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

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

Get to know the IDEC Group: IDEC Controls India Private Limited

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 #3: a technical support manager who enjoys problem solving and process optimization

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.

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

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

Resilient in harsh environments, from furnaces to freezers: the advantages of industrial equipment with a wide operating temperature range

For many people, the workplace is a temperature-controlled office – or home, where they can adjust the thermostat. For others, it could be: A frosty cold storage warehouse A sunlit, humid greenhouse A hot or cold rolling production line A welding station Temperature plays a vital role in many industrial processes in these environments. Businesses in some industries, such as food or pharmaceuticals, may even be legally required to implement and maintain strict temperature controls for regulatory compliance. As a result, industrial work environments can be significantly hotter or colder than the average office. FT and HG series operator interfaces (FT1J, FT2J, HG1J, HG2J) Operating temperature ranges: FT1J, FT2J, HG1J: -20°C to +55°C (no freezing) HG2J: -20°C to +60°C (no freezing) The UV-resistant tempered glass screen prevents clouding and/or deterioration from UV rays, and has strong heat tolerance (separately to the main unit). All units are ideal for high-exposure applications. CW series touchless switches Operating temperature ranges : -25°C to +55°C (when in use) -35°C to +70°C (when in storage) (no freezing) These switches are made with weather-resistant material, UL Type 4X approved for outdoor use. This feature is ideal in environments that are regularly exposed to the elements, such as parking lots, public restrooms and other outdoor facilities. Higher tolerance to extreme temperatures widens the use possibilities for industrial equipment Various products with high or low temperature tolerance fit the needs of specific use cases. Depending on your application, you may need a more flexible solution. There are many potential advantages of using industrial equipment with a wide operating temperature range. Devices that work effectively in both hot and cold environments can be considered for a greater variety of applications: Medical and pharmaceutical : production processes, sterilization, temperature-controlled storage, etc. Manufacturing and machine tools : hot working and cold working with metals, welding, furnaces, cooling processes, etc. Construction and agriculture : varying climates and indoor/outdoor temperatures Food and packaging : hot and cold processes for both food products and packing materials, refrigerated storage, heat sealing, etc. SX8R bus coupler module Operating temperature range : -25°C to +65°C (no freezing) The SX8R is durable in tough industrial environments and long-distance applications (e.g. outdoors, warehouses, etc.). It can withstand harsh temperatures and rugged conditions, has an IP20 rating for protection against dust, and features enhanced vibration resistance. IDEC’s robust solutions offer safety, reliability, and environmental resistance IDEC’s automation, HMI, and switch/indicator lineups include many products designed and developed for durability in harsh environments. Products with a reassuringly wide operating temperature range include: Increased reliability you can immediately see from the product data The ‘operating temperature range’ is the ambient temperature range at which the equipment works safely, reliably and effectively. You’ll find this information in the product specifications (on the datasheet). A device may still work outside of its stated operating temperature range, but it may not perform at its best. The ambient temperature range in commercial environments is typically narrower than that for industrial environments. As just one example, many commercial devices are not rated for use below 0°C. This difference makes purpose-made industrial components more robust and durable than commercial equivalents by design. Safe, reliable operation when temperatures rise or drop The stated operating temperature range is just one of many wide-ranging benefits of IDEC products. Our devices also fit the needs of industrial users by offering safety, durability, and long-term cost effectiveness. Explore the IDEC product lineup for your region to find many other industrial devices and components with a wide operating temperature range, built to perform in harsh and rugged conditions. Hot or cold, workers always need to be able to trust in devices and equipment Safety and reliability are critical in any climate. Regardless of the temperature, a key safety consideration is for the tools and equipment workers rely on to do their jobs. High temperatures could cause parts to overheat and change shape. Freezing temperatures could crack and shatter fragile materials, or solidify liquids and gels. In both cases, the industrial equipment used in that environment must be resilient and durable in order to avoid downtime, damage, and other safety risks. Choosing equipment with a wide operating temperature range helps to ensure their consistent performance in various working conditions.

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. 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. 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. 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. 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.

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

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

IDEC Engineering Insights #2: a relays and sensors product manager who balances firm foundations with new innovations

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

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

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

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.) 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!'" 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). 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 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 ) 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. 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. 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. Assistance products are a desired solution for transporting heavy loads. However, there are surprisingly few options 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". 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) 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. 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. Assist Wheel Drive can handle heavy loads, and also breaks down fixed mindsets at work sites 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 . 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".

Simplifying safety control logic system design: the IDEC FS1B safety controller

Logic simulation software for testing in a virtual environment Access the online logic simulator via the IDEC website (FS1B product page) for your region. The simulator is simple and user friendly – filter the logics by their safety category and function, then select the most suitable option. Every control logic is available to test. Choose input device types for your system, name them, and toggle them on or off. The simulator can create an example wiring diagram based on the chosen logic and input devices for you to download and print. The flexibility you need for a variety of applications The FS1B’s pre-configured logics are suitable for general applications, and for safety control systems in various industries: Semiconductor manufacturing Original equipment manufacturing (OEM) Food processing and packaging Metalworking AGVs/AMRs Robotics Pharmaceuticals It’s equally as effective in small, medium, and large-scale systems. Using a pre-certified logic in your safety control system simply makes sense The IDEC FS1B safety controller’s key features: No programming knowledge needed 24 pre-programmed safety logics, certified to international safety standards Compliant with IEC 61508, ISO 13849-1, and ISO 13849-2 Monitor up to 6 input devices and up to 4 output devices in a single system No need for program certification, configuration files, or version updates Operating temperature range: -10°C to +55°C Reach out to your IDEC sales team for more details. Clever design: straightforward installation and intuitive information displays As well as the DIP switches, the FS1B is designed with push-in terminals for easy wiring and device connections. It offers universal input device compatibility – each control logic’s safety inputs can be adjusted for different devices. Colored LED status indicators and numerical displays provide key operating information at a glance. The meaning of each display, color and status combination is explained in both the product catalog and user manual. Pre-certification makes system setup quick and simple All of the FS1B’s pre-set safety logics have been certified by a trusted independent body. This pre-certification enhances the overall safety of your system and ensure peace of mind. The safety control logic you choose doesn’t need to be recertified when you add a new safety input device or make other changes. In this way, system and machinery certification processes are streamlined – or completely avoided, saving you time and money. Depending on the application, the safety performance level can be up to SIL 3, PLe, Safety Category 4. At this level, safety control systems are designed so that no one component failing compromises safety, and the system integrity is strong enough to avoid serious incidents. The IDEC FS1B safety controller has launched in several global regions, following an initial release in Japan. It has the practical design, functionality, and options needed to ensure that your control system is fit for purpose and maintains a high level of operational safety. One compact module helps you to build custom safety control systems Establishing a safety control system with multiple devices is challenging. Typical safety circuit designs may need several modules and safety relays to handle inputs from various safety devices. The FS1B has the functionality to combine multiple devices – for example, a safety laser scanner, emergency stop switch, light curtain, etc. – into one safety control system. It comes with 24 built-in safety logics, which can be easily selected using DIP switches and an ‘Enter’ pushbutton on the front of the module. You don’t need a deep knowledge of programming or safety protocols to operate the controller. The switches are also used to set the power off delay timer. The safety control logic options include: Partial stop control Mode switching control Switch and sensor combined control OR control Two-handed control After configuration, secure the safety controller’s protective cover with a marked cable tie to prevent accidental or deliberate setting changes by other users.

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

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