i³-Mechatronics (i cube mechatronics) is a solution concept that aims to improve productivity and realize production lines that do not stop, through digital data solutions such as making the production site visible. As steps to realize that concept, we launched two new products that are compatible with MECHATROLINK-4, the open field network that has four times greater transmission efficiency than our previous MECHATROLINK-III. These products were a MECHATROLINK-4 communication command type Σ-7S AC servo drive and one module for the MP3000 series machine controller. These products enable motion control that maximizes system performance, and it also becomes possible to transmit various sensor and motion data to the higher layer without delay, so they contribute to the realization of smart factories.

There was a fall in demand in FY2019 due to the trade friction between the US and China. There were expectations for a recovery of the market in FY2020, but the havoc of the COVID-19 crisis around the world slowed down economic activity overall and resulted in a decline in demand and no market recovery.

There is currently a temporary dip in the demand, but there has been no great change in the actual requirements for automation, which originate from factors such as insufficient working-age population. At the same time, the robotics industry is still very much in development, such as with requirements for human collaborative robots becoming apparent globally, and the demand connected to that development is expected to continue growing. In the Chinese market, the boost from the recovery of the automotive industry has meant that the recovery of the demand for robots has already progressed remarkably. There has also been some concrete recovery in Europe and the US, with some customers moving to capital investment. We can also expect an increase in demand in Japan too, due to factors such as the advancing recovery of business achievements in the automotive industry. Other promising signs include that the value of semiconductor manufacturing equipment sales has recorded a new record high, which has been due to investment for 5G.

Yaskawa will of course work to capture this recovering and increasing demand from now on, and will also advance the development of key products to achieve preparation for new requirements in the market under the thinking of our i³-Mechatronics solution concept.

To realize i³-Mechatronics, we are working on activities to improve the quality of user solutions by increasing the usability of data, particularly process data and status data. As part of that, we will realize a digital twin for the facilities in cell units with our YRM-X controller, which is able to control a cell, gather synchronous data on the equipment and robots, and change the motion based on that data. It will then be important that this leads to the DX (Digital Transformation) of the cell so that there can be overall data coordination in the future. Our aim is to steadily advance our “products” towards this kind of trend.

In another area, we are also advancing the practical use of human collaborative robots, which will likely drive the expansion of applications and new automation. The promotion of automation has garnered more and more attention during the COVID-19 crisis. Human collaborative robots are products that motivate users to introduce automation, and they appeal not only to existing robot users, but also to users who are robot beginners and working on new automation.

We are also promoting the utilization of AI in collaboration with the Yaskawa subsidiary AI Cube Inc.

Conceptual image of a smart factory

We are advancing the development of products that will support the realization of i³-Mechatronics. We have launched a large number of products that respond to the needs of our customers. This includes products such as the MOTOMAN-GP4 high speed handling robot, which has a payload capacity of 4 kg and enhances our lineup of small-sized robots. It also includes the MOTOMAN-PL190 and MOTOMAN-PL320 palletizing robots, which can carry heavier payloads than previous models, have been made easier to use, and are compatible with the YRC1000 controller. We also launched a non-painted MOTOMAN-GP8 for the food industry and the MOTOMAN-MPXL2600 painting robot for general industrial use, and we improved the functions of the HC series of human collaborative robots.

In addition, we expanded our lineup with the development of the SEMISTAR-MU124D series for the handling of semiconductor wafers.

The COVID-19 crisis has brought great changes to the way we work and the various industries have searched for and implemented styles for working from home. Regarding the system engineering work, we used web conferencing systems for design meetings, however we had difficulties with the execution of witnessed inspections, where the customer checks the items produced, and with commissioning to operate plants actually, as this involves business trips and visits to the sites. To overcome this, we had customers check the images of the completed products we distributed from inside the plant, like a television broadcast, so that we could implement the witnessed inspections remotely. For the commissioning, we limited the on-site work to the minimum, such as just the operations that require safety checks. We performed the monitoring and operation of the system equipment we had delivered by connecting it via the Internet to a base station in our company plant. We obtained further information on the situation from IoT equipment such as webcams, and implemented the monitoring and operation remotely.

We also used IoT for the periodic audits for certified factories and achieved the auditing and renewals remotely. If we assume that this COVID-19 crisis will continue for some time, then there will likely be even more occasions when remote action will be required. We want to meet our customers’ needs for timely startup by preparing our IT to establish safer and more efficient methods. Also in production activities, we believe that the move to aim for the working style that prevents the crowds and for the contactless working environment, will be accelerated.

Additionally, we will contribute to improving working style under the COVID-19 crisis, offering the remote operation of production sites and totally automated production line where the 5G communication (available since FY2020) can be utilized.

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  Trial operation implemented remotely (work at Yaskawa)

The Tokyo Olympics have been postponed and the Japanese economy has been impacted by a downturn greater than that after the bankruptcy of Lehman Brothers. However, in the primary materials industry where most of our system electrical products are sold, the spread of COVID-19 infections did not have a particularly significant impact on the FY2020 market conditions. Despite this, the remarkable decline in the number of automobiles sold has impacted various related industries and the steel industry has seen several steel works having to suspend the use of their blast furnaces, which are very symbolic for them. The Chinese economy recovered rapidly in the second half of the fiscal year and the Japanese government is also executing positive economic measures to try to regain some calm, but it seems that the COVID-19 crisis will mean that the economic environment remains unpredictable for some time.

Up until 2019, BCP (Business Continuity Planning) has been concerned as preparation for natural disasters such as unexpected cloud bursts and typhoons based on the policy of strengthening national resilience. In 2020 under the COVID-19 crisis, how to continue business with safety and security was concerned, especially regarding the public infrastructure, which has brought a change in the measures required. For the operation and the provision of services for public infrastructure facilities such as water and sewer services, the “human workers” involved in the running, operation, and maintenance are essential. However, the COVID-19 crisis caused the changes in working style, and in order to prepare for the short of manpower, we strengthened our activities to contribute to BCP with AI technology following the veteran’s know-how which enables the less experienced personnel to operate.

In January 2020, the Japanese government formulated its “Environment Innovation Strategy” for the realization of a decarbonized society. It contained five fields as major development themes and the “Energy transformation” field was given as the first pillar for the innovation. It was stated that “Renewable energy will be made a main power source by drastic improvement to the efficiency and cost reduction of photovoltaic (PV) systems with innovative materials and structures.” As power conditioners are a key component of photovoltaic systems, this situation has led to demands for them to contribute to system cost reduction in the segments of high voltage for industrial use and extra-high voltage for power generation companies.

To respond to these requirements, Yaskawa launched the XGI1000 (65 kW output) product for Japan in 2018, and has now launched the high voltage, high output XGI1500 (150 kW output). Elsewhere, the feed-in tariff (FIT) system has so far supported the photovoltaic power generation business, but this photovoltaic power generation for FIT is now at a turning point. This is because the purchasing price fell from 40 yen/kWh in 2012 to 12 yen/kWh in 2020, so it is now less than one third of its previous value. However, there are still needs in this FIT market, and so we have updated the JET certification of the Enewell-SOL P2H we launched in 2016. This certification is compatible with the latest grid connect regulations and the broad sense.

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  Power conditioner for photovoltaic power generation
  XGI1500
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  Power conditioner for photovoltaic power generation
  Enewell-SOL P2H