IDEC Blog

Maximize the efficiency and reliability of your automation system with the IDEC SX8R bus coupler module

Factory automation is intended to help manufacturing processes run more smoothly by nature. Automating manufacturing processes can increase work efficiency and productivity, raise workplace safety levels, mitigate labor shortages, and contribute to sustainable manufacturing activities. To help realize factory automation, an important link in the chain of many remote I/O systems used at manufacturing sites is a bus coupler module. IDEC offers the SX8R bus coupler module: a device that’s compatible with a wide variety of control signals and helps to save space, wiring time, and labor costs. What is the SX8R bus coupler module? We will explain the role of bus coupler modules in factory automation systems in terms of a remote I/O system. I/O modules form the system alongside the main controller, such as a PLC, and act as input/output interfaces for each control device (switches, lamps, sensors, etc.). I/O modules are either housed with the controller (local I/O), or in a different location to the controller and connected via network cables (remote I/O). Local I/O is also known as a centralized system, and remote I/O is also known as a decentralized system. Remote I/O systems are commonly used in a variety of industrial applications, including for automated production lines, food and packaging equipment, machine tools, and logistics. The control devices connected to the system may not all be in the same place – for example, on production lines or in logistics warehouses. Setting up a controller in each location would be inefficient and expensive. Connecting each control device to an I/O module using long cables would be complicated, take up space, and increase the risk of data transmission errors. To build a decentralized remote I/O system, the I/O modules by themselves aren’t enough. Local I/O modules connected to the controller can share data directly. Remote I/O modules send and receive data via a dedicated communication module with network protocol support. This is where the IDEC SX8R bus coupler module comes in. So that I/O modules can transmit data between connected control devices and the controller, the SX8R bus coupler module helps to compile, interpret, and send the control signals. The SX8R is made for factory automation systems that rely on stable communication between a central control system with a controller and the remote I/Os. User-friendly features of the SX8R bus coupler module Where does a remote I/O system fit into your factory automation plans? The SX8R bus coupler module has the compact design and convenience needed in industrial settings. IDEC’s remote I/O system solutions offer control device compatibility, network connectivity, and flexible expansion. IDEC offers the SX8R bus coupler module and the FC6A I/O modules globally. Read through the product catalog and explore your options here on the IDEC website. 3. Simple, flexible installation Installing the SX8R is simple for 2 key reasons: its compact size and the use of push-in terminals. The SX8R can be mounted directly or on a DIN rail, so that it’s ideally positioned within your setup and takes up as little installation space as possible. Wiring time can be reduced by as much as 55% with push-in terminals, compared to wiring screw terminals. There’s no need to loosen and retighten screws with push-in terminals – or to use a screwdriver at all. 2. High level of safety The SX8R bus coupler module and FC6A I/O modules are products that comply with PLC standards (IEC/EN 61131-2), have the CE/UKCA mark, and hold UL/cUL, UL 121201: Class 1 Div 2, and RCM certification. As such, they can be safely used in major global regions. Depending on the location, industry, and operating environment, factory equipment can be exposed to extreme temperatures. The SX8R bus coupler module and the FC6A I/O modules maintain reliable performance in hot and cold environments, with a wide operating temperature range from -25°C to +65°C. 1. Modular design and scalability You can choose from a wide range of I/O modules, with the ability to expand to up to 15 modules. This allows for exceptional customization to meet diverse application needs. The SX8R supports up to 7 I/O modules, and by adding the expansion interface module, an additional 8 modules can be integrated. With a total of 15 modules, the system can handle up to 480 digital I/Os, 120 analog inputs, and 60 analog outputs. This expansion capability provides flexibility in building a remote I/O system tailored to the scale of any automation setup. The SX8R is compatible with over 40 IDEC FC6A MicroSmart PLC I/O modules, supporting a wide range of discrete and analog signals. 5. Easy setup and intuitive operation SX8R Configurator is the dedicated settings software with the SX8R, offered as a free download from IDEC websites. It helps users configure the SX8R’s transmission settings and each module’s operational settings, and enables module status monitoring. The SX8R Configurator program feels intuitive – even for first-time users. Start by using the ‘drag and drop’ function to create a layout of your SX8R and I/O module system. You can then configure each module’s operation via the user-friendly menu options. How the SX8R could simplify industrial automation and remote I/O systems Module configurations and I/O module setting parameters can be saved as project files for use in a future remote I/O system – a time-saving advantage during initial setup. Once the system is operational, you can use SX8R Configurator to carry out monitoring and diagnostics remotely. Information about each I/O module (on/off status for digital I/O modules, current values, set values and error information for analog I/O modules) can also be viewed remotely. If an error occurs, having data on the error type and a proposed solution can reduce the amount of system downtime. 4. Network compatibility and device communication Enjoy support for EtherNet/IP (adapter), Modbus TCP (server), and CC-Link IE Basic (slave station), the leading networks for industrial use. Using these communication protocols, you can build a remote I/O system with a PLC or controller. As the SX8R is compatible with multiple protocols, you can connect a controller (PLC) and a monitoring device (HMI) to the SX8R at the same time. (Note: simultaneous connection of EtherNet/IP and CC-Link IE Basic is not possible.)

New product release: IDEC FT1J controller with operator interface

Compare the IDEC FT1J and FT2J on the IDEC website To discover how the FT1J and FT2J controllers with operator interface could meet your specific needs, please get in touch with your local IDEC team. IoT connectivity, seamless integration and communication The FT1J’s compact design delivers powerful functionality with advanced IoT connectivity. At its core is a dual-CPU configuration, unlike similar products that rely on a single CPU for both HMI and control functions. By dedicating one CPU to HMI operations and the other to control tasks, the FT1J and FT2J achieve high-speed processing and rapid response times. The unit comes with up to 14 onboard I/O points, expandable to 22 I/O points to suit various application needs. Built-in analog inputs and outputs allow for seamless integration with complex control systems. Designed to handle advanced control functions, the FT1J includes PID control, Pulse Width Modulation (PWM), high-speed inputs, and script programming – offering the flexibility to address a wide range of automation challenges. For data logging, recipes, and program transfers, two USB-A ports support flash drives, and additional dongles enable features like speakers, Wi-Fi, and Bluetooth. The embedded Ethernet port allows easy access for remote maintenance and communication, while the unit supports multiple protocols – Modbus TCP/IP, BACnet IP, EtherNet/IP, and MQTT – for connectivity with other intelligent devices. Additionally, built-in RS232C and RS422/485 serial ports support Modbus RTU, enabling communication with serial PLCs or devices such as barcode readers and temperature controllers. All configuration for both the PLC and HMI is managed through IDEC’s intuitive WindOI-NV4 software, which offers a drag-and-drop interface and a comprehensive image library. Projects can be converted across different HMI sizes within seconds. Features such as script programming, PID loop control, PWM control, multilingual support, security settings, trend charts, data and alarm logs are fully integrated for both the PLC and HMI. With a unified program file that supports both, users can efficiently manage their automation projects. Tempered glass for clarity, durability, and environmental protection Both the FT1J and FT2J models feature a projected capacitive (PCAP) reinforced glass touchscreen, offering a robust and modern alternative to traditional analog resistive touchscreens. PCAP glass panels remain relatively uncommon in operator interfaces, making this design choice a significant advantage for the FT1J and FT2J in terms of both physical and environmental durability. These units are designed to operate reliably across a wide temperature range of -20 to +55°C. In harsh environments, where the interface may be exposed to constant UV light, the reinforced glass prevents clouding, ensuring long-lasting clarity. Additionally, the glass top has an IP66F/IP67F rating, providing superior protection against water, oil, dirt, and dust – making both models ideal for use in challenging, messy, or wet environments. With no moving parts, the touch panel avoids mechanical wear over time, delivering consistent performance regardless of how hard it is pressed. In fact, the FT2J’s screen, equipped with a protective film, successfully passed a drop test involving a 1kg steel ball dropped from a height of 60 cm, demonstrating its toughness. This high level of external protection ensures the device's internal components continue to perform optimally, maximizing the overall reliability of the FT1J and FT2J in demanding applications. Sleek design that minimizes installation space and maximizes the display area Are industrial control panels shrinking? Some reports suggest this 'downsizing' trend is a noticeable outcome of Industry 4.0. More accurately, modern control panels are being engineered to save space. Optimized and intuitive layouts not only enhance operational efficiency, but also future-proof systems. The first step in creating a space-efficient control panel is streamlined device installation. The FT1J’s depth is nearly half that of a separate PLC and HMI, making it much easier to fit into tight spaces. Additionally, the detachable push-in terminal blocks simplify and accelerate wiring. Wherever the operator interface is placed on the panel, it must display information clearly without obstructing access to other controls. The FT2J, with its already compact 7.0-inch width, set the standard. The 4.3-inch FT1J display features 16 million colors and 32 levels of brightness adjustment, delivering vibrant visuals and customizable clarity for any environment. Both units provide ample display space to give operators a complete view of their data. The slim bezel maximizes the panel's surface area, allowing as much information as possible to be displayed on screen. Which PLC + HMI to choose? A comparison of the FT1J and FT2J FT1J : Compact 4.3-inch display Approx. 1/2 the depth of a separate PLC and HMI (53.5mm) Up to 22 I/O points (analog and digital) TFT color LCD (16.77 million colors) 32 levels of brightness adjustment Weight: approx. 300g FT2J : Immersive 7.0-inch display Approx. 1/3 the depth of a separate PLC and HMI (35.3mm) Up to 30 I/O points (analog and digital) TFT color LCD (65,536 colors) 48 levels of brightness adjustment Weight: approx. 600g As Industry 4.0 continues to drive innovations in manufacturing, PLCs and HMIs in industrial settings must adapt to meet diverse user demands. Control is just one aspect. Interfaces must also save space, reduce energy consumption and costs, perform reliably in harsh environments, and provide the necessary connectivity for remote operation, monitoring, and maintenance. IDEC introduced the FT2J controller with an operator interface to help customers address these challenges. Now, the product line is expanding with the release of the FT1J PLC + HMI, offering an all-in-one automation solution in an even more compact design.

IDEC SE2L Advanced: the compact safety laser scanner to enhance your AGVs/AMRs

A new AGV/AMR solution from IDEC: the SE2L Advanced safety laser scanner The IDEC SE2L Advanced is a compact safety laser scanner with a 270-degree sensing range. A single unit can protect a wide area – the scanner has a 5m protection zone and a 30m warning zone. It’s also possible to monitor 2 separate areas with the SE2L Advanced’s dual protection function, replacing up to 2 light curtains. The scanner’s reference monitoring function can detect sensing area boundaries and position changes, such as whether a nearby door is open or closed. In shared working spaces, maintaining safe operations involves collaboration Think of a safety laser scanner as the ‘eyes’ of an AGV/AMR. As ‘automated’ and ‘autonomous’ devices, AGVs and AMRs are made to work independently. However, in environments where humans are also working nearby, an AGV/AMR needs full awareness of its surroundings and the ability to safely navigate shared spaces. When mounted on an AGV or AMR, a safety laser scanner has 2 key functions: Presence detection : sensing nearby humans and obstacles Collision prevention : slowing or stopping the AGV/AMR The combination of a warning zone and a protection zone around the scanner gives the AGV or AMR more time to slow down, change direction, or come to a stop. As such, the integration and position of a safety laser scanner on an AGV/AMR are key. Getting it wrong could leave ‘blind spots’ in the sensing area, which are both dangerous and harder/more expensive to cover after the fact. A long history of innovations in automation and sensing AGVs and AMRs have existed in various forms since the 1950s. The introduction of safety scanners to help position and guide them was in the 1970s. Both AGVs/AMRs and safety laser scanners have continued to evolve since then. Laser scanners aren’t the only safety sensing device – light curtains and safety mats also detect humans in hazardous areas. Even so, scanners are popular for use with AGVs/AMRs because of their small size, wide sensing range, and flexible customization options. Advances that keep collaborative safety moving in the right direction The IDEC SE2L Advanced safety laser scanner is designed to contribute to the evolution of wireless AGVs/AMRs. It’s available in global regions now. Enhanced capabilities that widen the scope of potential sensing applications Increased functionality ensures that the SE2L Advanced is a highly suitable safety laser scanner for use with AGVs and AMRs. Enhanced environmental resistance : reduce false positives in harsh environments (presence detection errors caused by dust, smoke, etc.) Enhanced Ethernet connectivity : connect to the AGV/AMR’s Ethernet access point to enable Wi-Fi communication with a PC. A maximum of 128 area pattern configurations : easily adjust the settings to suit the AGV/AMR’s operating environment. Master/slave function : connect up to 4 SE2L Advanced units (1 master unit and 3 slave units) mounted on the same AGV/AMR to create a 360-degree sensing range. Additional encoder input : 4 encoder inputs for 2-axis monitoring (left and right, as well as forwards and backwards). Speed-based sensing area switching : activates while the AGV/AMR the scanner is mounted on is turning. Hardware improvements : the SE2L Advanced in turn increases the AGV/AMR’s navigating accuracy. Obstacle detection : the scanner also transmits distance measurement data via the Ethernet port, while maintaining safety protection. Compatibility with other IDEC safety devices : building a custom AGV or AMR with fully integrated safety features is simpler than ever. Both automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) need sensing capabilities to safely navigate their surroundings. AGVs rely on guidance systems, which are steadily getting more sophisticated. AMRs constantly survey the area around them to learn more about their working environment. In each case, a safety laser scanner does more than just enhance sensing – it’s a vital element of AGV/AMR safety systems.

How ISO-compliant equipment, devices and systems enhance and assure long-term industrial safety (part 2)

1. Effects of automation The ISO notes that, as part of Industry 4.0, the number of machines that can outperform humans at specific tasks is rapidly increasing. Factory automation solutions are advancing at the fastest pace in recent history. ISO standards for automation may need to be revised more frequently to keep up. Long-term studies and forecasts of this evolution note that automation will eventually create just as many jobs as it replaces, if not more. Safety compliance is integral to this cultural shift. Manufacturing sites will need workers with specialist technical skills to manage and troubleshoot their new automated systems. Relevant ISO standards: ISO/TR 23087 (Automation systems and integration – The Big Picture of standards) ISO 3691-4 (Industrial trucks – Safety requirements and verification, Part 4: Driverless industrial trucks and their systems) Safety is a top priority in every industry. In manufacturing, achieving relevant certifications and maintaining compliance with international safety standards is a competitive advantage, with positive impacts on and off the factory floor. Safety standards set by the International Organization for Standardization (ISO) protect manufacturing facilities and workers worldwide. Compliance with ISO standards improves workplace security, efficiency, and health and safety. In the first article in our series on ISO safety standards, we explained how these guidelines became the global benchmarks for compliance. The next step is to look at the future influence ISO standards will have, as industrial safety systems and technologies continue to change with the times. In this article: The 5 safety compliance trends and considerations that will transform industries 1. Effects of automation 2. Robotics 3. Internet of Things (IoT) 4. Ethics of technology (AI) 5. Data privacy and cybersecurity IDEC’s continued work to ensure ISO safety standard compliance IDEC continues to work to ensure ISO safety standard compliance The ISO sets clear benchmarks for industrial safety that businesses worldwide need to meet. The many advantages of ISO compliance in the workplace go beyond health and safety, including enhanced data security, increased manufacturing efficiency, and a competitive edge in global expansion. The IDEC Group has departments and teams dedicated to international standardization and compliance in the industrial sector, constantly working to innovate and improve. In 2024 IDEC was recognized at Japan’s Ministry of Economy, Trade and Industry (METI) Industrial Standardization Awards, with the Minister of Economy, Trade and Industry’s Commendation. We received the award as an organization that substantially contributes to international standardization and leverages it to create new markets and solve social issues. We publish details about ISO standards that apply in industrial settings on our regional websites, so you can learn more about international safety standards and compliance. Safety compliance trends and considerations that will transform industries As there are tens of thousands of ISO standards, multiple standards apply to each industry. When existing standards are revised and new ones are introduced, businesses must respond accordingly. ISO looked at the future of standardization and compliance in 2022. It identified 15 ‘drivers of change’ – areas where societal and technological advances will further increase the need for global safety standards and guidelines. Of those 15 ‘drivers of change’, we’ve listed 5 that will continue to affect safety requirements in industrial applications: 4. Ethics of technology (AI) For AI-related ISO standards to remain relevant on a global level, countries need to agree on ethical frameworks for using AI. According to the ISO and other sources, global agreements on ethical uses of AI will affect business automation systems, AGVs/AMRs, cobot training, and predictive maintenance. This includes deciding when it would be unethical not to use AI. For example, in the healthcare and pharmaceutical industries, AI technology with the power to accelerate medical developments could save lives. The real-world impacts of AI, LLMs and other advanced technology make the decision more complicated. Relevant ISO standards: ISO/IEC TR 5469 (Artificial intelligence – Functional safety and AI systems) ISO/IEC AWI TS 22440 series (Artificial intelligence – Functional safety and AI systems) 2. Robotics The ISO singles out the automotive industry as a sector that will lead increases and advances in the use of industrial robots. Changes in the automotive industry will affect both input and output. Robots can quickly increase production and efficiency levels at manufacturing sites. The safe use of industrial robots is comprehensively covered by multiple ISO standards. The adoption of collaborative robots – a type of industrial robot designed to work alongside humans – has rapidly grown in recent years. So that these robots can safely operate in close range of workers, maintaining compliance with international standards for human safety is becoming a greater challenge for many companies. Relevant ISO standards: ISO 10218 series (Robots and robotic devices – Safety requirements for industrial robots) ISO/TS 15066 (Robots and robotic devices – Collaborative robots) ISO/TR 20218 series (Robotics – Safety design for industrial robot systems) 3. Internet of Things (IoT) In 2022, experts predicted that an average Internet user would interact with IoT-connected devices nearly 4,900 times every day by 2025. This includes IoT in the workplace – also known as the Industrial Internet of Things (IIoT). A typical IoT-enabled industrial safety system includes safety input devices, relays, a PLC or other host device, and safety output devices. Systems can be highly customized, including devices with wide-ranging capabilities. Japan was first to propose an international standard for IoT system lifecycle processes, one that covers IoT products and services: ISO 30147 (see below). Before looking at ISO standards related to individual devices, businesses should start with the guidance for effectively integrating an industrial IoT system. A fully researched, well implemented system is easier to maintain, audit, adapt and enhance in response to changing requirements. Relevant ISO standards: ISO/IEC 30147 (Information technology – Internet of things – Methodology for trustworthiness of IoT system/service) ISO/IEC 21823 series (Internet of Things (IoT) – Interoperability for IoT systems) ISO/IEC 30162 (Internet of Things (IoT) – Compatibility requirements and model for devices within industrial IoT systems) ISO/IEC 30165 (Internet of Things (IoT) – Real-time IoT framework) 5. Data privacy and cybersecurity There are concerns that the Internet of Things (IoT), safety sensors, and devices designed to collect and transmit data could all negatively affect personal privacy. This is an issue that businesses handling personal data on connected devices need to consider. As one example, RFID readers grant workers access to facilities, areas and equipment based on customized authorization data. Data security is already paramount in every industry. Businesses with water-tight personal data privacy policies enjoy higher levels of consumer trust and respect – privacy protection is now a competitive advantage. Gaining the same level of trust from employees enhances workplace well-being. This has the added effect of improving worker focus and productivity levels, driven by their strong peace of mind. Relevant ISO standards: ISO/TR 22100-4 (Safety of machinery – Relationship with ISO 12100, part 4: Guidance to machinery manufacturers for consideration of related IT-security (cyber security) aspects)

How ISO-compliant equipment, devices and systems enhance and assure long-term industrial safety (part 1)

Strategically using our ISO compliance to achieve safety, security, and well-being IDEC has a dedicated International Standardization & Collaborative Safety Department. We actively contribute to the international standard creation process, from initial proposals to final decisions. We take part in the development of ISO standards for industrial robots, AGVs/AMRs, and other relevant industry applications, as well as machine safety and functional safety. We are also involved in proposing and formulating international standards for Collaborative Safety – which we see as the next generation of safety. Through this work and more, IDEC aims to achieve safety, ANSHIN, and well-being for people around the world. (ANSHIN denotes a sense of trust and assurance without any fear or stress. Well-being is a concept that denotes that individuals are in good physical, mental, and social condition, where one’s rights and self-actualization are realized.) Manufacturers who focus on safety compliance, international standards and certification aren’t just doing it for show. There are wide-ranging advantages of ISO compliance at every stage of the manufacturing process. Ensuring operational compliance and worker safety is vital for businesses to meet regulatory requirements and industry benchmarks. For those in charge of maintaining compliance levels, it can also be seen as a moral responsibility. International safety standards, set by independent regulatory bodies such as the International Organization for Standardization (ISO), provide robust frameworks and clear guidelines for businesses to follow. In the first part of this 2-part series, learn more about the history of the ISO and how global safety standards have changed with the times. We also provide some insights into how important ISO-compliant equipment can be in industrial settings. In this article: ISO standards and their lasting positive impact on industrial safety The wide-ranging benefits of using ISO-compliant equipment The challenges involved in meeting global safety standards Examples of IDEC products that meet specific ISO safety standards How IDEC strategically uses ISO compliance to achieve safety, security, and well-being The challenges involved in meeting global safety standards The first hurdle in meeting an ISO safety standard is correctly understanding the requirements. ISO ensures that its standards are worded to be easily understood by all. Key technical terms are defined at the start, and the ISO ‘house style’ is based on Plain English. At the same time, standards are comprehensive in their scope. Finding the relevant sections and working out what needs to be done can take time. After that, implementation presents other challenges, such as: working with limited time and resources replacement and disposal of non-compliant equipment investments in and installation of compliant equipment employee training and skills development sustaining commitment and motivation levels These efforts are worth it in the long run – it’s important to remember that achieving ISO compliance isn’t a one-time event. ISO standards are worded to encourage businesses to actively monitor and ensure their ongoing compliance levels. ISO standards and their lasting positive impact on industrial safety The ISO was officially formed in 1947 and created its first standard in 1951. ISO safety standards cover almost every aspect of manufacturing, technology, and management. There are over 25,600 standards as of November 2024. New standards are developed by 800+ technical committees and sub-committees. ISO releases updates to standards on a regular basis, to reflect advances in technology and societal changes. For example, ISO 14001 – the first standard for environmental management systems – was released in 1996 in response to concerns about climate change. ISO revised the standard in 2004, and again in 2015. Workplace safety has also come to the forefront over time. Measures to foster a culture of safety in the workplace have grown to encompass more than just physical protection. Employees who know they are always safe and secure in their work environment enjoy better mental health and well-being. The universal acceptance and implementation of international safety standards puts them at the top of the regulation hierarchy. Businesses that comply with certain ISO standards can be certified by a third party, to demonstrate their commitment to safety. In some industries, this could be a contractual or legal requirement. Importantly, ISO compliance and certification are not mandatory for all businesses in every country. However, the global reputation of ISO standards is so strong that non-compliance can damage industry/market competitiveness and consumer confidence. The work needed to comply with ISO safety standards compels businesses to look closely at their current setup and identify weak points and risk factors. Any issues need to be addressed – and once compliance is achieved, it must be maintained. Examples of IDEC products that meet specific ISO safety standards IDEC constantly works to ensure that our products and processes achieve ISO compliance and keep customers safe. IDEC ISO-compliant products include: HT3P and HT4P Safety Commander : ISO 10218-1 (Robots and robotic devices – Safety requirements for industrial robots, Part 1: Robots), ISO 10218-2 (Robots and robotic devices – Safety requirements for industrial robots, Part 2: Robot systems and integration) XA/XW series emergency stop switches : ISO 13850 (Safety of machinery – Emergency stop function – Principles for design) KW2D RFID reader : ISO/IEC 14443 series (Cards and security devices for personal identification – Contactless proximity objects) HR series safety relay modules : ISO 13849 (Safety of machinery – Safety-related parts of control systems) HS series safety interlock switches : ISO 14119 (Safety of machinery – Interlocking devices associated with guards – Principles for design and selection) EW2A (Safety Wheel Drive) : ISO 3691-4 (Industrial trucks – Safety requirements and verification, Part 4: Driverless industrial trucks and their systems) As a company, we also comply with ISO 14001 (Environmental management systems), ISO 9001 (Quality management systems), and ISO 45001 (Occupational health and safety management systems). ISO compliance is the foundation of effective industrial safety systems worldwide ISO is the gold standard for industrial safety. Businesses that comply with ISO standards – and develop products and services that comply with ISO standards – have the reputational advantage needed to compete on a global level. More information about international safety standards, and specific ISO standards, is available on all of our regional IDEC websites. Wide-ranging benefits of using ISO-compliant equipment ISO standards are created to answer a simple question: “What’s the best way to do this?” ISO compliance signals that a business is following best practices for safety, agreed on by experts. When a business meets the requirements outlined by a specific ISO standard, they have achieved ISO compliance in that area. Some standards are universal: quality management, IT security, occupational health and safety, sustainability, etc. Some of them can be applied to equipment and devices, and to systems. If a system contains a technology or function covered by an ISO standard, that part of the system can be assessed and judged as compliant. There are safety standards for pressure-sensitive devices, emergency stop functions, interlocking devices, collaborative robots, AGVs/AMRs, and many other industrial safety devices. Depending on the standard, meeting it can lead to several business advantages: comprehensive risk management improved hygiene and food safety levels increased data security higher operational efficiency fewer workplace accidents and injuries lower pollution and waste levels cost savings

Exploring the benefits of PCAP technology and tempered glass for industrial HMIs

Scratch resistance In general, glass is more resistant to scratches than plastic and polycarbonates. This benefit is often cited by opticians, to help people decide which type of lenses to choose with their new pair of glasses. Tempered glass is resilient enough that scratches are almost always attributed to a manufacturing defect. Industrial applications where tempered glass PCAP touch panels can shine Heavy industries : PCAP touch technology isn’t affected by mechanical deterioration, and reinforced glass is robust in harsh environments. Hot and cold working environments (including outdoor use) : tempered glass can withstand high and low temperatures. Food and packaging : displays can be washed with disinfectant or water sprays to maintain hygiene, without causing accidental ‘touch’ inputs. Agricultural : glass panels left constantly exposed to natural light won’t fog or fade over time. Durable, responsive, highly visible, efficient, and intuitive to use: PCAP touchscreen HMIs can offer you more than meets the eye When PCAP touch displays were introduced with smartphones, they changed the way we interact with our personal devices. They have just as much potential to transform your working environment. UV resistance The glass top on a PCAP touchscreen prevents fogging and discoloration (e.g. turning yellow) caused by long-term exposure to UV rays. IDEC operator interfaces with PCAP technology also claim a wide operating temperature range – up to 60°C for the HG2J, and up to 55°C for the HG1J, FT2J and FT1J. PCAP touchscreen technology: established in some applications, continuing to evolve and advance in others The use of PCAP technology in industrial HMIs has grown in recent years. Many people are familiar with the technology – PCAP displays are how we interact with smartphones, tablets, and other personal touchscreen devices. The ‘capacitive’ element of PCAP touch panels enables them to recognize gestures such as finger swipe directions, and to sense multiple points of contact. The technology also enhances the sensing accuracy and responsiveness of displays. A barrier to entry for older versions of capacitive touchscreens was difficulty of operation when wearing gloves. In food production and other industries with strict hygiene standards, gloves protect both factory workers and the items they handle. Newer PCAP displays work effectively with certain types of gloves. For example, IDEC FT series and HG series operator interfaces – all with a PCAP touch panel – can be used while wearing gloves less than 1.5mm thick. (Note: touchscreen operation with gloves always depends on the glove material and operating environment.) As a result of this and other technological advances, PCAP is now a preferred type of interactive display for industrial use. Easy cleaning Clean workspaces are important for hygiene, efficiency, and employee well-being. When a touch panel is covered in fingerprints, dust, dirt, or all 3, you may also notice issues with device responsiveness. Some touchscreens can’t be cleaned with dry cloths or harsh chemicals. Using the wrong cloth may leave lint and scratches on the display, and using chemicals could damage the device itself. Tempered glass can be cleaned with a water or chemical washdown, or by using a cloth wipe soaked in water, alcohol, or disinfectant. Durability HMIs in work environments are put under literal stress and pressure with every tap on the touchscreen. In high-traffic areas of a facility, this type of repetitive wear and tear on the display’s surface can continue throughout the working day. Compared to untreated glass, tempered glass can be significantly stronger. It’s a more robust material that holds up to heavy use in industrial settings. HMIs used in industrial settings need to be durable, reliable, and easy to maintain. In harsh conditions – extreme temperatures, messy/dirty environments, etc. – a resilient touch panel keeps working effectively. When comparing displays to use in these environments, a HMI with a projected capacitive (PCAP) touch panel and reinforced glass top is often the leading option. Let’s look at why. Tempered glass: tough enough to withstand daily use, environmental factors, and regular washdowns A protective glass layer is a key component of PCAP touch panels. It covers the sensor board and detection wiring, acting as an insulator. Overall, PCAP glass displays have fewer layers than traditional analog resistive plastic film tops. A tempered glass top doesn’t interfere with the touchscreen – in fact, it enhances and protects the display. The many advantages of tempered glass include: Safety Tempered glass is commonly used as safety glass. It doesn’t break easily – in our in-house testing, the FT2J’s glass panel passed a drop test with a 1kg steel ball. (Note: steel ball dropped onto the center of the glass from a height of 60cm. Our in-house test results don’t guarantee real-world performance.) If tempered glass does break, it doesn’t splinter in the same way as standard glass. It crumbles into smaller pieces with dull edges that are less likely to cause damage and harm. Water resistance When water hits a PCAP touchscreen, the size and force of the water droplets could cause accidental ‘touch’ inputs. Moisture on the screen can also reduce the device’s overall sensitivity and responsiveness. IDEC HMIs with PCAP technology and tempered glass are IP66F/IP67F rated for resistance to water, oil, dirt and dust. We tested that resistance to IPX6 and NEMA4 standards, using direct high-power water jets.

Assist Wheel Drive: the electric wheel that helps workers safely transport heavy payloads

The ez-Wheel EW1A Assist Wheel Drive series is designed to improve productivity and efficiency, and to reduce physical stress on workers when transporting heavy loads. A high load capacity makes Assist Wheel Drive electric wheels suitable for transporting heavy parts and equipment. The EW1A-150 wheels can effortlessly move a maximum transferable load of 1,000kg. To help you imagine it, here’s what 1,000kg looks like in various industries: Automotive: between 3 and 7 petrol engines Food and packaging: between 5,000 and 6,000 average-sized apples Logistics: approx. 8,000 square meters of bubble wrap Construction: between 43 and 59 standard concrete blocks Manufacturing: almost 17 meters of rubber conveyor belt (if 1m wide, and 20mm thick) Assist Wheel Drive is fully compliant with ISO 11228-2 (ergonomics – manual handling part 2 – pushing and pulling). The system makes a real difference in work environments where heavy loads need to be transported safely and reliably. Improved ergonomics reduce musculoskeletal injuries in the workplace ISO 11228-2 is an international standard for ergonomics. It contains guidelines and requirements for preventing work-related musculoskeletal disorders (MSDs). Manual handling puts workers at repeated risk of MSDs. As the body’s musculoskeletal system includes the bones, joints and muscles, MSDs include: muscle sprains and strains back injuries bone and joint injuries nerve damage chronic pain conditions Assist Wheel Drive is engineered to prevent musculoskeletal disorders in the workplace, by reducing manual efforts and repetitive strain. The potential positive impact of the system goes beyond individual employees’ health. Lower risk of injury reduces the number of working days lost to sick leave. Overall, workplace productivity could rise by as much as 50%. Workers stay safer when using carts with electric powered wheels to transport heavy loads In many countries and industries, pushing and pulling are common causes of workplace injuries – especially back strain, sprains, and other MSDs. Pulling and pushing heavy payloads can result in other accidents, such as trips, slips and falls. Workers are at risk of injuring their fingers and hands – for example, if their hand is trapped between the trolley and a surface. Trolleys in motion can bump into a worker’s legs or run over their foot. A motorized trolley (with an electric wheel) that is easier to move and control can mitigate all of these risks. The Assist Wheel Drive controller has forward and reverse controls, and a stop button. The trolley’s speed, braking, and other settings can be easily adjusted using the dedicated ez-Config PC software. Improve workplace safety and employee well-being with Assist Wheel Drive Incorporating motorized equipment into manual handling processes can enhance health and safety for workers and reduce work-related injuries. The Assist Wheel Drive all-in-one system is compatible with the trolleys and carts that workers already use. The simple, integrated structure has universal compatibility and is simple to retrofit. Quick and easy access to trolleys powered by electric wheels could transform manual handling processes in your workplace. Set things in motion by learning more about Assist Wheel Drive now. Humans can focus on pushing the payload, not their physical limits When pushing, pulling, lifting or carrying items, the weight of the load is a key consideration. W orkplace health and safety standards in different countries vary. They agree on one thing – setting a fixed weight limit for manual handling is difficult. This is because the amount of weight that a person can safely lift, carry, push or pull depends on: their heights and weight their overall strength and frequency of their efforts their position, stance and posture the amount of friction on the floor how far away from the load they are how far the load needs to be transported, and how long it takes to move As a result, workplace load limits are often based on the amount of force needed to set a load in motion and keep it moving. ISO 11228-2 also defines acceptable force limits for manually handling loads. Electric power assistance via the wheels means less human force is needed to move a payload. Assist Wheel Drive helps workers by cutting the amount of physical effort required by as much as four fifths.

An overview of the IDEC KW2D RFID reader and how it simplifies access management on factory floors

The KW2D’s smart RFID reader technology, in simple terms RFID systems use radio waves set to a certain frequency. For the IDEC KW2D, this is 13.56MHz. Many industries use high frequency 13.56MHz RFID readers – the most common application you may be familiar with is contactless payment cards. IDEC case studies: customers who benefit from access control using RFID The IDEC KW2D RFID reader has repeatedly proven itself as a reliable access management solution. These anonymous case studies come from our international sales teams. IDEC KW2D key features and advantages Manufacturing facilities are also businesses and workplaces. As such, security around sites and equipment must be tightly controlled to prevent unauthorised access and changes by workers or visitors. Traceability – of people and their actions – is essential. Many companies are looking to radio frequency identification (RFID) systems to efficiently manage individual access rights and data logs. In this article, we introduce the IDEC KW2D smart RFID reader. It’s an advanced industrial RFID tag reader with strong connectivity and compatibility. 1. Compact design and easy mounting IDEC provides a wide variety of control panel pushbuttons and switches in the 22mm mounting hole size. The KW2D is also this size, easily and cohesively fitting in with other control panel equipment. As the KW2D is designed for mounting on metal surfaces, you can install it close to machines, access doors and safety fences. The main unit can be fitted with or without the custom holder. Wiring up to the power supply is quick and simple, thanks to the push-in terminals. Security challenges in factories: the human element In some industries, it’s estimated that over 80% of errors, accidents and other security issues at manufacturing sites are caused by humans. Among the many causes of human errors, unauthorized access is a universal concern. Employees and visitors may enter restricted areas – accidentally, or deliberately. Factory workers should know the ins and outs of the access management system at their facility. They should be aware of their authorization level and what they can and can’t do. 3. IP65/IP67 environmental protection rating High water, dust and oil resistance levels keep the KW2D’s authentication functions fast and accurate in harsh industrial environments. The reader can be wiped clean – or washed down with industrial water jets – without affecting the ability to transmit signals and identify tags. Example 1: machine user traceability A customer in the factory automation industry needed more reliable data on who had operated machinery and when. The customer chose the KW2D over competitors after successful product trials. The tests demonstrated how consistently accurate and reliable RFID access control systems can be. RFID readers for higher security and operational efficiency on factory floors The security benefits of using RFID-based access management in the manufacturing industry are reassuringly comprehensive. Protect your factory against unauthorized access, data leaks, property damage, and human errors – all with one automated system. The IDEC KW2D RFID reader, access cards, keyfobs and other accessories are on sale globally. Visit the product page to find out more. 2. Audio/visual alerts The RFID reader’s smart design includes green, red and white LED status indicator lights that are visible from the front and sides. White is used as the ‘standby’ color. As green and red are respectively recognized as the ‘success’ and ‘error’ colors internationally, the reader’s status can be quickly understood by all users. The KW2D also comes with an auxiliary buzzer as standard. The same ‘success’ and ‘error’ statuses can be set as audible feedback, with a different sound for each. The LEDs and buzzer settings are controlled via KW RFID Configurator. Example 2: preventing accidental operation A customer in the semiconductor industry was dealing with severe productivity issues caused by unintentional changes. Some workers were unfamiliar with the equipment, so the number of human errors made on the factory floor was unusually high. In this case, employee education alone didn’t solve the problem. The customer needed an automated access system to eliminate as many opportunities for human error as possible. A major reason behind the customer’s decision to implement KW2D RFID readers was customization. Using the KW RFID Configurator software, security managers can customize up to 500 tags with up to 255 authorization levels. Now, only the site manager has the authority to change settings. RFID readers contribute to building digital records of user activities Work logs and inspection checklists written on paper by hand take more time to record, use more physical storage space, and can be harder to read and understand later. Instead of holding a clipboard and checking off items on a list, workers can hold their ID card over an RFID reader when each process is complete. Data entered on a touch panel is linked to the user who entered it, increasing traceability and accountability. RFID readers help to restrict access to areas, machines, and specific controls With an RFID system, workers who want to operate devices are first checked against an access rights database and authenticated. A KW2D RFID reader is mounted on the machine, and users must present their ID to gain access. Workers don’t need to remember passwords or use a keyboard – access is granted with one tap. RFID readers support individual authorization level settings Any user’s ability to access the system and change settings depends on their authorization level. You can customize and manage employee access using the KW RFID Configurator software. If a user has authorization, the ‘success’ status is indicated with a green LED and/or buzzer sound. A red LED and/or buzzer sound indicates an ‘error’ – an attempt at unauthorized access.

Easily convert your existing trolley into electric power-assisted rolling equipment with ez-Wheel® Assist Wheel Drive

5. Long-term savings (ROI) Depending on the number of trolleys that need to be converted, implementing Assist Wheel Drive may represent an up-front investment. However, the potential cost savings over time are just as much of a benefit as the increased safety and enhanced productivity. In some cases, return on investment could be achieved in less than 12 months. In fast-paced industrial environments, moving materials (especially heavy loads) efficiently from point A to point B is key to success. Manually-powered trolleys are still in widespread use, but aren’t always optimized for ergonomics – adding to workers’ fatigue and limiting their productivity. An innovative solution that’s gaining traction in various industries is Assist Wheel Drive. The all-in-one electric wheel system is designed to be fitted on existing trolleys, instantly transforming them into electric power-assisted rolling material trolleys. Supported by Assist Wheel Drive, factory teams can transport heavy loads more easily, enhance their overall working efficiency, and improve workplace safety. In this article, we explain how rolling equipment can be converted into power-assisted versions with Assist Wheel Drive. Read on to learn more about the technology behind the system, the benefits, practical use cases, and tips for installation. Industry applications where Assist Wheel Drive excels Manufacturing : retrofitting rolling equipment that moves materials between production lines and different stages of the manufacturing process can streamline workflows. Healthcare : the Assist Wheel Drive 160 is specifically designed for use in medical settings. Hospital trolleys and other trolleys used to transport patients and supplies are easy to upgrade – maintaining a high safety level for everyone involved. Pharmaceuticals : turn sterile containers, stainless steel lifting trolleys, pharma rolling material trolleys and more into motorized equipment for smoother transportation. Logistics (retail, etc.) : workers who focus on picking and packing won’t need to spend as much time and effort on the process. Power-assisted trolleys are also easier to push across longer distances (such as warehouse floors). Food and packaging production: in temperature-controlled environments, time is of the essence to prevent hygiene/health risks and waste. Electric wheels keep things moving – forwards or in reverse. Step 4: Make sure workers are comfortable using Assist Wheel Drive The system is made to be user-friendly and reliable – even so, workers who will use Assist Wheel Drive-powered trolleys will benefit from training. Giving employees the opportunity to try the system in a real-world setting and learn the controls in advance will prevent future issues. Step 1: Inspect and assess your equipment first In advance of installing the Assist Wheel Drive system, evaluate your current manual trolley fleet. Identify which ones are regularly used to transport heavy loads, and which ones would function more effectively with electric power assistance. Step 3: Install and test the system The installation process is straightforward. Everything needed to convert standard rolling material trolleys will be provided: the wheel, the controller, cables, buttons and the mounting bracket. Once Assist Wheel Drive is fitted to the equipment, you can start using it immediately. The intuitive controls are simple to learn. See how it works in our installation video (with English subtitles): Use a trolley fitted with Assist Wheel Drive, and you won’t go back to manual handling Assist Wheel Drive is helping manufacturing businesses power ahead with improvements to both their industrial material handling and worker well-being. By retrofitting existing factory trolleys with electric powered wheels, you can improve operational efficiency, protect employees from physical harm, and bring down labor and equipment costs. Are you ready to bring a fleet of electric power-assisted rolling equipment into your manufacturing facility? IDEC offers the Assist Wheel Drive system in several global regions. Step 2: Decide which version of Assist Wheel Drive meets your needs The Assist Wheel Drive 150 is made for industrial applications. It’s the ideal power-assisted wheel on a mobile workstation, factory trolley or other rolling equipment. The Assist Wheel Drive 160 has an IP66 rating – full protection against dust, and strong water resistance. It’s suited to use on food and catering trolleys, as well as gurneys, chairs and beds. Assist Wheel Drive: the fully integrated industrial autonomous wheel Assist Wheel Drive is a clever system that works with you. It acts as a highly effective, flexible parts and material transport solution at distribution centers and warehouses, and in other industrial settings. Assist Wheel Drive is designed to both handle substantial amounts of weight and reduce physical stress on the workers transporting those loads. Electric assistance keeps the movement smooth and steady, reducing the risk of accidents and injury. Once installed, Assist Wheel Drive can support a maximum transferrable load of one ton (depending on the model – keep reading for more details). Fitting Assist Wheel Drive to your rolling equipment: what to think about Top 5 features and benefits of the Assist Wheel Drive system How does Assist Wheel Drive work? The Assist Wheel Drive system is composed of an electric wheel and an ergonomic wired controller. The motor and battery are integrated within the wheel. This space-saving design also protects the parts inside, with reinforced cast iron and a shockproof housing. In the same way as the wheel can be installed on the underside of the rolling equipment, the controller is designed to fit onto the handle. It has an on/off button, forward and reverse controls, and a stop button for braking. 3. Ergonomic and safety benefits Assist Wheel Drive facilitates compliance with the ISO 11228-2 standard for ergonomics (manual handling part 2 – pushing and pulling). The system has been carefully designed to help reduce musculoskeletal disorders in the workplace. 1. Compatibility with existing equipment The ability to fit Assist Wheel Drive to any rolling material trolley you already use is an advantage in many industries. No matter what the equipment is made of – wood, steel, etc. – the electric wheel and controller are simple to install. At most, only minor modifications to the frame of the rolling equipment are needed. There is no reason, or need, to replace parts that are otherwise in good working order. By implementing Assist Wheel Drive, you can avoid the downtime and costs normally associated with replacing equipment. 2. High transferable load limit The two versions of the Assist Wheel Drive system have different load capacities – both are impressive and can meet the demands of various industry applications. The Assist Wheel Drive 150 is designed for industrial environments. Thanks to the cast iron housing, it can support a maximum transferable load of 1,000 kg. The Assist Wheel Drive 160 is built for use in controlled environments and logistics, with a load capacity of 750 kg. 4. Productivity, efficiency, and well-being Heavy loads can be moved more quickly, without rushing or compromising on workers’ safety. As less effort is needed to transport the load, it may require fewer workers to do so – they can then focus on carrying out other tasks. Making the work simpler and safer drastically reduces the chances of someone being injured in the process. Sick days lead to more than just lost productivity: employee motivation levels and their willingness to do the work are equally important.

The power of IoT-enabled PLCs for predictive maintenance

Predictive maintenance: decision-making support based on real-time data The Internet of Things (IoT) is a network of devices that collect and share data. Connected smart devices (e.g. voice-controlled lighting, appliances that can be used remotely, security cameras with motion sensors) are the ‘things’ in the IoT. When used in industry applications, the IoT is also commonly known as the Industrial Internet of Things (IIoT). IoT-based predictive maintenance is more proactive than preventive maintenance. This approach is also driven by data, making greater use of real-time information compared to prescriptive maintenance. The IIoT is ideally placed to bring predictive maintenance to industrial applications. As predictive maintenance depends on the IoT to provide the most accurate data, the PLC must also be compatible with, and connected to, the network. All of this means that a PLC with IoT integration is essential to build the most effective predictive maintenance systems for industrial equipment. Before technological advances, humans had to simply wait and see For a long time, the most common form of equipment maintenance has been corrective maintenance (also called reactive maintenance). In other words: fixing something after it breaks. Downtime, repair costs and lower productivity are unavoidable in these cases. This type of unplanned maintenance is the most costly and time-consuming overall. Investing in the technology needed to perform other types of maintenance – explained below – may be expensive at the outset, but often results in higher long-term ROI. IoT-enabled predictive maintenance: IDEC PLCs make it a reality Unlock the potential of the data that’s already available in your manufacturing system. Explore the IDEC website for more on the FC6A Plus and our other IoT-enabled PLCs. IDEC FC6A Plus: a PLC designed to handle large volumes of IoT data IDEC offers several PLCs with integrated IoT functionality. The FC6A MicroSmart Plus PLC has one of the most comprehensive feature lists: Up to 2,060 I/O points (a maximum of 511 analog I/O points) for connecting devices (when using expansion modules) Unlimited number of I/Os can be configured using the IDEC SX8R bus coupler module MQTT Sparkplug B Dual Ethernet ports , can be configured for FTP server/client communication Data logging via the SD memory card slot Compatible with open network protocols such as EtherNet/IP, Modbus TCP, and BACnet/IP 800kb of program memory (100,000 steps) , over double the data memory capacity of a typical micro PLCWeb server function, reporting and alerts via email The key to unlocking the FC6A Plus’s potential for user-centric predictive maintenance is the built-in WindLDR (Automation Organizer) software. It enables PID controls, custom reports and alerts, with no HTML programming knowledge needed. The role of PLCs in collecting and analyzing data from IoT-connected devices A PLC is the central control hub of many modern manufacturing systems. A PLC in the IoT (or IIoT) becomes one of the most important ‘things’ in the network. Connected devices use sensors to gather data from various equipment: temperature, liquid levels, energy usage, vibration and noise, and other key factors. Once gathered, the available data gives a comprehensive overview of the current state of the equipment. The next step is for the PLC to effectively help the operator to analyze this data and determine when maintenance is needed. Historical data (including failure data) and real-time data are used to precisely estimate the remaining lifespan and future health of the equipment. Operational issues can be identified far enough in advance to mitigate them. This means predictive maintenance is only carried out when genuinely needed (rather than on a fixed schedule), reducing downtime and associated costs. Required maintenance can be flexibly scheduled to minimize the impact on operations and productivity. Preventive maintenance: planned manual servicing on a set schedule As a broad term, preventive maintenance covers several types of proactive work: Usage-based (related to frequency of equipment use) Calendar/time-based (carried out on a pre-set schedule) Manual predictive maintenance (estimated based on equipment condition) Prescriptive maintenance (standardized strategy based on historical data) The schedule and maintenance level are based on the expected condition of the equipment at the time the work is done, not the actual condition. Even so, proactive preventive maintenance is preferable to corrective maintenance. With data collection, automation and other forward-thinking technologies, manual predictive maintenance of industrial equipment can be taken a step further. Factories and other work sites that use industrial machinery rely on equipment maintenance to keep things running smoothly. Each part and component will need servicing at some point – without any maintenance at all, every machine will eventually break down. However, nobody can perfectly predict the future. The frequency and amount of maintenance needed depends on many factors: the equipment type, how long it’s been in use for, overall condition, etc. That’s a lot of information for workers to remember and keep track of. What if your manufacturing system could collect that information, analyze and present it in a way that makes industrial machine maintenance easier? IoT-based predictive maintenance using a PLC could be the answer you’re looking for.

When implementing a smart manufacturing system, an IoT-enabled PLC is the brains behind your operations

Every business wants to work ‘smarter’ to stay competitive in their field. That could mean streamlining their processes, using project management systems, or making the most of automation tools. In industrial settings, a smart manufacturing system can reduce labor costs, improve product quality control, lower the risk of accidents, and prevent wasted energy and resources. These wide-ranging advantages mean that the adoption and use of smart manufacturing is growing rapidly on a global scale. The automotive, food and packaging, semiconductor and construction industries are leading the way, transforming their facilities into ‘smart factories’. The shift towards the smart factory model is led by a familiar piece of equipment: programmable logic controllers (PLCs). They continue to play a vital part in industrial automation, and can support smart manufacturing systems with forward-thinking features. Consider building your smart manufacturing system around an IDEC PLC Even as smart factories evolve, they continue to revolve around PLCs with IoT integration and strong adaptability. Read more about the FC6A Plus and our other IoT-enabled PLCs here on the IDEC website. Instead of OT vs. IT thinking, the IoT (and IIoT) can bring them together Traditional production models rely on operational technology (OT) architecture – human control and monitoring of devices and processes, and of the systems needed to run them. Robots, safety systems, PLCs, lighting controls, programming software, and scientific/technical equipment are all examples of OT. They can all be supported by information technology (IT) – data and cloud application management. Companies may see their IT system as separate to their manufacturing system, only relevant to emails, accounting, and other back-end information processes. However, technological advances mean that IT’s focus on data and OT’s focus on equipment are far more effective when combined. The fusion of OT and IT can create even greater possibilities than ever before, thanks to the Internet of Things (IoT). A network of connected devices sharing data is maybe the best example of how well they work together. The role that the IoT plays in smart manufacturing is to facilitate full system integration. Device compatibility is no longer an issue. Access to real-time information enables more responsive – and even proactive – decision making. What makes a manufacturing system ‘smart’? In the context of Industry 4.0, ‘smart manufacturing’ means using digitalization and modern technologies to make basic manufacturing processes even more efficient. Importantly, those technologies (sensors, data analytics, the IoT and IIoT, robotics, automation, AI, machine learning and more) are built into the system from the start. Other, more traditional manufacturing models have fixed systems that are harder to change and upgrade in response to technological advances. Digital integration is limited as a result, and replacing individual parts of the system is only a temporary solution. How and where a PLC fits into a smart manufacturing system PLCs act as the hubs of modern industrial automation systems. As physical devices, they are central to OT architecture. The latest PLCs can do far more than just control and monitor equipment. They integrate and communicate with other systems, gather data, and provide visualizations and analytics to help operators make key decisions. Of these functions, it can be argued that connectivity and data collection are the most important – to smart manufacturing, to the IoT, and to Industry 4.0 overall. Many devices can now supply large amounts of operating data. The PLC that receives this information has to be able to handle, interpret and display it effectively. A PLC is the brain of a smart manufacturing system, and the Industrial Internet of Things (IIoT) becomes the backbone. The data collected from connected devices is shared throughout the system. The PLC can be programmed to analyze and present this information in the most suitable way for the specific application. IDEC FC6A Plus: an IoT-enabled PLC with numerous smart features IDEC PLCs can provide the integrated IoT functionality needed to implement a smart manufacturing system. As one example, the FC6A MicroSmart Plus PLC has a variety of clever built-in features: Scalability of digital/analog I/O points : up to 2,060 I/O points (up to 511 analog I/O points) (when using expansion modules) IIoT ready : dual Ethernet ports, compatible with open network protocols such as EtherNet/IP, Modbus TCP, and BACnet/IP MQTT Sparkplug B Reliable data handling : more than double the memory capacity of a standard micro PLC E-mail notification : e-mail instruction can be used for alerts when a connected device causes an error The FC6A Plus makes it simple to combine OT (connected devices) and IT (data transfer and management). Over 800kb (100,000 steps) of program memory and fast basic instruction processing and execution speeds ensure reliable responses to user needs and system changes.

How Hitachi Construction Machinery Co., Ltd. uses Assist Wheel Drive to streamline and improve heavy machinery assembly processes (case study)

Assist Wheel Drive can handle heavy loads, and also breaks down fixed mindsets at work sites We asked why the company hadn't switched from conveyor transport to cart transport until now, given the significant improvements that can be achieved by doing so. Hasegawa-san: "Of course, we knew that switching to cart transport would lead to benefits, such as manpower reductions and more effective use of space. However, a cart loaded with parts can weigh close to 600kg. Carrying such heavy loads with human power alone is hard physical work, and difficult to continue doing each day. From a safety perspective, without Assist Wheel Drive these improvements would not have been possible." Matsuzaki-san (Production Reform Promotion Dept., MONOZUKURI Innovation Office) was formerly Hasegawa-san's superior. He discussed the difficulties faced during their search for a solution: "That meant we needed to find an assistance product that could safely transport 600kg, but it was hard to find one that could handle such a heavy load. We even carried out on-site tests, but some products couldn't support the load weight even though it was within the listed specifications. It was really worrying. So I went to an industry event and discovered this Assist Wheel Drive system. It wasn't on sale yet at the time, but I still remember thinking 'this is the one!'" Assistance products are a desired solution for transporting heavy loads. However, there are surprisingly few options The adoption of Assist Wheel Drive prompted a review of the site's work processes, jigs, transportation methods, kitting and packaging, resulting in numerous benefits (explained below). It's easy to understand why "people from other factories visit to see what we've done". To assemble lower rollers of different sizes and weights in the same place on the line, the company previously used a dedicated pallet for each roller type. These pallets were carried by forklifts, supplied to the working side (lower level) of a two-level conveyor. After use, each pallet would be moved to the upper conveyor by a lifter and collected by a forklift. 50 pallets of roller parts for that day's production, which had been prepared at an external warehouse the previous day, were laid out flat next to the assembly area. Eventually, a worker on site noticed the risk of parts falling from the upper conveyor, and contacted the TIPS Promotion Sec. The introduction of Assist Wheel Drive was the catalyst behind these improvements, which have produced numerous benefits. We asked Hasegawa-san about this impact and changes within the company. "This assembly line has been running for close to 50 years, and we've made many improvements to it over time. However, many workers who do repetitive work every day tend to be trapped in fixed mindsets and believe "the way things are is only natural". We hope that, by making improvements that break fixed mindsets in this way, we'll see an increase in requests and insights from workplaces that are free from those mindsets. We wouldn't have achieved these things if we hadn't found Assist Wheel Drive, which is capable of transporting heavy loads. That was thanks to the TIPS Promotion Sec., which carried out a thorough search and came up with this solution. In particular, Assist Wheel Drive does not require any qualifications to operate, unlike forklifts. Being able to transport heavy loads regardless of qualifications, age, gender, or experience is extremely helpful at workplaces such as ours, where many workers handle heavy loads. Moving forward, we are accelerating our efforts to further reduce the amount of heavy physical work." Hasegawa-san is keen to expand on the success of Assist Wheel Drive at the mother factory by introducing it at facilities in Japan and overseas. As Hasegawa-san (TIPS Promotion Sec.) explained as part of the background to Assist Wheel Drive's introduction, Hitachi Construction Machinery's basic philosophy is that "safety and health are all priorities". In fiscal 2024, the company established the Safety & Health/Compliance Group to further strengthen their health and safety management under the direct control of the president. The team carried out a risk assessment, and prioritized hardware-related safety measures. After careful consideration, the company decided to use Assist Wheel Drive to 1) supply parts loaded on a jig to the assembly line and 2) collect the jig afterwards . Assist Wheel Drive (AWD) Assist Wheel Drive can be quickly installed (in appx. 10 minutes by 2 people), and provides immediate electric power assistance to the trolleys you already use. It adds supporting force to push the trolley when transporting heavy objects. The controller is mounted on the trolley handle for easy access. The forward/reverse speed can be adjusted to suit the operating environment. The Assist Wheel Drive 150 series can transport a maximum load of 1,000kg (1 ton), and the Assist Wheel Drive 160 series can transport up to 750kg. TIPS Promotion Sec. TIPS* is a term invented by Hitachi Construction Machinery, used within the company to describe internal activities. It refers to a production method that brings innovation, originality and ingenuity together. Specifically, this department takes up concerns from workers at production sites, determines their importance level, and drives improvement. These activities are wide-ranging, including safety measures, improvements to productivity, reducing work-in-process inventory, and reviews of logistics. * Total Innovative & Inventive Production System: a production method that combines "innovation" with "originality and ingenuity". Safety measures were the catalyst for improvements. The effect was so great that workers from facilities in Japan and overseas visited to see First, we'll discuss the process through which Hitachi Construction Machinery Co., Ltd. adopted Assist Wheel Drive. The Tsuchiura Works facility primarily produces medium-sized hydraulic excavators (10-35 ton load limits). There are 15 models and 300 variations (specifications). Production is carried out from scratch on an assembly line over 100 meters long, with a different excavator built each time. Assist Wheel Drive was introduced as part of the assembly process for the lower rollers, which form part of the undercarriage (for crawler excavators). We are grateful to Hitachi Construction Machinery Co., Ltd. for trusting in the Assist Wheel Drive system and sharing their positive experiences. Thank you for your time and cooperation during the interview and filming. We were also encouraged to learn that Assist Wheel Drive made such a strong impression from the start. We hope that the system continues to strongly support your business activities and reduce the physical burden on workers. Safety measures that led to substantial improvements to parts delivery lines. Safety and efficiency improvements so impressive, "people from other factories visit to see what we've done" An interview with Hitachi Construction Machinery Co., Ltd. employees Hasegawa-san (TIPS Promotion Sec.) and Matsuzaki-san (Production Reform Promotion Dept.) Hitachi Construction Machinery Co., Ltd. is a manufacturer of high-performance hydraulic excavators, wheel loaders, dump trucks, road construction machinery, and other equipment. The company has implemented the Assist Wheel Drive system at their Tsuchiura Works facility. For this case study, we spoke with Hasegawa-san from the TIPS Promotion Sec. and Matsuzaki-san from the Production Reform Promotion Dept. They’ve made significant improvements to parts transportation at Tsuchiura, the company's mother factory. (video has English subtitles) The effects of improvement Disposal of appx. 280 pallets Elimination of pre-picking at external warehouses ( effective manpower reduction: two workers ) (previously, appx. 800 rollers were set on dedicated pallets each day using a crane) No need for transport to return dedicated pallets to an external warehouse (improved loading efficiency using general purpose pallets) Work-in-process inventory reduced from 50 units to two with lineside kitting Products are delivered in their original packaging, reducing the storage space needed for dedicated pallets As a result of the above changes, pallet delivery using forklifts has been halved Improved assembly work efficiency ( effective manpower reduction: 0.5 workers ) Work flow before and after implementation 1. Delivery to upper and lower conveyors With a forklift: 2. Supply of parts 3. Collection of dedicated pallets With Assist Wheel Drive: 1. Supply of parts placed on a jig 2. Collection of jig Company Overview: Hitachi Construction Machinery Co., Ltd. Hitachi Construction Machinery Co., Ltd. is a manufacturer of high-performance hydraulic excavators, wheel loaders, dump trucks, road construction machinery, and other equipment. The company is the third largest construction machinery business in the world, with a strong global reputation built on the diverse product lineup's safety, reliability and durability. Hitachi Construction Machinery has seven production facilities in Japan that work to global standards. They also carry out localized production in the Netherlands, India, Indonesia, China, Canada, and other countries.