How System Controls Improve Safety and Compliance

New technology improves safety for employees working alongside robots, and reduces downtime for maintenance or troubleshooting.

Control solutions safeguard an increasingly digital footprint within material handling operations. Image courtesy of Bosch Rexroth.

A Q&A with Garrett Wagg, Product Manager – Automation & Electrification, Bosch Rexroth

Safety is paramount in operations, and advanced control solutions are optimizing production, material handling safety and compliance. Based on the risk assessment and application being controlled, a control system with safety features can offer a variety of safe motion options to reduce the risk of injuries and incidents, while also improving productivity.

For example, safe motion allows applications for motion to utilize safe limited speed and positioning functions, rather than stopping. This can improve throughput in material handling operations, and improve safety for employees working alongside robots and automated machinery.

Q What challenges are manufacturers facing with legacy control systems?

Legacy control systems would be lacking in the more updated safety functions and update speeds because of their older processors. Connecting to newer safety devices such as safety sensors via current industrial communications would likely be more challenging. This would ultimately limit production throughput in applications.

Q What are the latest advancements in system controls for material handling applications?

There have been many advancements in system controls for material handling applications. Some of these include AI driven control systems that allow predictive analytics, real time decision making and machine learning procedures for robotics like pick and place robots and autonomous mobile robots (AMRs).

Some other advancements include internet of things (IoT) enabled smart controls that provide real time data and connectivity through the entire facility from the machine level to the server and cloud. This allows for smart tracking of materials and prevents material blockages and optimized material flow. Lastly, safety embedded controls utilizing functional safety features like safe limited speed and safe operating speed allow facilities to safely integrate collaborative robots in their processes without risking the safety of their human workers. These functions like safe stop also allow less downtime during maintenance and troubleshooting.

Q How can new technology bridge the gap to modernize material handling capabilities?

New technology like functional safety add-ons allow for a safer working environment for employees handling material alongside robots and less down time when maintenance or troubleshooting occurs. Vision and AI allow data to be collected and used as a learning tool for faster and more efficient production.

Advanced control solutions like Bosch Rexroth’s ctrlX CORE and ctrlX SAFETY provide end-users with enhanced capabilities compared to traditional controls. Image courtesy of Bosch Rexroth.

Q How are Industry 4.0 and IoT technologies enhancing automation and controls for material handling machinery?

IoT technologies are exponentially enhancing automation and controls in material handling machinery by enabling real time data collection, secure connectivity and intelligent decision-making. IoT sensors track materials and equipment in real time across warehouses and the supply chain. For example, IoT devices can monitor machine health via vibration, temperature, and speed allowing for predictive maintenance. IoT integrated programmable logic controllers (PLCs), gateways, and edge devices can enhance control through supervisory control and data acquisition systems (SCADA) to enable dynamic adjustments at the machine level based on real-time data.

Q Is AI impacting control systems?

Yes, AI is impacting control systems in a multitude of ways. Some of these ways include optimization through algorithms like reinforcement learning that can optimize control parameters in real time. Other ways include predictive and adaptive control based on changing conditions and anomalies. This can lead to fault detection and longer run times. Finally, the integration with AI and IoT leads to smarter warehouses and logistic centers with the large amount of data the AI platform can utilize.

Q Looking ahead, what emerging technologies or trends do you see having the biggest impact on material handling and control systems over the next 5–10 years?

5G, AI, vision systems, and mobile robotics/humanoid robotics are some impactful technologies that are emerging. 5G will enhance IoT connectivity and real time data transfer. This allows vey low latency in the transfer of data and can impact AMRs instantly by helping reroute based on warehouse obstacles and traffic. AI and vision systems will enhance pick and place systems, material transport systems and reduce mishaps in the industry. Enhanced mobile robotics and humanoid robotics will continue to automate once manual processes and allow a warehouse or logistic center to run nonstop and further reduce the risk of injuries and unwanted events at these facilities. WMHS

Garrett Wagg is a product manager at Bosch Rexroth for their Automation & Electrification division. Wagg manages Rexroth’s controls portfolio, including several ctrlX AUTOMATION products. Wagg previously worked as a sales engineer for Elmo Motion Control (a Bosch Company) and has helped companies advance their automation for the last twelve years. Visit: https://www.boschrexroth.com/en/us/