IoT-compatible Equipment and Business Development … Industrial Equipment Systems Co., Ltd. has...
Transcript of IoT-compatible Equipment and Business Development … Industrial Equipment Systems Co., Ltd. has...
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F E A T U R E D A R T I C L E SEnvironmentally Conscious Technology in Industrial Fields Aiming for a Low-carbon Society
1. Introduction
In recent years, the trend in the manufacturing indus-try has been to utilize huge amounts of data to realize smart factories. This is called the Industrial Internet in the USA and Industrie 4.0 in Germany. Both are aimed at realizing smart factories by collecting data from the sites and the external environment, and utilizing the data to perform optimization utilizing operational experience and knowledge.
Production systems and equipment in the manufac-turing industry have become more advanced over the
years through technological innovation. Production systems and equipment undergo advanced control according to large quantities of information, data and various field networks. Recently, information exchange between the supply chain, delivery chain, and factory has started, and the importance of data and information processing technology is increasing.
In one form of smart factory, a large number of busi-ness establishments and companies mutually interact to ultimately provide products and services. These business establishments and companies are connected to each other via a network. Furthermore, connecting suppliers, factories, logistics, and consumers to this network would enable real-time information sharing,
Atsushi ItoMakiko NaemuraNobuhiro TottoriKazuo SatoFumiyuki Tamura
Yoshinori MochizukiMitsuhiro ImaiKazuto Shirane, Dr. EngMasahiro Yamazaki
In the manufacturing industry around the world, industrial equipment is being made IoT-compatible in a move toward the realization of smart factories that utilize massive amounts of data. Hitachi Industrial Equipment Systems Co., Ltd. provides two industrial IoT solutions that collect and utilize data based on the company’s long experience in supplying products to the industrial sector. The first of these is a lifecycle management service that optimizes the operation and maintenance of facilities and equipment. A service that can monitor the status of equipment through the cloud was launched. The other is a programmable automation controller system that optimizes the operational control of production systems, and provision of the HX Series Industrial Controllers for IoT Applications that forms the core has commenced. The HX Series has been applied to the Hitachi Industrial Equipment Systems inverter production line and is accumu-lating know-how on productivity improvement activities. Moving forward, Hitachi will link information between these two industrial IoT solutions to contribute to further optimization.
IoT-compatible Equipment and Business Development for the Industrial Sector
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the creation of data on human work and know-how, and the accumulation and application of know-how and knowledge. As a result, a wide range of decisions can be made quickly in real time in the manufac-turing process and manufacturing can be visualized from individual processes to overall production. Based on this, quality and troubleshooting capabilities are expected to improve, and furthermore, the benefit of being able to accumulate human-dependent know-how as data is expected through utilizing innovative information and communication technology (ICT) (see Figure 1).
2. Industrial IoT Solutions of Hitachi Industrial Equipment Systems
Hitachi Industrial Equipment Systems Co., Ltd. has supplied products to the industrial sector for many years. Based on these achievements, the company has launched initiatives on industrial Internet of Things (IoT) solutions that collect and utilize data and feed back the results in order to respond to expectations for smart factories.
Based on the concept of “can connect, can be con-nected,” Hitachi Industrial Equipment Systems prod-ucts contribute to the realization of smart factories through manufactured items and services.
Specifically, a lifecycle management (LCM) ser-vice and programmable automation controller (PAC) system are introduced below as two industrial IoT solutions that Hitachi Industrial Equipment Systems is working on.
Figure 2 — IoT Cloud Monitoring Service in the LCM ServiceAn outline of the monitoring system configuration is shown. This aggre-gates equipment information on the cloud and makes it available for viewing on the web. This strengthens links between customers and maintenance service networks, leading to the provision of added value.
Network
Confirmation of operation status on the web
User Hitachi Industrial Equipment SystemsService/agentDistributor/maintenance company
Hitachi private cloud
System image
Internet
Tablet PC
Mobile
DB
Web server
Firewall
CompressorInk jetprinter
Mobile network
Figure 1 — Industrial IoT Solution by Hitachi Industrial Equipment SystemsHitachi Industrial Equipment Systems will work on the realization of smart factories via two approaches: optimization of operation and maintenance of facilities and equipment, and optimization of operation and control of production systems.
Optimization of operationand maintenance of facilities and equipment
Enhances operations and maintenance services based on a core of many years of achievements (know-how)
LCM service monitoringProvides high value-added services according to customer needs from the introduction of industrial facilities to after-sales services.
Optimization of operationand control of production systems
Informationlinkage
Integration of control and information and enhancement of automation/drive equipment
Analysis/diagnosis
Management/business planning
Sales/maintenance
Realization of LCMincluding maintenance and leases
Manufacturing
Replacements
Data collection/accumulation
NetworkHitachi private cloud
FirewallWeb server
Safe and securenetwork environment
DBDedicated
line
Air compressor
Mobile network
Measures planningOT x ITKnow-how
Sens
e
Act
Feedback to the site
PAC SystemProvides a new ecosystem applying ICT to the optimization of operations in addition to the advancement of production system control
ThinkAutomationPAC System
Internet
Expansion overseas under consideration
DB: database ICT: information and communication technology IoT: Internet of Things IT: information technology LCM: lifecycle management OT: operational technology PAC: programmable automation controller
PC: personal computer
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The LCM service strengthens operations and main-tenance services based on a core of many years of achievements (know-how) with the aim of optimizing the operation and maintenance of facilities and equip-ment (see Figure 2). An IoT cloud monitoring service is applied to enhance the LCM service. The concept of the LCM service is to provide high value-added services according to customer needs from the intro-duction of industrial facilities to after-sales services.
The PAC system integrates control and information to enhance automation and drive equipment in order to optimize the operation and control of production systems. Various solutions cultivated over the years are applied for this purpose. The concept of the PAC system is to provide a system that applies ICT to the optimization of operations as well as the advancement of production system control.
Hitachi will mutually link these two IoT solutions to contribute to further optimization.
2. 1 LCM ServiceThis section describes the LCM service and IoT cloud monitoring service for equipment at industrial facilities.
The Hitachi Industrial Equipment Group has a full-service network. Using this, the LCM service supports “safe, secure, and stable operations” accord-ing to the customer’s needs from introduction of equipment to after-sales service, and provides high added-value through things such as labor reduction, simplification, efficiency, and optimization.
To realize this LCM service, Hitachi Industrial Equipment Systems launched an IoT cloud monitor-ing service.
Air compressors are one of Hitachi Industrial Equipment Systems’ main product lines. For example, the application of the IoT cloud monitoring service to the LCM service of these air compressors contrib-utes to the realization of one-stop maintenance by enhanced coordination with the maintenance services of retailers and dealers. Data such as discharge tem-perature, current value, and power consumption are gathered in the cloud from the air compressor using a mobile network, and the data can be monitored on a dedicated screen (see Figure 1).
Figure 3 shows the monitoring screen of an air com-pressor. Operation data and graph displays, inspection and fault histories, troubleshooting guides, and other information are prepared so that the operating state of the air compressor can be seen at a glance. In addition
Figure 4 — Conceptual Diagram of PAC SystemThe PAC system is positioned between the produc-tion system and the higher-level system, enabling a seamless connection between the systems. Therefore, an environment can be quickly con-structed for data collection, analysis, determina-tion, and so forth.
Analysis/diagnosis/determination
Heterogeneous system linkage Development of various servicesHigher-level
cloud systemData accumulation
Data collection
Visualization
Information network
Field network
Coexistence of ICT and control
Servo system, inverter, I/O, etc.Various field devices
EtherCAT*
Various industrial machinery/equipment
Field
Visualization
Seam
less
conn
ectio
n
Control execution
PAC system
Figure 3 — Example of Monitoring Service Screen and ReportIn addition to confirming operation data, inspection histories, and other information, it is also possible to output operation reports.
(1) Order online parts from terminals(2) Output forms such as operation
information and monthly reports(3) Status display at a glance(4) Status can be confirmed without
going to the site(5) Preventive maintenance and graph
display for streamlined early investigations of fault causes
(6) Registered terminal mail notification in event of trouble
(7) Cloud maintenance history management due to information sharing
(8) Manual support-type troubleshooting
(1) (2)(3)
(4)
(6)
(8)(5)
Display of compressor operation status
(7)Alarm
activation
I/O: input/output*EtherCAT is a registered trademark of and licensed by Beckhoff Automation GmbH.
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to the monitoring screen, operation reports and the like are also submitted.
2. 2 PAC SystemNext, this section introduces the PAC system, which optimizes the operation and control of production systems. The system realizes manufacturing and ser-vice innovation through application of the IoT. A conceptual diagram of the PAC system is shown in Figure 4.
At the production site, automation and drive equipment controls the machinery and equipment that constitute the production system. The PAC sys-tem focuses on the data and control content handled by the automation/drive equipment, and seamlessly connects the production system to the higher-level systems in the factory or the cloud system.
The features of the PAC system are that it enables the production system control and ICT to coexist, and that it simplifies connection with the host system, which was problematic with conventional systems from an information systems perspective.
These features make it possible to quickly construct an environment for the collection of data and visu-alization of the production site; the accumulation of data in higher-level systems; the analysis, diagnosis, determination, and visualization of the data; and the execution of control based on the analysis results. This enables flexible modifications thereafter.
The accumulated data in the higher system can be linked with heterogeneous systems and developed into various services.
3. Industrial Controllers for IOT Applications HX Series
This section introduces the Industrial Controllers for IoT Applications HX Series, which were developed as the core controllers of the PAC system.
3. 1 PAC SystemThe main point regarding IoT-compliant communica-tions is the enhancement of communication functions and open access. Figure 5 shows a diagram of this.
This includes Object Linking and Embedding (OLE) for Process Control Unified Architecture (OPC UA), File Transfer Protocol (FTP) servers, and simple monitor functions, all of which support ease of connection with the production system from an information systems perspective, as well as Modbus support, which has been used for many years on site, the recently popular EtherCAT support, and motion control that operates above it.
In addition, the HX Series is equipped with Universal Serial Bus (USB) memory, Secure Digital (SD) memory, and three Ethernet ports, integrating control and communication functions and achieving space savings.
3. 2 Application Examples for the HX Series Production SystemHitachi has applied the HX Series to one of its pro-duction lines and used information system functions to commence trials of IoT solutions that support pro-duction improvement activities.
The HX Series was applied to a Hitachi inverter production line, continual improvement processes were established, and support for continuous pro-ductivity improvement activities and accumulation of know-how is being promoted (see Figure 6).
Figure 5 — Feature Functions of the HX SeriesThe HX Series is compatible with many communication methods and saves space by integration of control and communication functions.
Industrie4.0OPC UA*1
Legacy protocolModbus*2
Featured field networkEtherCAT
Motion modelMotion control
Field network
Informationsystem protocol
FTP
IoT ERP MES
Web server
USB memory
Ethernet×3 ports
SD memory cards
Simple monitor
ERP: enterprise resources planning FTP: File Transfer Protocol MES: manufacturing execution system OPC UA: Object Linking and Embedding (OLE) for Process Control Unified Architecture USB: Universal Serial Bus SD: Secure Digital*1 OPC UA is a registered trademark of OPC Foundation.*2 Modbus is a registered trademark of Schneider Electric USA, Inc.
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The HX Series is installed in an automated inverter production line that has been in operation since 2010. The process information is acquired from an existing programmable logic controller (PLC), and data are accumulated on ThingWorx by PTC on the factory-owned servers. By utilizing these data, the operating
status was visualized on the computers or mobile devices of relevant persons in such a way that it could be understood at a glance. In addition, monitoring of the detailed status of the HX Series itself has been made possible along with remote operation of pro-grams and setting changes from the office.
Figure 6 — Examples of Application to Production LinesThe HX Series was applied to a Hitachi inverter production line. Data acquired from the production facility were accumulated on a server. Using these data to visualize the operating status promotes improvement activities at the production site.
PTC* ThingWorx*Inverter production site
Automatic assembly production line
Production technology department
Acquisition of process information from existing PLC
Manufacturingdepartment
Linkage with other system(3) Accumulation
(4) Visualization (5) Remote operation
Higher-levelsystem
(1) Connection of existing equipment
Industrial Controllers for IoT Applications(2) Collection
Figure 7 — Concept and Features of the HX SeriesThe concept is open/global access, high-perfor-mance, and simplicity.
Communicationcontrol
• International standard programming language (IEC 61131-3)
• Industrial open network (EtherCAT)• Industrie 4.0 recommended standard communication
(OPC UA)
• Equipped with soware PLC (CODESYS) to enable motion control
• Communication functions (Ethernet×3 ports, USB 2.0 High Speed)
• Equipped with SD card slot (32 GB maximum)
• Site control by soware PLC, information communication by IP communication (TCP/IP, Web)
• Integration of communication control, motion control, sequence control
• Ethernet×3 ports standard, various field net options
Integrated core control of automatic machinery/production facilities and communications
Motioncontrol
Product concept Integration of controland communications
Security functions
Ethernet×3 ports
Field networks
SD memory slots
Ethernet
Prevention of unauthorized external accessAccess user managementDedicated function library (hidden)
Ethernet
Ethernet
Higher-levelcloud system
OPC UA
Modbus
FL-net
DeviceNet*3
PROFIBUS
Global/open access
High functionality
Simplification
Sequencecontrol
Communications
SequencingMotion
EtherCAT CODESYS*1
PLCopen*2 motion control
PLCopen*2
logic
PLC: programmable logic controller*PTC, ThingWorx are trademarks or registered trademarks of PTC Inc. or its subsidiaries in the U.S. and in other countries.
IEC: International Electrotechnical Commission IP: Internet Protocol TCP: Transmission Control Protocol*1 CODESYS is a registered trademark of 3S-Smart Software Solutions GmbH.*2 PLCopen is a registered trademark of PLCopen.*3 DeviceNet is a trademark of ODVA, Inc.
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The period for adding and launching the HX Series was about two months without stoppage of work done at the factory. Thereafter, the system has been continu-ally used through incorporation into ongoing daily improvement activities at the production site.
A feature of this system is that the existing PLC, which controls the whole production line, utilizes the control data, thereby making a small start toward productivity improvements. Moving forward, the HX Series will be applied to improvement activities for continuous production activities.
3. 3 Features of the HX SeriesAs shown in Figure 7, the HX Series units collect data in the information management field while conduct-ing control in the industrial field. The units utilize the collected data and enable the seamless coordination of control based on the analysis results. As a new indus-trial controller that integrates core control and com-munications for automatic machinery and production facilities, the product integrates communication con-trol, motion control, and sequence control based on the concept of global/open access, high-performance, and simplification.
Regarding global/open access, the HX Series has support for international standard programming lan-guages, EtherCAT, and OPC UA communication. For high performance, the series is equipped with functions that enable motion control, communication control, support for SD cards, and so forth. Regarding
simplification, the on-site control is made into a soft-ware PLC, information communication can be done through Internet Protocol (IP) communication, each control is integrated, and options for various field networks are also supported in addition to three inde-pendent Ethernet connections.
Furthermore, control security measures are imple-mented by means such as prevention of unauthorized access from the outside, management of user access, and hidden display functions for dedicated function libraries.
By way of a linking function with the information field, the HX Series has a function for data visual-ization. Conventionally, a dedicated display device such as a PLC is required to display data, but it has become possible to display graphs and control panel-like displays as shown in Figure 8 in the browser of a handheld personal computer (PC) or mobile device. Concerning the pictures and variables to display in the HX Series, programming software is provided to enable visualization even without a dedicated display unit.
The series is equipped with OPC UA server func-tions for connection with a higher-level system.
OPC UA is a protocol that enables secure and reli-able vendor-independent transmission from a sensor or site level to the manufacturing level, production planning, or enterprise resources planning system.
Conventionally, in the case of constructing a sys-tem using supervisory control and data acquisition (SCADA) or a manufacturing execution system (MES), communication software suitable for use
Figure 8 — Monitoring by Web Browser FunctionData in the HX Series can be displayed without using a dedicated display.
Monitoring by web browser
• Reduction of dedicated terminals for monitoring and operation
• Reduction of burden on on-site staff
• Bar graph by“figure extension/contraction”
• Trend graph by “trace”• Operation instruction using
“operation button”
Benefits
Ethernet
No dedicated display device required
Web Visualization
Generic web browser
Use of mobile devices*
*When combined with a commercially available wireless LAN unit
Equipped with web server function
Example screen creation
Bar chart
Trend graph
LAN: local area network
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into a file [e.g., a comma-separated value (CSV) file]. This file can be retrieved and read out by a PC (see Figure 10). It is also possible to retrieve and write files remotely by FTP operation.
At the Hitachi Industrial Equipment Systems pro-duction line introduced earlier, a CSV file was created from the data collected by the HX Series, the data were viewed using the visualization function, and the system was constructed while ascertaining the situ-ation in detail. An engineer specializing in parallel information systems created a screen to confirm and display data on a desktop PC by FTP operation.
Next, the control programming of the HX series is described (see Figure 11). The HX Series employs
of the PLC was prepared, an OPC server was con-structed on a PC or server, and SCADA or MES software was executed that carries out screen display and operation instructions.
SCADA, MES, and a controller supporting OPC UA eliminate disjointed communications by various companies and enable multi-vendor compatibility (see Figure 9).
The HX Series is equipped with functions that make it easier for information engineers to manage, and SD memory and FTP servers can be used in addition to visualization functions and OPC UA.
A file can be created in the SD memory by using a function block for turning the data in the HX Series
Figure 9 — Multi-vendor Support by OPC UAThe HX Series is equipped with OPC UA server func-tions for connection with higher-level systems. Enables vendor-independent data transmission when connecting with SCADA, MES, or ERP.
Conventional system New trend
Multi-vendor support by OPC UA
• Improved connectivity such as SCADA or MES• Multi-vendor, secure communications
Enables secure, reliable vendor-independent transmission from a sensor or site level to the manufacturing-level, production-planning, or ERP system(Recommended standard communication protocol of Industrie 4.0)
Individual connection for each vendor Connect any vendor
Upper-level communication by international standard OPC UA
OPC UAserver connection
OPC DA client OPC UA client
OPC DA server
SCADA,MES, etc.
OPC
UA
Company Bdriver
Company Adriver
Company Cdriver
Benefits
Built-in OPC UA server
Figure 10 — Data Exchange by SD MemoryThe HX series is compatible with the SD memory commonly used with PCs and other devices. It can be used for exchanging data and can temporarily store data when communication is not possible.
• Save data when communication is disabled• Easy to understand for information engineers
Data exchange with higher level by FTP operation
• SD memory operated by a PC, etc.• File exchange by FTP operation
• Data files manipulated using file operation function block
• Possible to save collected data when communication is disabled
Control data, site dataProduction information, operation data
Field networks
Information engineer
SDCSV
Open
Close
Read
Write
Rename
GetSize
GetTime etc.
Since a file system is supported, it is easy for information engineers to exchange data with the siteData exchange by SD memory
Benefits SD memory and FTP serverOperation by information engineer
Information programming
FTP server function
DI/DO AI/AOPROFIBUSEtherCAT FL-net
DeviceNet
FTP operation
Various interfaces
DA: data access SCADA: supervisory control and data acquisition
AI/AO: analog input/output CSV: comma-separated values DI/DO: digital input/output
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LLC, Everyware Cloud*3 of Eurotech, and others are being trialed, enabling flexible support through open access and expanding the potential of various kinds of connections (see Figure 12).
software called the International Electrotechnical Commission (IEC) 61131-3 Development System CODESYS. There are more than 400 vendors equipped with CODESYS, and tens of thousands of users worldwide.
IEC 61131-3 has five different languages which can be used according to the purpose. Many motion con-trol libraries are provided together with CODESYS. Software development accounts for a large proportion of the cost in system construction, so by adopting IEC 61131-3, software development efficiency for users is enhanced in comparison with vendor-specific programming methods.
3. 4 Linkage with IoT PlatformsThis section describes connections with various infor-mation system IoT platforms.
In addition to ThingWorx of PTC described in the Hitachi production system trial above, connection operations with Axeda of PTC, PI System of OSIsoft,
Figure 11 — IEC 61131-3 Programming SoftwareThe HX Series can be programmed in languages conforming to international standards. Five different languages can be used according to the purpose. Software development efficiency can be improved compared with conventional vendor-specific programming methods.
IEC 61131-3 language features
Five languages selectable according to skill and purpose
• Program visibility (readability)• Optimal language selection according to processing• Improved program reusability• Free design of memory allocation
(address assignment of work memory unnecessary)As machinery and equipment become more complicated and larger in scale, cost reductions and quality improvements depend on so�ware
C-like structured text languageIdeal for applications where LD is weak such as conditional branching
Bit-level processing orientation, such as interlock processing of I/O equivalent to a relay circuit
Mnemonic correspondence
Graphical language good at expressing function-to-function data and signal flow
Flow chart expression suitable for limited expression of process progress
Vendor specific programming
Conception Design
Conception Design
VerificationProgramming Debugging
Debugging Verification
So�ware
Shortening of designto verification
Appliance
Mechanical
Source: PLCopen1970
Main usage conditionsSimple relay sequence processing
Mathematical calculation processing
Continuous analog signal processing
Strict program memory constraints
Performance at highest speed required
Easy-to-understand expression of operation plan and response
Visual check of operations
Symbols: : most suitable; : suitable; : sometimes di�icult; : not suitable
Complex information processing
Sequence restriction based on state transition (step sequence processing)
LD IL ST FBD SFC
0%
50%
100%
1980 1990 2000
Programming
IEC 61131-3-compliant programming
ST
SFC
IL
LD
CODESYS
FBD
Figure 12 — Linkage with the IoT Platforms of Each CompanyThe HX Series can connect with the IoT platform provided by each company.
ThingWorx
AgentAgent OPC UA
CloudCloudCloud
Onpremises
MQTT
PTCAxeda*1
OSIsoft*2
PI System*2Everyware*3
HX series
PTC
IL: instruction list LD: ladder diagram FBD: function block diagram SFC: sequential function chart ST: structured text
MQTT: Message Queuing Telemetry Transport*1 Axeda is a trademark or registered trademark of PTC Inc. or its subsidiaries in
the U.S. and in other countries.*2 OSIsoft and PI System are trademarks or registered trademarks of OSIsoft, LLC.*3 Everyware, Everyware Cloud are trademarks or registered trademarks of
EUROTECH S.p.A.
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For Lumada, connection is being promoted for the operational technology connection part utilizing the HX Series within the Hitachi Group to enable data links to various solutions.
4. Conclusions
This paper described IoT solutions for industrial facilities and IoT-compatible equipment. The LCM service using cloud monitoring for facilities was intro-duced as a solution and the Industrial Controllers for IoT Applications HX Series was explained by way of IoT-compatible equipment. Furthermore, an initia-tive to apply the HX Series to an actual production line and support production improvement activities was described.
AuthorsAtsushi ItoInternet of Things & Life Cycle Management Development Office, Business Operations Group, Hitachi Industrial Equipment Systems Co., Ltd. Current work and research: Development of business utilizing industrial IoT solutions.
Makiko NaemuraInternet of Things & Life Cycle Management Development Office, Business Operations Group, Hitachi Industrial Equipment Systems Co., Ltd. Current work and research: Development of business utilizing industrial IoT solutions.
Nobuhiro TottoriLife Cycle Management Center, Service Division, Solution & Service Management Group, Hitachi Industrial Equipment Systems Co., Ltd. Current work and research: Development of the Life Cycle Management business.
Kazuo SatoBusiness Planning Department, Drive Systems Division, Business Operations Group, Hitachi Industrial Equipment Systems Co., Ltd. Current work and research: Planning of business for drive system products.
Fumiyuki TamuraIndustrial Control Systems Design Department, Drive Systems Division, Business Operations Group, Hitachi Industrial Equipment Systems Co., Ltd. Current work and research: Development of industrial controller for IoT applications.
Yoshinori MochizukiInfrastructure Systems Research Department, Center for Technology Innovation – Systems Engineering, Research and Development Group, Hitachi, Ltd. Current work and research: Research on information and control platforms. Society memberships: The Society of Instrument and Control Engineers.
Mitsuhiro ImaiInfrastructure Systems Research Department, Center for Technology Innovation – Systems Engineering, Research and Development Group, Hitachi, Ltd. Current work and research: Research on information and control platforms.
Kazuto Shirane, Dr. Eng.Information Control Project, R&D Center, Hitachi Industrial Equipment Systems Co., Ltd. Current work and research: Research on information technologies applied to industrial equipment. Society memberships: The Society of Instrument and Control Engineers, and The Robotics Society of Japan.
Masahiro YamazakiInformation Control Project, R&D Center, Hitachi Industrial Equipment Systems Co., Ltd. Current work and research: Research on information technologies applied to industrial equipment.