions for the AGV/AMR industry are just the start. We’re developing and rolling out other ways that Safety Wheel Drive can meet customer needs and add value, especially when implemented alongside other IDEC products and technologies. Subscribe to our mailing list and follow us on social media for regular product updates. IDEC is working to create the optimum environment for humans and machines. Learn more about our HMI-X initiatives on the IDEC corporate website . Building on the HMI-X concept: Safety Wheel Drive Together, IDEC and ez-Wheel have continued to take this holistic approach to technological transformation and product development. The innovative Safety Wheel Drive system is the result. It’s designed to work with a variety of IDEC safety devices to create a flexible, reliable industrial safety system. For example, when Safety Wheel Drive and the SE2L Advanced safety laser scanner are installed on an AGV, the result is a simple, safety compliant AGV. Installing Safety Wheel Drive on AGVs/AMRs that operate in the same areas as humans immediately gives those AGVs and/or AMRs advanced safety controls: Safe motor disconnection (STO) when a stop is requested Safe brake control (SBC) to ensure a standstill Safe direction (SDI) in case of collision risk Safely limited speed (SLS) to prevent hazardous situations Safe maximum speed (SMS) to secure operating range The SE2L Advanced safety laser scanner has a 270° sensing angle. It senses when someone (or something) is within the warning area or safety protection zone for the AGV. If the scanner detects a person or object in the warning zone, Safety Wheel Drive will slow down. In the safety protection zone, Safety Wheel Drive will stop.

Empowering autonomous mobility with HMI-X: IDEC and ez-Wheel’s integrated approach (part 1)

What is HMI-X? IDEC defines Human-Machine Interface Transformation (HMI-X) as “the change in the optimal interface that accompanies major changes in the relationship between humans and machines.” The ‘X’ represents transformation, and ‘HMI’ is short for Human-Machine Interfaces. We first introduced this concept in 2022, as part of our Medium-Term Management Plan for FY2023-FY2025. It remains part of our plan for FY2026-FY2028. Our work so far is only the start: transformation never ends The IDEC products introduced in this article – the KW2D, HT3P and HT4P, CW series, and the HG series – are all available globally. Contact us directly for more details, follow us on social media , or subscribe to our mailing list. In part 2 of this series , we’ll introduce another highly innovative IDEC product that embodies our HMI-X approach. These user interfaces and the ways they interact with HMIs are equally important. For example, demand for contactless devices and remote monitoring with HMIs rapidly increased during the Covid-19 pandemic. Each new IDEC product represents a technological advancement – and they’re even more effective when used together. By providing products and services that combine safety and HMIs, IDEC will drive HMI-X and contribute to achieving well-being for our diverse stakeholders. Transformation leads to new solutions – and those solutions will transform processes and safety at industrial work sites The aim of IDEC’s HMI-X concept is to combine the control element of HMIs with: Increased safety and well-being Automation Dedicated hardware and software IoT (IIoT) connectivity The products, services, and solutions we develop through HMI-X will together create environments where humans and machines can safely coexist. Keeping our thinking flexible and dynamic, to develop wide-ranging innovations As a leader in HMIs, IDEC has grown globally – and continually works to achieve consistently high levels of safety and contribute to society. HMI-X means more than simply innovating in the HMI segment. HMIs are just one aspect of comprehensive solutions that incorporate hardware and software. We're driving new initiatives in key fields, including automation and driverless industrial trucks and their systems (AGVs and AMRs). These efforts have resulted in several new product launches, including: The KW2D smart RFID reader : custom authorization and high security, to help customers manage equipment access and work logs. The HT3P and HT4P Safety Commander tablet holders : forward-thinking design that includes a 3-position enabling switch and emergency stop switch. The CW series of touchless switches : designed for convenience, accessibility, and hygiene, with built-in sensors and indicator lights. The HG1J and HG2J operator interfaces : touchscreen display panels with high clarity and environmental durability. Change is inevitable, and it never stops. People and businesses continue to move with the times, and with new trends and technologies. More than simply aiming to ‘change’ or to do things differently, many companies are pursuing ‘transformation’. Business transformation is ambitious – it involves creating new processes, redefining company culture, and improving the customer experience. You may be familiar with ‘digital transformation’, commonly known as DX. It generally refers to using digital technologies to rethink business processes and drive value creation. IDEC and ez-Wheel are taking a groundbreaking approach to business transformation with the HMI-X concept. We intend to reimagine human-machine interfaces (HMIs) in the age of Industry 4.0 and beyond. In this article: What is HMI-X? Flexible and dynamic thinking that drives innovations The transformation > solution > transformation cycle for industrial safety

Moving two tons without the strain

Handling multi-ton data servers in narrow aisles presents both ergonomic and operational challenges. Discover how an electrically assisted mobility solution eliminates operator strain while improving precision and safety.

Safety integration in ultra-slim remote controls

This month, discover how the XW1E-BV3SG unibody Emergency-Stop enabled a sleek, space-efficient design for a customer's remote control unit application with extremely limited panel depth.

Safety-certified presence detection in dust

The key challenges were to provide a dependable laser scanner capable of operating in a dusty environment while also reducing the number of control system inputs. The IDEC SE2L Advanced addressed these issues effectively, operating reliably in dusty environments owing to its built-in amplifier, which distinguishes airborne particles from distant obstacles . Its 270-degree wide-area coverage ensured full protection of the monitored area. Additionally, the SE2L’s Master–Slave functionality allowed most slave scanner signals to be managed by the master, significantly reducing control system inputs. The customer’s challenge: The customer required a reliable presence detection system to safeguard the area around a hydraulic lift-powered frame used to lift large metal plates during their press plate manufacturing process. Their existing solution relied on four competitor laser scanners, which frequently triggered machine shutdowns due to false presence detection and required numerous control system inputs to manage safety zones and area switching. The initial system in place: Our initial site visit focused on understanding the process, identifying the causes of false detections, and exploring opportunities to optimize the overall system which allowed us to accurately define the customer’s requirements. The safety-monitored area measured 9000 × 6500 mm, necessitating four scanners to achieve full 360-degree coverage. The area was mapped and configured with a 600 mm warning zone to slow operations, multiple areas were programmed for area switching, and the system was rigorously tested to confirm complete coverage with no blind spots. The solution we provided: During operation, heavy metal plates were lifted and aligned before pressure or heat was applied to ensure no defects or warping when cured. However, dust and metal shavings released from the plates interfered with the competitor scanners, repeatedly triggering false detection errors and unwanted shutdowns.

4 fundamentals for selecting the best PLC for your needs: take simple steps toward smarter automation

Your system doesn’t need to have the same number of PLC inputs and outputs. That said, if your system has a combination of digital and analog inputs it’s likely to have both digital and analog outputs as well. Common analog output types include: 0-10VDC current signals 0-20mA current signals 4-20mA current signals As with the input signals, the current signal output range can represent different output variables: speed, rpm, degree of opening/closing, etc. The number of I/Os a PLC can provide is important – so is scalability. If you’re considering adding inputs and/or outputs in future, I/O expansion capabilities should factor into your purchasing decision. Use these 4 steps to work out which PLC is best for you Armed with this core information about your system needs, you can put together a basic requirements list for a PLC. It doesn’t need to be complicated: Fundamental What I need Digital inputs 54 Digital outputs 39 Analog inputs 3 Analog outputs 2 Special functions PID control Communication Ethernet, Modbus TCP (Optionally add the required power supply and operating voltage to this list.) You can then focus your search down to PLCs that can meet – or exceed – these requirements. In the case above, the IDEC FC6A MicroSmart Plus PLC would tick all the boxes: Fundamental Needed FC6A MicroSmart Plus PLC Digital inputs 54 Up to 2,060 I/Os , depending on your choice of added FC6A digital/analog I/O modules Digital outputs 39 "" Analog inputs 3 "" Analog outputs 2 "" Special functions PID control YES with simple configuration using WindLDR software Communication Ethernet, Modbus TCP YES (2 Ethernet ports) as well as Modbus RTU, EtherNet/IP, BACnet, and MQTT Sparkplug B It offers a variety of other useful features that you might decide you want or need, such as: Web server functionality Email and text messaging Data logging (SD card slot) Bluetooth and FTP client/server communication options A dedicated iOS/Android app (WindEDIT) PID algorithm With IDEC, selecting your PLC is as easy as ABC IDEC has been developing PLCs and other similar control and safety products for over 50 years. Get more advice from our regional sales team on the best PLC for your needs. Common analog input types and devices include: 0-10V DC current signals 0-20mA current signals 4-20mA current signals Resistance temperature detector (RTD) Thermistor (temperature sensor, current measurement) Thermocouple (temperature sensor) Current signal ranges can be used to represent almost any relevant variable: flow, fill level, temperature, pressure, etc. One input device that can be either digital or analog is the high-speed counter – a common feature in industrial PLC systems. Some inputs (e.g. rapid pulses, machine rotations, items on a production line) have such a high frequency that a standard sensor is unable to count them all or process the results fast enough. High-speed counters are specific, assigned input devices to quickly and precisely measure high-speed input values. Once you know which inputs your system requires, you can start narrowing down PLC options to only those with a suitable number of I/Os. 2. Outputs: using data and logic to take action After receiving and processing data, the PLC sends signals back out to external devices. Digital outputs : simple ON or OFF signals (start/stop, open/closed, etc.). Common examples of digital output devices: Contactors Indicator lights and buzzers Simple valves (fully open or closed) Relays Analog outputs : a variable output signal determined by the PLC’s data processing. Common examples of analog output data: Motor or pump activation Temperature changes (heating or cooling) Speed control Partial opening/closing of valves 3. Special functions: system customization that adds value Some PLCs have built-in functions tailored to specific applications. They make life much easier for users looking for a customized solution. As just some examples, you may decide that you need: High speed counting : as mentioned above, dedicated inputs to count rapid signal pulses from a specific device. PID control : constant monitoring and adjustments for optimization of e.g. fill level, pressure, temperature, etc. Motion control : precise control of motors or actuators to coordinate (synchronize) the movement of machines. Email : settings to send alerts, status updates, and other notifications via the PLC’s Ethernet connection. Web server : the ability to access and view PLC (CPU) data via the web browser on a mobile device. In some cases, the website is predefined and built into the PLC, configurable with dedicated software. Data logging : the ability to record system events with timestamps and user data, stored on either the PLC itself or on an SD card. Recipe handling : management of multiple pre-set instructions and parameters (recipes) that can be loaded and used as required. Other things to think about – not functions, but equally important to your application – are the PLC’s power supply and operating voltage. Whether it runs on AC or DC power, the input/output voltages, and the current ranges will all affect wiring. These factors typically vary by maker, helping you to slim down the field. However you choose to design and build your industrial control system, a programmable logic controller (PLC) is an essential element. But which one? How do you select a PLC in the first place? Numerous manufacturers offer PLCs with different functions and specs to meet various user needs. It’s easy to get lost in (what feels like) endless lists of product codes and datasheets. Finding the right PLC for your system doesn’t have to be a daunting task. At IDEC, we break down the selection process into just 4 simple steps. 4. Communications: how your system devices share their data Effective communication between multiple devices is the backbone of industrial automation systems. The PLC and other devices in your system need to be able to talk to each other in a language they can both understand. As such, communications use standard network protocols. There are several ways to connect your devices, depending on the PLC: Ethernet (one or more ports) Serial ports (RS232C, RS422, RS485) Network protocols via either the Ethernet or serial ports*: e.g. EtherNet/IP, Modbus TCP, Modbus RTU, BACnet, MQTT Sparkplug B, CC-Link IE Field Basic * Some network protocols only work via Ethernet, and some only work via a serial port. Be sure to check this when confirming device compatibility. 1. Inputs: devices that keep the PLC informed A PLC without inputs may as well be a brick. If no devices are connected, the PLC has no data to process. Start by identifying the input devices your system needs – digital, analog, or a mix of both. Digital inputs : typically signals from machine-mounted devices and control panel switches. Common examples of digital input devices: Sensors Switches and pushbuttons Encoders Analog inputs : signals that come from devices that measure variables. Common examples of analog input data: Solid/liquid fill level Liquid pressure and flow Temperature and humidity The position, speed, and distance of an object Other questions to ask yourself: How many communication protocols does my PLC need to support devices in the current system? – ensuring compatibility with all necessary input and output devices is key. Does the PLC need to communicate with another PLC? – some network protocols specifically support PLC-to-PLC communication. Does the PLC offer the flexibility and compatibility needed to expand the system and add additional devices? – if it’s likely that your system will grow and change, scalability is important. Are devices in the system communicating 1-to-1, or are any devices communicating with multiple others? – as an example, RS232 is designed for single point-to-point connections.

End-to-end traceability with RFID automation

Throughout the year, we will share one customer challenge each month and show how IDEC helped resolve it. These real-world use cases demonstrate how our broad portfolio of solutions supports industrial applications. This month, discover how RFID enabled full traceability for a customer’s fuel distribution process.

Workplace safety for older employees: industrial automation and assistance technologies to support and empower workers in physically demanding jobs

The need to take ergonomics and physical limitations into consideration The amount of time someone remains in a physically demanding job can be uncertain. If an older worker postpones their retirement to help train others, a workplace injury caused by overexertion would quickly put them out of action. People change as they get older: it’s a fact of life. This is equally true when it comes to their physical capabilities and their needs as employees over time – even if they remain in the same role for many years. Companies must consider ergonomics and physical limits when trying to create an age-inclusive work environment. Physical changes associated with aging include reduced muscle strength, lower endurance, and limited flexibility. When ergonomics aren’t optimized for the worker, that person will get tired more quickly – leading to a sharp drop in productivity. As part of Industry 4.0 and increased adoption of industrial robots, some advances in automation are helping to support workers rather than replace them. Use Assist Wheel Drive to create a more supportive working environment Transporting heavy loads with AWD significantly reduces physical stress and the risk of muscle strain and other injuries. The EW1A series AWD 150 can help workers move a maximum transferable load of 1,000kg (per wheel). The AWD system’s ergonomics and convenience offer many advantages for companies seeking to retain and support their aging workforce. The direct benefits for employees who use AWD in their work are clear from our customer case studies. You can explore the advantages of the Assist Wheel Drive system in more detail online, then contact your regional IDEC sales team to arrange a demo. The rise of robot workers and industrial automation technologies In jobs that require physical effort, older workers are at higher risk of musculoskeletal disorders and take longer to recover (on average) if injured. Robots and other automated solutions have begun to help automate physical processes in many industries. Repetitive manual tasks, such as picking up materials, moving them, and putting them back down, are relatively simple to program. Industrial robots can lift and carry heavy loads without getting tired or taking a break. They aren’t at the same risk of physical injury or fatigue as humans. Adopting them as part of the workforce feels logical, particularly for businesses and industries where the workforce skews older. A study from 2014 showed that industrial automation in manufacturing was already more common in countries with a higher ratio of workers over 55. Manual labor requires effort and takes a toll on the body at any age. Manufacturing often involves many physical processes and stresses: Standing in one place for a long time Working in a tiring or difficult (e.g. uncomfortable, or painful) position Lifting and carrying heavy loads Pushing, pulling, bending, turning and stretching As the working population gets older, they may not have as much strength or stamina to complete these demanding tasks. This article covers: The realities of an aging workforce in the manufacturing industry The rise of robot workers and industrial automation and assistance technologies The value of the experience and reliability older workers provide The need to take ergonomics and physical limitations into consideration The benefits of Assist Wheel Drive for manual handling of heavy loads Assist Wheel Drive: electric assistance for manual handling For example, the Assist Wheel Drive (AWD) electric-powered wheel system was designed to prevent musculoskeletal disorders. It’s fully compliant with ISO 11228-2 (Ergonomics – Manual handling, part 2: Pushing and pulling). The AWD system can be fitted to existing trolleys that users are already familiar with. After some practice, installation (by 2 people) can take as little as 10 minutes. Once workers are trained to install AWD, they’ll find it even simpler to use. The ergonomic design includes a choice of controller styles for ease of use. Each controller has a thumbwheel, enabling forward and reverse operation with a hand movement – no need to exert any force with the shoulders, back, or hips. The value of the experience and reliability older workers provide The introduction of industrial robots to do physically demanding work has taken literal stress and pressure away from workers. However, that’s been replaced with concerns that robots will eventually eliminate jobs for humans. Collaborative robots are designed to operate safely in the same space as humans. Others can be programmed and trained to do a worker’s entire job on their behalf. In that scenario, a less efficient older worker may be surplus to requirements. However, when humans leave jobs they take learned experience with them. A robot only ‘knows’ what it’s been designed to understand. It may not anticipate or adapt to change as effectively as a human would, or solve problems as quickly. A skills shortage would put manufacturers – as well as other businesses – at risk of economic losses. Companies that are adopting robots on a wider scale need to ensure that the specialist knowledge an employee holds isn’t lost when they leave the workforce. The realities of an aging workforce in the manufacturing industry There are 2 key drivers behind the rising average age of workers in many countries: Global governments increasing the national retirement age Economic (financial) concerns leading people to keep working past the national retirement age Research has suggested that by 2030 , over 25% of workers in major global economies will be 55 or older. That’s roughly 150 million people worldwide – close to the entire working population of the US (as of 2025) . This shift will affect all industries. The effects have been felt in manufacturing for some time already – in the US, over-55s represented nearly a quarter of the industry’s workforce back in 2017. As such, manufacturers are both very aware and very concerned about this trend. Working out what to do in response is a challenge for businesses of all sizes.

The role of data visibility in preventing industrial equipment failures and operational errors (part 2)

The ultimate cause of industrial equipment failure: a lack of accurate data Every cause listed in part 1 has something in common: the amount of information available. Specifically, that the amount of information available isn’t enough to keep equipment in the best possible condition. In manufacturing and other industrial applications, trends shaping new processes and their effectiveness are driven by real-time data. As such, the data that businesses hold must reflect their current situation as accurately as possible. Industries with poor data visibility deal with varied problems: They don’t collect enough data to gain a clear picture of their situation They can’t collect enough data due to data silos and system incompatibility They collect a lot of data but don’t trust the quality (inconsistency/bias) They collect a lot of data but don’t know how to analyze/use it effectively Thankfully, technological advancements (Industry 4.0 developments) continue to simplify data collection and analysis. The Industrial Internet of Things (IIoT) has revolutionized system design, and the ways that connected devices can be used to enhance data sharing and analytics. Alongside IoT-enabled predictive maintenance, cloud computing gives workers the ability to view the latest information remotely. Data visibility: the key to anticipating errors and transforming work processes The most effective decision making is informed by a wealth of reliable data, and supported by tools for accessing, analyzing, and using that data: Real-time status information: improve quality control and prevent failures. High-quality displays: see outputs, trends and anomalies with greater clarity. IIoT-connected devices: understand how efficiently and effectively devices work together in your system. Portable interfaces and controls: respond to changes and make adjustments at any time, even remotely. HG series operator interfaces: for clarity and reporting The slimline bezel on the HG1J and HG2J is designed to maximize the display size. Both screens grant literal high visibility, with high-resolution TFT color LCDs and a glass top surface. The PCAP touchscreen’s tempered glass surface has advantages in industrial settings where displays are physically harder to see: UV resistance, scratch resistance, and easy cleaning. Both units are made for full integration with IIoT-enabled systems, with MQTT cloud communication alongside FTP server/client and web server functions, network protocol support, Ethernet, USB, RS232C, RS422/485, and Wi-Fi (using a dongle). Safety Commander series: for remote operation The HT3P and HT4P securely hold industrial-use tablets of varying sizes. The attached tablet can be positioned horizontally or vertically, and operated comfortably by left-handed or right-handed users. With a connected tablet in hand, workers don’t need to be standing in front of the control panel to view operational data and check work logs. It’s also possible to activate the machine’s emergency stop function while using a tablet, with the Safety Commander’s built-in emergency stop switch. FC6A MicroSmart Plus PLC: for web server functionality The built-in web server provides two-way communication between the PLC and connected computers, tablets, etc. Remote users can view data on custom web pages, easy to create without HTML knowledge using the editing software. The FC6A MicroSmart Plus can also connect to the cloud (AWS IoT Core/Azure IoT Hub) and on-premises servers via the MQTT and MQTT Sparkplug B protocols, act as an FTP client or server for data transfer, or send system update emails and texts via Ethernet. Industrial equipment runs on more than power – machines and their operators need a reliable flow of data. Without it, inefficient processes and uninformed actions can easily lead to equipment failures. The resulting downtime and loss of productivity can cost businesses time, money, and more. In the first part of this series, we looked at the typical causes of equipment failures and operator errors, and the most common factors behind them. In this article, find out more about: The ultimate cause of industrial equipment failures Data visibility to anticipate errors and transform work processes IDEC safety devices that bring added data visibility to industrial systems Use quality, highly visible real-time data to prevent industrial equipment failures and work smarter IDEC’s reliable connected device range adds value in every area of an industrial control system. Discuss data visibility levels and IIoT solutions with your regional IDEC sales team. FT series operator interfaces (PLC + HMI): for control and monitoring The FT1J and FT2J are essentially HG1J and HG2J models with an additional PLC located behind the display. They feature dual CPUs—one dedicated to control functions and the other to HMI functions—to maintain high processing speeds. With a PCAP touchscreen at the front, full IIoT capabilities internally, and a PLC with I/O points at the back, the FT series is an ideal control and monitoring solution for equipment or systems with space constraints. SX8R bus coupler module: for remote I/O systems Take advantage of the SX8R’s support Modbus TCP/IP and EtherNet/IP network protocols to enhance device communication and data sharing. For preventive maintenance, some additional sensors are required to detect equipment failures. If sensors are added, wiring becomes more complex. The SX8R for remote I/O solves this wiring issue, as it can collect all sensor data via just one Ethernet cable. IDEC’s IIoT-enabled and safety-related devices help you bring added data visibility to industrial systems Smart, connected devices in your system work to reduce the risk of industrial equipment failure. The IDEC product lineup makes real-time analytics in industrial automation systems easier to achieve.

The role of data visibility in preventing industrial equipment failures and operational errors (part 1)

Next time: our top tip to reduce industrial equipment failures Depending on the size and scale of your industrial system, checking for these potential issues may mean you have a lot of ground to cover. However, there’s a way to get straight to the core problem – and fix it. In part 2, we’ll look at (what we believe is) the ultimate factor in industrial equipment failures. Typical causes of equipment failure also have common reasons behind them When you investigate a case of industrial equipment failure more closely, you’re likely to find out that one or more of these issues played a part: 4. Too much maintenance You may not think that doing even more to keep a machine in ideal condition is a bad thing. However, when that equipment is already well maintained and in good working order, “over-maintenance” can have the opposite effect. At best, additional maintenance takes time and resources away from other work tasks – at worst, it could shorten the working lifespan of the equipment. 4. Outdated hardware/software Hardware and software updates often contain patches for known issues, security exploits, and other bugs. Updates can also add features that make equipment more efficient and/or versatile. Forgetting to regularly check for and install updates, or leaving longer periods between checks, increases the risk of system errors. 2. Operator error Something as simple as a worker overtightening a screw could accidentally cause equipment to break down. Unintentional changes to an operation routine – skipping or repeating a step, forgetting the right timing, or pressing the wrong button in a moment of panic – could also trigger equipment failures. 2. Lack of knowledge and training ‘Improper operation’ of equipment sounds deliberate – but operator error may not always be on purpose. In many cases, errors are the result of workers not having the training, qualifications and/or information they need. 3. Lack of predictive/preventive maintenance Reactive maintenance – waiting for an issue to occur and then fixing it – is still surprisingly common in many industries. It keeps the complexity and up-front costs of maintenance low, but is only ever a short-term measure against the risks of long-term damage and downtime. Common causes of operational errors and equipment failure Failures can be caused by: 5. Working remotely Some equipment requires constant monitoring for optimization and efficient running. Whenever remote monitoring of HMIs and other data outputs isn’t part of the operation and control system, workers who aren’t on site may not have the latest, most accurate information. As a result, they could make uninformed decisions and/or take unnecessary actions. 3. Electrical failures Issues with unreliable power sources have the potential to severely impact industrial operations. If a circuit is overloaded or a power surge happens, connected sensitive equipment may be damaged beyond repair. Facilities that don’t have safeguards and/or backups in place may also take longer to recover from outages. Every business wants – and needs – to be efficient and productive. Inefficient processes and other hurdles to streamlined operation affect: Costs and time spent Output levels and quality Employee workload and motivation levels Supplier, distributor and customer relationships Equipment failure is a common cause of downtime and lost productivity. According to the International Society of Automation, downtime causes up to a 20% drop in productivity – and most facilities don’t realize how much this costs them, underestimating the total cost of downtime by as much as 300%. To quickly respond to – and ideally prevent – equipment failures, it’s important to understand the many potential causes. In the first article of our 2-part series on industrial data visibility, we’ll cover: Common causes of operational errors and equipment failure The common reasons behind these causes 1. Environmental factors (hot/cold, moisture, dust and dirt, etc.) Factors such as the ambient temperature and the amount of air pollution can increase the wear on machines installed in that space. Some risks remain whether the equipment is running or in storage – for example, in harsh industrial environments where the humidity level is always high. 1. Wear and tear Even if you follow best practices for operation, maintenance and storage, general wear and tear eventually affects all machinery and components. This gradual damage is unavoidable, making wear and tear one of the most common causes of industrial equipment failure.