IDEC Blog

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.

5 environmental factors that don’t bother the IDEC SE2L Advanced safety laser scanner

The new IDEC SE2L Advanced builds on the accuracy and reliability of our safety laser scanner lineup. It’s also more robust in rugged, demanding operating environments than the standard model. Why is a safety laser scanner’s overall environmental resistance important? The scanner’s detection accuracy is vital – not just its ability to sense obstacles in the warning and protection zones, but to detect what is an issue and what isn’t. The SE2L Advanced is designed as a ‘presence sensing device’. That means it can detect when a human: Enters a hazardous area Stands too close to a robot or cobot Steps into the path of a moving AGV/AMR Opens or closes a door It can also be configured to maintain safety levels at workpiece entrances on production lines. Air pollution on and around a safety laser scanner can cause false positives. In the warning zone, a false positive will slow the equipment down – in the protection zone, it’ll bring the equipment to a stop. If a safety laser scanner detects a human in the protection zone and stops the equipment, the equipment can’t be restarted until the human is no longer detected in the zone. If a false positive is the cause, it needs to be removed from the environment before restarting the equipment. This unexpected, repeated downtime is a headache for businesses trying to run efficient operations. It’s better to be safe than sorry, but some users may find that their scanner causes more problems than it solves. The technology used within our SE2L Advanced safety laser scanner has been improved to give it more resilience in harsh (dusty/dirty) environments. As well as reducing the likelihood of false positives, this enhanced build improves the scanner’s durability. The 5 environmental factors that the SE2L Advanced takes in its stride are: A high-performance scanner with optimized safety for harsh environments IDEC has launched the new SE2L Advanced safety laser scanner in several global regions. Visit the product page to learn more, and reach out to discuss how the scanner fits into your industrial safety system. 5. Other SE2L Advanced safety laser scanners You can place 2 scanners facing each other – again, we recommend a 5-degree offset for the best results. The intervals in light sequences emitted by the SE2L Advanced are random, making each scanner immune to mutual interference. The master/slave function allows you to connect up to 4 scanners (3 ‘slave’ scanners to 1 ‘master’ scanner), creating an even wider sensing and protection area around equipment. 4. Ambient light (glare and reflections) Light sources near to the SE2L Advanced have a low impact on device functionality. We’ve tested this with bright LED lighting at close range – scanning and proximity detection were unaffected. The safety laser scanner also performs well in applications where ambient light conditions can fluctuate. We recommend installing the SE2L Advanced with at least a 5-degree angle to nearby light sources for added peace of mind. 2. Dirt (particles and air pollution) The conductive coating on the optical window prevents dirt and other particles from sticking to the scanner. As well as lowering the likelihood of false positives, it makes the scanner body easier to clean. An optional cover bracket (SE9Z-HS2-CM01) is available, to further protection the optical window against accidental damage (bumps, scratches, AGV/AMR collisions, etc.) 1. Dust Fine particles in the air (dust, powder, wood shavings, etc.) have a much lower impact on the scanner’s sensing capabilities. This is a significant advantage in harsh environments that produce large amounts of airborne waste, such as: Paper mills and wood processing plants Welding factories Machining factories Food and packaging lines 3. Water (moisture and other liquids) High levels of moisture in the environment, such as fog and mist sprays, can pose the risk of affecting not just sensing effectiveness but device electricals and other internal components. The SE2L Advanced can be operated and stored at up to 95% relative humidity (no condensation). Its improved sensing performance lessens the impact of airborne moisture on detection accuracy. (Please note that the SE2L Advanced is not suitable for outdoor use.)

A spotlight on robust and reliable industrial LED lighting (featuring the IDEC LF3D ‘Rugged’ series)

1. Visibility It’s the most obvious requirement for industrial lights – workers need to be able to see what they’re doing. Poor lighting and patchy light distribution are also common causes of workplace accidents and injuries. LEDs are often significantly brighter than light bulbs with a filament. LED lights have contributed to advances and revolutions in industrial settings over the years, and this progress shows no signs of stopping. In Japan, for example, production, import and export of all fluorescent lamps will be banned by the end of 2027. The US similarly banned the production and sale of incandescent light bulbs in August 2023, alongside other countries which have gradually implemented legislation to phase them out. In response, manufacturers and industry groups have pushed for LEDs to replace them – in shops, in offices, and on factory floors. LED lights have been widely adopted in homes and businesses globally. Compared to traditional fluorescent lighting, LEDs have a longer lifespan, lower energy consumption and carbon emissions, and offer color and brightness options. Further advances in industrial LED lighting: the IDEC LF3D series The LF3D LUMIFA LED light series has been a reliable option in IDEC’s industrial lighting range since 2021. The series claims robust construction and excellent optical performance. 4. Safety Most of the power fluorescent bulbs use is converted into heat. This makes them more temperature-sensitive in both hot and cold working environments. Overheating or sudden exposure to cold are just as likely to break the bulb’s fragile glass. LED lights have a much wider operating temperature range in comparison. 5. Energy efficiency that helps to keep running costs down The expected light source life for the LF3D’s LEDs is 50,000 hours (based on continuous use at a minimum of 70% brightness). At the rated power of 9.2W (at the rated voltage of 24V DC), the LF3D would use a little over 0.2kWh in a 24-hour period. 3. Durability In an industrial environment, every surface can come under stresses – from water and other liquids, air pollution, airborne scrap materials, machining noise and chatter, high temperatures, etc. Where impacts, vibrations and shocks might crack or shatter glass bulbs, LEDs typically remain unaffected and reliable. 3. Our most rugged and durable industrial LED lights yet LF3D series lights are made with reinforced glass, stainless steel, die-cast zinc, and aluminum. The secure housing helps to prevent damage from flying waste scraps, etc. In addition, the series has an IP67G/IP69K protection rating for water and oil resistance. Cleaning with high-pressure washdowns is convenient and straightforward. Manufacturers are switched on to the many benefits of LEDs for industrial lighting Industrial lighting solutions must meet multiple demands at once – providing a light source is only the start. We’ve chosen 5 key considerations to highlight: LF3D rugged series: a user-friendly, uniform lighting solution The IDEC LF3D series is available in all IDEC global regions. View the full range and find out more. 4. Safe operation across a wide temperature range All LF3D series units have an operating temperature range from -30°C to +55°C (no freezing). 1. Even higher visibility Our unique optical technology and LED arrangement ensures illuminance (up to 1800 lux) and even light distribution. It suppresses reflections and shadows, making any scratches, chatter marks and uneven surfaces easy to spot. 5. Efficiency When you look at power consumption, wasted energy, carbon emissions, etc., LEDs are one of the most efficient and cost-effective lighting solutions available. They convert more of the energy they use into light than fluorescent bulbs and other alternatives do. 2. Adaptability Space constraints (for example, inside machine tools) can limit the available lighting options. If lights don’t fit, or are too tricky to install, they can’t be used. A single LED can be far more compact than a light bulb. More lights can be installed in the same amount of space, and in a more effective, creative layout. 2. Adapted for use in machine tools and other compact work areas The LF3D is slim and light, available with either a surface mount or recessed mount to meet the constraints of the installation space. It’s also been designed to fit more LEDs onto the surface area.

Stay ahead in food production safety: the IDEC KW2D RFID reader for precise worker traceability and accurate data logs

When you think of ‘traceability’ in food supply chains and production, you may think of the food itself. People want to know where their food comes from, and the journey that it took to reach their plate. If you work in food production, you’ll also want key information about the workers who helped that journey happen. There are food safety risks at every stage of the supply chain. As food products move along conveyor belts and between processing facilities, inspections and quality controls help to prevent defects and other issues. Under many food safety regulations, keeping comprehensive records of these checks and inspections is mandatory. The global food manufacturing industry is under constant pressure to maintain the highest levels of safety and hygiene, and to comply with laws and regulations. RFID systems – such as the IDEC KW2D – offer a centralized, real-time solution for worker traceability and record keeping. IDEC supports the food production industry with safety and security solutions The IDEC KW2D RFID reader has both the features needed for inspection history management and for reliable use in food production environments: Easy installation : designed for mounting on metal surfaces Dedicated software : easily adjust tag and reader settings Credential control : customize up to 500 tags with up to 255 authorization levels Visible/audible feedback : white/green/red LEDs and a buzzer Added authentication layer : recognizes IDEC tags Ethernet connectivity : for use with touch panel HMIs and PLCs IP65/IP67 rating : highly resistant to water, dust, and oil Find out more about the KW2D here on the IDEC website. How RFID supports worker traceability and inspection history management To register their work history, employees simply hold their ID card or keyfob up to the reader. Every time the RFID reader detects a tag, it registers the UID, the holder’s authority level, and the verification result. When used to create inspection history logs during food production processes, RFID system records can show you: When an inspection took place Who carried out the inspection How long the work took to complete (start and finish times) The number of days since the previous inspection Whether more than 1 inspection took place on the same day Whether anyone else attempted to access the area/equipment These time-stamped records can be transmitted to a host controller. Digital records have the added benefit of bridging physical gaps between work locations and different stages of the production process. With data collected and transmitted almost instantly, everyone has the latest information at any given time. Safety, quality, and traceability levels can be increased across all work sites. RFID systems and their applications in manufacturing: the basics RFID stands for ‘radio-frequency identification’. RFID readers send out an electromagnetic pulse (radio waves) to identify nearby RFID tags. The radio wave frequency often used for RFID tags embedded in keyfobs and contactless cards – common access methods at factories, warehouses and other manufacturing facilities – is 13.56MHz. Every tag has a unique ID code (UID), which is set during production. Tags contain other identifying data, such as the holder’s name and authority level, which can be set and changed using software. In industrial settings, RFID systems can be used to efficiently record and manage: Entry/exit times (start/finish times) Access to areas and equipment Use of tools and materials Operational restrictions (user authority) Settings changes Inspection history etc. Added worker visibility in environments that demand protective equipment In many industries, including food production, inspections must be carried out by a “qualified person” – a formally named representative, and/or someone with recognized qualifications. As such, workers with the authority to inspect certain items need to be uniquely identifiable. Using biometrics and other facial/visual recognition can be difficult in food production facilities. Workers must wear protective equipment such as face masks, hair nets, goggles and gloves. This equipment is essential for food hygiene – but also makes traditional identification methods, such as checking ID cards, ineffective. In these situations, manufacturers need another way to be sure the appropriate person has done the necessary work. RFID tag data is separate to the holder’s appearance – workers can easily be identified even when fully covered. The identifying data includes the holder’s authority level, so the RFID reader can instantly confirm that person’s credentials on detecting the tag. This also enables user-specific customization of control options on a connected HMI display.

Illuminated emergency stop switches on teaching pendants: the future of industrial safety looks even brighter

Updates to safety standards also mean new ways to ensure compliance The specifications for e-stops to meet the requirements of ISO 13850:2015 are: “4.1.12: The emergency stop function shall be available and operational at all times . 4.3.6: The actuator of the emergency stop device shall be coloured RED . As far as a background exists behind the actuator and as far as it is practicable, the background shall be coloured YELLOW.” For the emergency stop function on portable operator control systems: “4.3.8: When emergency stop devices are installed on detachable or cableless operator control stations (e.g. pluggable portable teaching pendants), at least one emergency stop device shall be permanently available (e.g. in a fixed position) on the machine. In addition, at least one of the following measures shall be applied to avoid confusion between active and inactive emergency stop devices: device colour changing through illumination of the active emergency stop device; automatic (self-actuating) covering of inactive emergency stop devices; where this is not practicable, manually-applied covering may be used, provided that the cover remains attached to the operator control stations; provision of proper storage for detached or cableless operator control stations.” Up to now, emergency stop buttons haven’t used color illumination to indicate the active/inactive status. When users need to make it clear that the emergency stop function is inactive, they’ve often had to cover the switch or keep it stored in an appropriate location. IDEC’s XA/XW series of short body emergency stop switches offer a new type of illumination that complies with the requirements of ISO 13850:2015. They make it easy to determine the emergency stop function’s status based on the illumination: not lit up (off) when inactive, and lit up (on) when active. They also meet the requirements for an emergency stop, as they turn red when lit up (on). Teaching pendants and e-stops: long established as a reliable combination The e-stop has been an essential safety feature for industrial robot teaching pendants (also known as teach pendants) for many years. Even if the switch is rarely used, it’s important – and reassuring – for the operator to have one easily accessible at all times. This reliability has stayed true as teaching pendants have evolved: from wired devices to lightweight tablets with touchscreens and wireless communication. The importance of emergency stop switches hasn’t changed – that said, they have similarly moved with the times. As automated equipment continues to become smaller, the need for e-stop functionality is being met by a trend towards ever smaller solutions. The revised ISO 13850:2015 standards uphold the importance of the emergency stop switch, while incorporating market changes. What makes this illuminated emergency stop switch, which complies with ISO 13850, a logical safety step? According to the requirements, the emergency stop function “shall be available and operational at all times” to meet safety standards. In addition, ISO 13850 includes a measure to indicate the active/inactive status of the switch by changing the color of the lighting. However, conventional e-stops with illumination are only partially lit up. The light may be harder to see as a result. If you want to use the color of the lighting to distinguish between active/inactive status, if the unit handle color is originally red then it is harder to determine whether the emergency stop is active or inactive. This means it is not easy to see if the unit is lit when indicating an active status. The switch handle on IDEC’s new XA/XW series illuminated e-stop is fully lit up whenever the function is active. If the button is not lit up in red, you immediately know it is not available or operational. The status can be confirmed from further away, from more angles, and in work environments with lower or minimum lighting. When mounted on a teaching pendant, an e-stop that lights up can support operators who are concentrating on other work processes. In other words, a teaching pendant equipped with IDEC's illuminated e-stop can clearly indicate a machine failure to you before an unexpected situation occurs. IDEC continues to lead the way with bright ideas and safety innovations Illuminated models are options in the IDEC XA and XW emergency stop switch lineups (white body with a red light, or red body with a red light). The newest XA series illuminated switches are fitted on the IDEC HT3P and HT4P Safety Commander tablet holders with built-in safety functions. On Safety Commander tablet holders, the switch is positioned for easy access with either hand. It visually and physically stands out from the other optional buttons and switches available. IDEC’s illuminated e-stop switches maintain the space-saving design, reverse energy structure, lock/opening mechanisms, and environmental protection ratings that users expect. The combination of a teaching pendant with an illuminated emergency stop switch is still relatively rare. You can explore this possibility with IDEC products and solutions right now. Would you take a robot teaching pendant without an emergency stop button inside a safety fence where a robot is working? No, you wouldn’t. If the robot malfunctions or the operator is put in a dangerous situation, the emergency stop (e-stop) function can save their life and prevent damage and injury.

New product release: IDEC 4.3” HG1J IIoT-ready PCAP HMI for an intuitive touch interface

Empower your connectivity with IIoT technology In manufacturing systems, HMIs and other devices need to not only display data but also enable seamless data sharing across networks. The HG1J and HG2J offer IoT functionality, multiple connection ports, and support for open network protocols. With two USB-A ports, these HMIs support flash drives for data logging, recipes, program transfers, and dongles for speakers or Wi-Fi. The embedded Ethernet port provides easy access for remote maintenance, while Modbus TCP/IP, BACnet IP, EtherNet/IP, and MQTT protocols enable connectivity with other intelligent devices. These connections allow the HMIs to function as gateways between the work site and the cloud. Once connected, the HG1J and HG2J can read data from other system devices and send it to cloud storage. Built-in RS232C and RS422/485 serial communication ports with Modbus RTU support let the HG1J and HG2J communicate with other serial PLCs or devices, such as barcode readers and temperature controllers. A comparison of the HG1J and HG2J HG1J : Compact 4.3-inch display TFT color LCD (16.77 million colors) 32 levels of brightness adjustment Operating temperature range: -20 to +55℃ Available in black and silver HG2J : Sleek 7.0-inch display TFT color LCD (65,536 colors) 48 levels of brightness adjustment Operating temperature range: -20 to +60℃ Available in black Seamless remote monitoring and control with Wi-Fi enabled HMI solutions System-wide communication is crucial to keep production lines and processes running smoothly. However, not every device in a manufacturing system is always on site or connected by control panel wiring. Wireless connections help bridge the gaps between facilities and remote equipment. By plugging a Wi-Fi dongle into the USB port, users gain wireless connectivity. In addition, the web server function enables device information to be remotely viewed on a PC or tablet. Operators can now monitor and control equipment without needing to be physically present. Data and controls are also accessible via a dedicated app. Many communication options are available for users to create automation and IIoT solutions. They can easily incorporate multiple industrial protocols, the FTP protocol, remote monitoring and control, email/text messaging, Twitter/X, iOS and Android apps, and custom web pages. Smart manufacturing calls for intelligent devices. Industrial equipment operators rely on HMIs that work with them – not just for them – to boost efficiency and productivity. A critical aspect of interface usability is display 'visibility'. Thoughtful placement and clarity are essential for effective control panel layouts. Devices must also be resilient in harsh conditions, adaptable across diverse work environments, and dependable for unmanned operations. To meet these varied demands, IDEC introduced the HG2J PCAP touchscreen operator interface. Now, the more compact HG1J HMI joins the lineup. A robust and durable HMI with an expansive, clear display The projected capacitive (PCAP) HMI combines a compact size with powerful functionality – ideal for space-limited applications. Its design maximizes display area while keeping a minimal footprint. The PCAP display is water- and scratch-resistant, highly responsive, and resists false signals from dirt or water droplets on the surface. The durable glass top design ensures long life, with a backlight rated for 50,000 hours, and requires minimal maintenance. It passed a 1kg steel ball drop test from 60cm (with protective film) without damage, demonstrating resilience against rough handling, harsh conditions, and water sprays. The HMI also supports multi-touch with thin glove compatibility. The tempered glass prevents UV clouding for lasting clarity, and the touch panel's lack of moving parts minimizes wear. The HG1J and HG2J are built to last, with a 3-year warranty. They also have ratings for extreme temperatures (-20 to 55˚C), IP66 and IP67 for washdowns, IP66F and IP67F for oil resistance, and UL61010, UL Type 4X/13, and Class I Div 2 for safety. Both HMIs are ideal for diverse applications and environments. Learn more about the HG1J and HG2J here on the IDEC website Contact your local IDEC team for specific advice on HMIs and tailored solutions.

Functionality and compliance, fully integrated: Safety Wheel Drive’s 5 key features to ensure the safety of AGVs and AMRs

When it comes to industrial automation, any product whose name starts with ‘Safety’ needs to live up to high expectations. Safety Wheel Drive (SWD) is a turnkey solution for OEMs and industrial machine integrators seeking an easier way to build safe, reliable motion control into AGVs/AMRs. The all-in-one design incorporates the components and safety functions needed to meet both comprehensive international safety requirements and highly specific mobile robotics needs. In this article, we take a closer look at SWD’s advanced built-in safety functions: what they’re designed for, how they’re activated, and what happens after activation to ensure safe operation. Safety Wheel Drive: a solution that lives up to its name Safety Wheel Drive enables AGV/AMR designers to embed advanced safety functions into their build, without any additional components or effort. Explore the many other benefits of Safety Wheel Drive here on the IDEC website. Safe Brake Control (SBC): safe braking engagement Safety level : up to SIL2, PLd, Safety Category 3 SBC is commonly used to control external (mechanical) brakes, especially when the motor is off but still bearing a load (e.g. a hanging weight). SWD offers 2 engine braking modes for added support: internal motor braking and external braking. The internal brake essentially works by short-circuiting the motor. The external brake works by cutting power to the electromechanical brake. SBC often works in combination with STO. In SWD’s configuration, the STO function can be triggered with or without SBC. Safely Limited Speed (SLS, SLSa): safe speed limitation Safety level : up to SIL2, PLd, Safety Category 3 SLS prevents the drive (the motor) from going over a pre-set target speed. Exceeding this speed triggers the safety function, activating and maintaining deceleration until the AGV/AMR reaches the target speed again. The SLS function continues to monitor the AGV/AMR’s speed to make sure it stays at the target level. SWD has 8 levels of SLS speed limitation, so up to 8 different speed limits can be monitored at the same time. Speeds can be limited in both rotation directions (forward/reverse) in a symmetrical (SLS) or asymmetrical (SLSa) way. If SLS is active and the motor’s rotation speed exceeds the set threshold, STO may be automatically triggered. Safety requirements applied to mobile robotics AGVs/AMRs made for use in collaborative work environments must be equipped with essential safety functions. These requirements are guided by ISO 3691-4 (Industrial trucks – Safety requirements and verification, part 4: Driverless industrial trucks and their systems). ISO 3691-4 is a relatively recent standard, published in response to how industrial mobile robots’ capabilities have evolved. It specifies requirements for all of these safety measures: Speed and direction control Speed monitoring and limitation Obstacle detection Braking system Emergency stop SWD’s certified safety functions are used to achieve safe motor control and support AGV/AMR designers in meeting current safety requirements. These functions can be split into 2 categories: Safe motor shutdown and brake functions : Safe Torque Off, Safe Brake Control Safe speed supervision functions : Safe Direction, Safely Limited Speed, Safe Maximum Speed SWD, in combination with other safety devices (such as the IDEC SE2L Advanced safety laser scanner), contributes to the safe operation of AGVs/AMRs with tailored motion and safety management. Each safety function is triggered automatically when a hazardous condition or other specific event is detected: Detection : sensors monitor the environment. As an example, a safety laser scanner sends safety signals to the safety controller built into SWD. Monitoring : the safety controller monitors whether a dangerous condition has been reached (e.g. the AGV/AMR is moving too quickly, or the AGV/AMR’s movements are abnormal). Action : the safety function is triggered. This Detection > Monitoring > Action process chain enables mobile robots to maintain a consistently high level of safety and protection. Safe Maximum Speed (SMS): maximum speed limitation independent of activated safety functions Safety level : up to SIL2, PLd, Safety Category 3 SMS is the only safety function that’s always active if enabled by the configuration. It’s activated if a maximum speed threshold is set for the AGV/AMR. (This is different to the target speed(s) that can be set with SLS.) If the user doesn’t specify a maximum speed when configuring SWD, SMS will remain inactive (disabled as a result of the configuration). SWD users can set maximum positive and negative velocity commands – negative velocity referring to travel in the opposite direction than intended. The AGV/AMR’s velocity (speed) is constantly monitored. If the maximum speed is exceeded while SMS is active, the default response is to trigger STO. Safe Torque Off (STO): safe disconnection of motor torque Safety level : up to SIL3, PLe, Safety Category 4 STO is seen as a safe way to stop the motor operation, a basic requirement for drive-based functional safety in mobile robots. It can be activated by a variety of safety devices and inputs to SWD, including emergency stop switches or a safety relay/safety controller. Connected emergency stop switches must be compliant with ISO 13850. Once STO is engaged, the motor is disconnected electrically. In this way, STO prevents any more torque (force) from being generated within the motor. This slows the AGV/AMR down, but doesn’t activate the braking function – deceleration speed is affected by the mobile robot’s inertia, so it coasts to a stop. Safe Direction Control (SDI): safe control of direction of rotation Safety level : up to SIL2, PLd, Safety Category 3 SDI activation is based on commands that can prohibit rotation of the motor in either direction. This is designed to prevent the AGV/AMR from moving in an unintended direction – for example, toward a worker. Similarly to SMS, SDI has positive and negative thresholds that represent the AGV/AMR’s forward or reverse motion. With SWD, it’s possible to set 2 threshold levels for positive movement and 2 for negative. When a threshold for the direction of movement is exceeded, SDI activates and prevents further motor rotation. If SDI is active and the motor’s rotation speed exceeds the set threshold, this condition can also automatically trigger STO. 5 advanced safety functions that streamline design, certification, and use These integrated functions remove any need for additional safety monitoring devices and safety logics when using SWD as part of an AGV/AMR build.

Safety Wheel Drive: disruptive electric wheel drive technology for integration with autonomous mobile robots

In logistics and other collaborative spaces (where humans and industrial robots work together), the adoption of autonomous mobile robots (AMRs) and automatic guided vehicles (AGVs) continues to increase. The safety requirements for AMRs and AGVs are comprehensive – they need to be, to reduce the risk of collisions, other accidents, and injuries. Under the ISO 3691-4 international safety standard, driverless industrial vehicles and their systems must have the following safety functions: Speed control Speed detection and limitation Human presence detection Braking system Emergency stop function AGV/AMR designers must keep up with both the current safety requirements for mobile robots and the rapid evolution of industrial automation technologies. There are a lot of yellow crates in that video, but did you spot the bright yellow wheel? That’s our Safety Wheel Drive electric wheel. The Safety Wheel Drive (SWD) system is an all-in-one solution for safe operation and controls, combining the following parts in a compact build: Wheel Gearbox Motor Safety encoder Safe motion control There’s no longer a need to source these different components from several manufacturers, or to spend extra time verifying their functionality and compatibility. In this way, SWD streamlines the AGV/AMR design process – reducing the number of build components needed by up to 50%. The ‘plug and play’ architecture is reassuringly simple, unique and innovative enough to lead the way in the evolution of mobile robot design. At the time of writing, no other equivalent self-contained solution is available in the US. Build a flexible, reliable AGV/AMR with fewer components, in less time Here’s a video of a mobile robot in action at one of our production facilities: Compatible with IDEC safety devices for customized AGV/AMR solutions Using other IDEC safety products in combination with Safety Wheel Drive further simplifies compliance with ISO 3691-4. SE2L Advanced safety laser scanner : the obstacle detection function can engage speed control and limitation. The SWD’s many safe motion monitoring functions can be spread out across scanner detection zones. XA/XW emergency stop switches : emergency stop function. Short body and 16mm diameter options fit easily onto smaller AGVs/AMRs. HK2H/HK2L safety edge switches : detection of human/obstacle presence in the mobile robot’s path. The HK series’ R80 (80mm) bend radius makes installation on AGVs/AMRs simpler, and takes up less space. SWD’s versatility and the variety of combinations offer suitability for numerous industrial applications. As AGVs and AMRs become a more common site on factory floors, at logistics facilities and on production lines, more custom solutions will be needed to build mobile robots for specific purposes and situations. Safety Wheel Drive product video Essential functionality for safe operations, included as standard The SWD’s built-in safety features include: Safe Torque Off (STO) – motor disconnection when a stop is requested Safely Limited Speed (SLS, SLSa) – to prevent hazardous situations Safe Maximum Speed (SMS) – to secure operating range Safe Brake Control (SBC) – to ensure a standstill Safe Direction Control (SDI) – in case of collision risk Together, they cover the safety requirements needed for compliance with several international safety standards: Safety function required under ISO 3691-4 Minimum Performance Level (PL) required under ISO 13849-1 Applicable SWD safety features Braking system PLb, PLd Safe Brake Control (SBC) Speed control, speed detection and limitation PLc, PLd Safe Maximum Speed (SMS), Safely Limited Speed (SLS) Emergency stop function PLd Safe Torque Off (STO) Detection of human presence in the mobile robot's path PLd Safely Limited Speed (SLS), Safe Direction (SDI), Safe Torque Off (STO) With these integrated technologies, the certification process for an AGV/AMR built with SWD is quicker and kept under control. Safety is assured, so designers can concentrate on optimizing the HMI and control elements of each mobile robot. Explore scalable options for simple mobile robot setup There are 2 versions of Safety Wheel Drive to choose from: SWD 125: Designed to move medium-weight loads 125mm diameter wheel Max. vertical load: 250kg Max. speed: 11km/h SWD 150: Designed to move heavier loads 150mm diameter wheel Max. vertical load: 700kg Max. speed: 3.7 km/h Both versions have a shockproof housing with an IP66 rating for electronics protection against dust and water. Your safe, responsive and fully compliant mobile robot build could start with just 2 SWD wheels and a safety laser scanner. Take the first step today – speak with your regional IDEC sales team.