IDEC Blog

IDEC Engineering Insights #6: an engineer dedicated to raising awareness of safety and IDEC products in the China market

IDEC Engineering Insights is a series of interviews with IDEC employees who hold specialized product knowledge. Through this Q&A format, they share some of their professional experience and personal opinions on IDEC products and solutions.

Safety integration in ultra-slim remote controls

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

Behind the ISO 10218 series safety standards updates in 2025: understanding the real-world shifts in industrial robot technology that drove the revisions (article 2 of 2)

Behind the ISO 10218 series safety standards updates in 2025: understanding the real-world shifts in industrial robot technology that drove the revisions (article 1 of 2)

You may know that the ISO 10218 series of international safety standards (ISO 10218-1 and ISO 10218-2) were republished in early 2025 with significant revisions. Those revisions didn’t happen overnight – experts from over 20 countries spent close to 8 years working on the ISO 10218 updates. Our recent white paper on the new ISO 10218 safety standard explains what’s changed and who’s affected – in this series of articles, we’ll go into more detail on why those changes were made. Contents: Technology has changed Industrial robots have changed The requirements for industrial robots have changed The way we use industrial robots has changed The way we talk about industrial robots has changed IDEC is making changes You can read part 2 here . The requirements for industrial robots have changed: the expansion of various robot applications Updates to ISO 10218-1 for 2025 include a robot classification system. This helps users to determine the required level of safety measures when using a specific robot. Industrial robots now fall under Class I or Class II, depending on their “total mass per manipulator”, the “maximum force per manipulator”, and their maximum speed. The safety level for each class is aligned with the risk level of robots in that class. Class I robots , with their lower force and speed, are expected to pose a lower hazard to operators. Class II robots – the majority of industrial robots – are subject to stricter requirements, in line with their wider capabilities and added features. By establishing this functional classification, ISO 10218 sets out safety requirements that match the specific needs of an industrial robot application. Further reading: our next article, and our white paper on ISO 10218 Keen to learn more? Our second article on the ISO 10218 series is ready to read . We do more than just report on changes to international safety standards – IDEC’s history of involvement in standardization spans decades. You can also access our white paper on ISO 10218 revisions . Technology has changed: the world is a very different place ISO 10218 was last revised in 2011, which was a big year for advances in digital technology: Apple launched the iPhone 4S with Siri built in Spotify launched in the US Netflix moved from DVD rentals to streaming We’ve seen other tech products and services from 2011 come and go: Microsoft acquired Skype (shut down in 2025) Amazon launched the Kindle Fire (rebranded in 2013) Google launched Google+ (shut down in 2019) Looking back, it’s hard to believe those events were nearly a decade and a half ago. The general public are likely to be familiar with the above examples. In the world of robotics, advances in sensing technologies have widened industrial robot applications and adoption. Interoperability – the ways industrial robots compatibly work with other robotic parts and systems – has also contributed to an increased focus on cybersecurity measures over the years. Most ISO standards are reviewed every 5 years. It then took roughly 8 years to revise and republish the ISO 10218 series. Why did it take time to update this standard, compared to others? One reason might be that, as shown by key events from 2011 alone, technology evolves quickly. Another possible reason for the experts to take time and care in updating the ISO 10218 series would be the standard’s continued importance in many industries and applications. Industrial robots are widely used on a global scale, more so than other machinery and equipment. The need for robot-related safety standards – comprehensive, accurate standards that reflect current needs and use cases – is higher. Industrial robots have changed: they can do more, and present more risks to humans The ISO 10218 series has 2 parts: ISO 10218-1 : Robotics – Safety requirements, part 1 – Industrial robots ISO 10218-2 : Robotics – Safety requirements, part 2 – Industrial robot applications and robot cells You may see them written as ISO 10218-1:2025 and ISO 10218-2:2025 . Part 1 is aimed at robot manufacturers, with a focus on industrial robot design and construction. Part 2 is aimed at systems integrators and end users, and focuses on how industrial robots are used. The ISO 10218 series of standards is also relevant to the employers of people who work with robots, and to industrial health and safety organizations. Major developments in robotics in recent years have included AI-driven enhancements, IoT (IIoT) integration, and – most significantly – the emergence of industrial robots that can work in harmony with humans. As the ISO Technical Committee for Robotics noted, industrial robots now have greater capabilities to handle collaborative applications. As robot functionality has increased, along with the amount of direct collaboration with human operators, these changes need to be accounted for in safety requirements. When it was time to start reviewing the ISO 10218 series standards and requirements, the working group had a lot of new ground to cover. ISO 10218-2:2025 by itself has 3 times as many pages as the previous version, with significant changes and updates to several sections: Terms and definitions: increased from 2 pages to 15 pages Safety requirements and protective (risk reduction) measures: increased from 28 pages to 50 pages List of significant hazards: increased from 3 pages to 8 pages The additions include many new sections that reflect modern robot capabilities: 4.3.2 : Risk assessment for contacts between moving parts of the robot application and operator(s) 5.2.16 : Cybersecurity 5.3.5 : Local control, remote control, and single point-of-control 5.5 : Safety functions 5.6.4 : Normal stop Annex C (normative) : Safety function performance requirements Annex D (informative) : Required safety function information

Safety-certified presence detection in dust

A monthly newsletter from the IDEC EMEA team. Discover how Safety Laser Scanner enabled safe presence detection in a challenging environment for a European customer’s press plate manufacturing process.

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

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. 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 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. 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 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. 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. 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 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. 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. 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.

End-to-end traceability with RFID automation

A monthly newsletter from the IDEC EMEA team. 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 European customer’s fuel distribution process.

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

IDEC Engineering Insights #5, part 2: Get to know the IDEC Group (APAC)

The IDEC Group has a presence in many global regions. In this Q&A interview format, we share more about specific regions in the words of local employees.

IDEC Engineering Insights #5, part 1: a tech expert who’s witnessed the evolution of our products and solutions

IDEC Engineering Insights is a series of interviews with IDEC employees who hold specialized product knowledge. Through this Q&A format, they share some of their professional experience and personal opinions on IDEC products and solutions.

IDEC Engineering Insights #4: a leader with overwhelming enthusiasm for engineering who inspires the next generation

IDEC Engineering Insights is a series of interviews with IDEC employees who hold specialized product knowledge. Through this Q&A format, they share some of their professional experience and personal opinions on IDEC products and solutions.

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

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. 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. 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. 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. 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). 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 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. 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. 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. 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.