AUTOMOTIVE_SOLUTIONS_BROCHURE

Solutions for Your Automobile Production Line

Solutions for Your Automobile Production Line

Presenting a total solution for automobile production lines

L(NA)08114ENG-A 0709

New publication, effective Sep. 2007 Specifications subject to change without notice.

A total solution, featuring a wide variety of components and a close relationshipwiththeclient-MitsubishiElectric offers better productivity, higher energy efficiency, and a safer working environment.

Demands made of state-of-the-art factories Demands of company

Demands of society

Higher facility operation rate Higher manufacturing quality Quicker response to specification changes in production Safety of the workers and facilities

Energy saving, energy monitoring Zero emission, utility monitoring Traceability, status monitoring Safety of the local community and environment

In all kinds of factories, not only those producing automobiles, there is a need for solutions to issues such as ensuring security, improving productivity, and successfully coexisting with the environment and society.

Challenges Improvement Quality of design improvement efficiency Production history management

Productivity improvement

Shorter tact time

Higher facility operation rate

Shorter down time Improvement of maintenance efficiency

Energy saving Concerns on local community and environment

Costeffectiveness

Information system

Quality Early launch management

Reduction of spare parts

Mitsubishi Electric's families of products, combined with a close relationship with the client, provide solutions to all the demands made of your factory.

"Visualization" provides clients with total solutions with the scope for further improvement.

ERP

Enterprise Resource Planning

MES

Core information system FRP

Safety of workers

Production site

Manufacturing Execution System

Demand forecasting, production planning, production command, process control Ethernet

Safety Solutions Energy-saving Solutions

Information network HMI equipped with MES Interface

Production information system (MES)

PLC equipped with MES Interface

Control function programming data

To address these issues, we need a "powerful product" and "visualization*."

MES linkage function

CC-Link IE

Information linkage

Controller network

Controller

Maintaining safety

1

Improving production value

Product family

Monitoring of the production, quality, and facility Visualization of production

Monitoring of the utility status

Monitoring of the energy consumption Visualization of energy consumption

* "Visualisation" is that process whereby problems are identified by collecting and analyzing data.

Coexistence with the environment and society

Visualization of safety control

ON/OFF Numerical value (temperature, pressure)

PLC as an equipment controller

Safety PLC

PLC as a utility controller

Field network

D-I/O

Field device

Motion controller

A-I/O Valve

Robot

Inverter

ID controller

IPM Servo

MDU

EMU

Safety remote I/O Light curtain Robot

Collaborative solutions to resolve fundamental issues in manufacturing from a TCO perspective iQ Works (TCO: Total Cost of Ownership)

2

The most effective solution for an automobile factory Mitsubishi FA products are your best choice for productivity improvement. With the our products, your information system and production equipment can operate together in an integrated network, allowing the process control to be more precise and the most suitable control to be conducted in real time.

Using Mitsubishi FA products together with products of our partner manufacturers, we can make your production the best it can be. Introduce our system for the better quality, shorter work period, and higher productivity, and to have a framework to solve problems.

CNC C70

Power train machining

Incorporates Mitsubishi Electric's achievements in factory automation technology and solutions.

Ideal CNC for controlling the machine tools used to configure a machining line.

CONTENTS Power train machining Power train assembly

p.5

The best TCO reduction effect is provided to the machining line Higher quality and traceability realized by information linkage

Power train assembly

Inverter Faults can be avoided thanks to the self-diagnosis alarm that is output when an inverter component is nearing the end of its service life.

Stamping

p.9

Introduction of iQ Platform for higher total performance

MES Interface The PLC that controls equipment can be directly connected to the database stored on the production controllers. There is no need for a communication gateway such as a personal computer.

Final assembly

Geared motor Reliable maintenance with long-life design.

Welding

p.11

Mitsubishi Electric makes a fusion between control and the safety

Stamping Motion controller Features fast and highly accurate motion control, using a high-speed bus that is dedicated to connections between multiple CPUs.

Painting

p.13

The gigabit communication creates new potential for control systems

Painting Welding

Final assembly

p.15

Enhanced support for workers IPM motor Designed for lower-torque loads such as fans, pumps, and blowers. The IPM motor can offer greater energy savings than a high-performance induction motor driven by an inverter.

Field network

3

Safety PLC

The field network system performs control and data processing simultaneously and at high speed, so as to respond to the FA system needs of different customers.

A safety system can be established in compliance with the international safety standards (IEC61508 SIL3, EN954-1/ISO13849-1 category 4).

Controller network

HMI (GOT)

This next-generation network is realized from the collected Ethernet technologies, and features gigabit communication to meet the needs of high-speed and large-capacity communication.

Indicator equipped with the touch panel featuring a high intensity, wide-view angle, and large screen.

With the multilingual environment supported, GOTs meet the needs of globalization.

Solutions for the environment and energy saving

p.17

Achievement of coexistence with society

4

Solution1 Power train machining

Higher machining accuracy Power train Higher production efficiency machining Higher designing efficiency Higher maintenance efficiency

Power train assembly

Stamping

Welding

Painting

Final assembly

(1) Advanced technology reduces machining cycle time

Optimum TCO reduction for machining lines SYNERGY

PLC

+ CNC CPU CNC C70

High-speed communication between multiple CPUs PLC CPU and CNC CPU are connected using a dedicated high-speed bus. ultrahigh-speed linkage between PLC CPU and CNC CPU is realized.

PLC CPU

High-speed communication between multiple CPUs

CNC CPU

High-performance CNC CPU Interpolation control performance and also auxiliary function processing capacity is greatly improved, allowing you to improve machining accuracy and reduce cycle time.

16.8kBlock/min

High-performance servo and main shaft drive unit The servo and main shaft drive unit feature the world's fastest control loop, together with a full complement of machine interpolation functions to support ongoing progress in machine tools.

(2) Verification of safety signals and monitoring of speed satisfies EN954-1 Category 3 requirements Verification of the safety I/O signals Inputting a safety I/O signal through another route verifies (double-verifies) the input/output signals on two CPUs. In addition, a safety output signal can be output through another route.

PLC CPU (Q0xUD(H)CPU) CNC CPU (Q173NCCPU) Safety signal module (Q173SXY)

Servo motor

User safety sequence

Verified with NC side I/O signal

Sharing of machines reduces need for spare parts!!

CNC CPU

PLC CPU Machine sequence NC side verify error signal

User safety sequence

PLC side verify error signal

Verified with PLC side I/O signal

NC side signal

PLC side signal

The MELSEC Q series module can be utilized.

Terminal block Safety signal module (Q173SXY) Safety signal

PLC side safety output signal

GOT Servo motor

Safety signal

Main shaft motor

NC side safety output signal

Double monitoring of the speed Two CPUs monitor (double-monitor) the command speed and feedback speed.

The speed of operation assures safety.

GOT PLC for gantry control

CNC CPU(Q173NCCPU)

CNC C70

CNC CPU

Drive CPU Speed feedback

CNC servo amplifier Main shaft drive

Cycle time reduced!!

The machining cycle time is reduced by the high-speed CPU, high-speed servo and main shaft drive unit.

5

NC Designer GX Developer

CC-Link IE

Speed monitoring

Speed monitoring

Feedback speed monitoring

Feedback speed monitoring

Servo control

Servo control

Servo control

Easier design, installation, and maintenance of equipment!!

The controller has a wide variety of maintenance functions that can be controlled easily.

POWER TRAIN MACHINING

Position/Speed command

Motor driving current

Encoder on the motor

6

Solution2 Power train machining

Higherproductivityandhigherqualityrealizedthroughareal-timeaccesstothehostdatabaseserver Power train Highertraceabilitybytheautomaticdatacollectionandmanagement assembly Easyandpromptstartup,maintenance,andtroubleshootingofsystem(comfortableoperability)

Power train assembly

Stamping

Painting

Final assembly

(1) Special programs not required for database server communication

Higher quality and traceability realized by information linkage SYNERGY

Communication without programming With the MES Interface module, communication can be made without programming by simply specifying the required data using the setup software (MX MESInterface). Select the database most suitable for your needs from a wide variety of products.

+ PLC

Welding

Information management server (MES, ALC, etc.)

MES interface Ethernet Actual performance report information Operation status (Running time, Stop time) Parts management information Traceability information Quality information (Tightening torque, Condition value) Power consumption, etc.

Command information Equipment operation/stop command Automobile model change information Operating command, etc.

SQL SQL XML MES interface

XML processing function SQL operation execution command (Actual performance report, automobilemodelchangeinformationreadcommand,etc.)

Controller network (CC-Link IE)

Inspection histories, production information, and quality data can be collected easily!!

Precise data can be collected in both batch and real-time modes.

Direct transmission to a database server is supported, with SQL statements being generated automatically.

Indicator light Server

(2) Network load is drastically reduced in the production control system Polling processing not required When data is monitored on the MES Interface module side and the condition is met, the data (SQL statement) can be sent to the manufacturing execution system. The network load is greatly reduced compared to a conventional system where a personal computer is used as a gateway to constantly collect and monitor data.

Servo motor

Information linkage

Sensor

Information system

Information system

MES (Manufacturing Execution System)

MES (Manufacturing Execution System)

Conversion processing to SQL statements Data processing (Operation processing, Logging, etc.)

vent transmission Event transmission (SQL)

Network load reduced

PLC communication Gateway personal computer Polling processing

MES Interface

Communication module

GOT

(3) Changing production commands or recipes with the host system

PLC

MES Interface module

Automatic generation of SQL statements After a message from Manufacturing Execution System (MES) is received, the registered processing (SQL statement) can be executed. With the manufacturing command from MES, the system in which the production information is downloaded from the database can be realized.

Servo amplifier Servo motor

A system can be set up easily!!

A system can easily be added and deleted by making settings.

Using the MX-MES Interface, no programming is required to make the settings.

7

PLC (CPU)

PLC (CPU)

Cost savings can be realized easily!!

Production command

A gateway personal computer is not required (a personal computer is not requiredat production site).

The system can be established by simply adding your current PLC (Q series) forthe production control, and the MES interface module.

POWER TRAIN ASSEMBLY

SELECT (to extract data)

Production condition Actual operation performance

MES Interface module

UPDATE (to update data) INSERT (to insert data)

MES database server

8

Solution3 Power train assembly

Power train machining

Shorter tact time Faster and more accurate machine control Stamping More efficient development, debugging, and startup tasks

Stamping

Welding

Painting

Introduction of iQ Platform for higher total performance

Introduction of iQ Platform for improved overall performance SYNERGY

iQ Platform Based on the Mitsubishi FA integration concept, "iQ Platform", we offer a product lineup that features a "Controller", "Engineering environment" and "Network" as a set, and provide you with support to reduce your TCO*. *TCO : Total Cost of Ownership

+ PLC

Final assembly

Motion controller

Functions required for each phase of the development are integrated here

iQ Works

Efficient system installation and maintenance!! iQ Works realizes designing and maintenance on an integrated platform. The labels can be shared by PLC project and motion controller project.

System design

Programming

Test/Startup

Operation/Maintenance

With the system configuration diagram where an entire system can be graphically described and the workspace tree where various projects can be managed in one place, the overall control system can be set at once and projects can be managed easily.

The jump function between programs and the global label shared between multiple PLCs/motion controllers and GOT reduce the number of operations and remove troubles for changing programs.

The functions such as a simulation based on the system configuration diagram created at a design phase, the multiwindow monitoring and the system diagnostic function reduce the time for adjusting the machine linkage section and the time for identifying a place where an error occurs.

Executing a batch read/write linked with the system configuration diagram removes troubles for the system management.

In addition, the history management allows you to manage the version of backup data.

System configuration management

Label programming

Monitoring

Batch read/write

Maintenance without having to access the board!!

A personal computer is connected using the USB i nterface installed on the front of GOT, and it can start and adjust the programming of FA equipment via GOT.

Pressing machine

GOT Servo motor Pressing machine

Feeder

Servo motor

Feeder

iQ Works compatible engineering environment Motion controller

Servo amplifier

PLC

CC-Link IE

Tact time reduced!!

By reducing the handling time between the pressing machine and the feeder, the tact timeis reduced, and productivity is improved.

9

STAMPING

Integration of software for PLC, motion controller, GOT, etc.

10

Solution4 Power train assembly

Power train machining

Ensuring safe environment for workers Easy connection between welding robots and a PLC Welding Shorter tact time in the high-speed shuttle control

Stamping

Welding

Painting

Final assembly

Safety control network with the safety PLC

Mitsubishi Electric fuses control and safety SYNERGY

Safer welding line environment Safety is secured on a welding line featuring multiple welding robots.

Integrated control panel

1st phase

2nd phase

nth phase

+ PLC

Safety PLC

Ethernet, etc.

(CommunicationbetweenstandardCPUs)

POWER

Q25HCPU MODE RUN ERR USER

POWER

Q25HCPU

QY42P QY42P

POWER

Q25HCPU

QY42P

MODE

QY42P

RUN

QJ71LP21-25

ERR USER

MODE

Q25HCPU

POWER

QY42P

ERR USER

MODE

QJ71LP21-25

PULL

PULL

PULL

USB

USB

USB

USB

RS-232

RS-232

RS-232

RS-232

Line integrated control

QY42P

ERR USER BAT BOOT

PULL

PULL

QY42P

RUN

QJ71LP21-25

BAT BOOT

PULL

PULL

QY42P

RUN

QJ71LP21-25

BAT BOOT

BAT BOOT

PULL

Phase control CPU

MELSECNET/H

Line control network

Line control network

Line control network

Safety PLC (Safety control)

Safety-related functions assure machine safety!!

A safety system can be established with MELSEC-Q series in compliance with the international safety standards (IEC61508 SIL3, EN954-1/ISO13849-1 category 4).

High affinity between control and safety is realized.

CC-Link Safety Remote I/O module Standard input

Safety input

Standard output

Emergency stop switch

Connection system for cost performance!!

(Restart switch)

Safety input Light curtain

(Warning light)

Robot

Robot

Safety output

A wire-saving connection can be made between a PLC and dispersed robots on the CC-Link.

Peripheral devices such as a welding timer can also be connected on the CC-Link.

CC-Link Safety Remote I/O

Safety PLC

Light curtain

Body welding line

Safety PLC GOT

Safety switch

MELSECNET/H

PLC

Servo amplifier

Emergency stop switch Servo motor

The safety PLC is a programmable logic controller for providing safety control that is compliant with the safety standards of "ISO13849-1 (JIS B 9705-1) EN954-1 category 4" and "IEC61508 (JIS C0508) SIL3".* Safety equipment such as an emergency stop switch or light curtain are connected, and safety control for turnning off the safety output is performed to shut off the power supply to hazardous robots or others based on a program created by the user.

Machines such as robots or conveyors are operated by a standard PLC. If an error occurs on the safety PLC, it is detected by the self-diagnosis function and the safety output is forcibly turned off. This safety function differentiates the safety PLC from a standard PLC. * Certified by TUV Rheinland

Safety PLC

Welding robot

POWER

MODE RUN

Emergency stop switch

Standard PLC

Q25HCPU

ERR USER

Robot

QY42P QY42P

QJ71LP21-25

BAT BOOT

PULL

PULL

USB

Light curtain

Safety remote I/O Safety control

RS-232

Power shutoff of hazardous factors (robot, etc.)

Machine control

Tact time reduced!!

The shuttle is transported at high speed by the high-speed control via SSCNET III. A large body with large load (inertia) can also be transported at high speed.

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WELDING

12

Solution5 Painting

Power train assembly

Power train machining

Real-time interaction with the production control system and reliable traceability Quickerdataupdatetoadjustthepaintingdataaccordingtotemperature/humidityorautomobilemodels Smooth startup and easy expansion of the equipment

Stamping

Welding

Final assembly

High-speed network reliably carries huge amounts of data

Gigabit communication creates new potential for control systems

CC-Link IE

SYNERGY

Database server

ALC server

+ PLC

Painting

CC-Link IE Large amount of actual performance data Operation data

Ethernet

Large-capacity data batch transmission

Data sharing Data exchange

Data sharing Data exchange

Base coating

Top coating

Reduced tact time increases production efficiency!!

Automobile model or painting related commands are transmitted at faster speed via the high-speed and high-capacity network.

The time for communicating with the host server is reduced by the interactive data transmission using the MES Interface module.

CC-Link IE Data sharing Data exchange

Server

Ethernet

Network type shared memory (Cyclic data)

Sealer

Data sharing Data exchange Clear coating

Shorter preparation time!!

Since a large amount of data can be stored in a PLC, the detailed data of painting can be saved. Therefore, less data is required for adjustment.

Furthermore, with the high-speed and highcapacity network, the painting data can easily be changed from either the central control room side or the equipment side.

GOT Robot board

Data sharing Data exchange

Data sharing Data exchange

Middle coating

Oven-drying

Punctuality

Large capacity

Stabilized tact time improves manufacturing quality.

A large amount of data can easily be collected from the production equipment.

Faster speed Shorter tact time improves productivity.

Communication speed:1 Gbps

The punctuality of link scan time is made more accurate

Link register (LW) points: 128 K points

Link scan time:Approx. 5ms

The constant scan time is assured without depending on the host SCADA communication or the monitoring communication of the i ndicators/programming tools.

Link relay (LB) points:32 K points

(Configuration with 32 stations) (2 K points equally assigned per station) (No disconnected station or reconnected station)

MES Interface module Robot board

PLC

CC-Link IE

Visible network connection status

Strengthened check function of optical fiber cables

The connection status of the entire network is visible.

This is convenient to visibly identify the location of an error, if any occurs.

This is also efficient for cost reduction in maintenance and troubleshooting.

Faults in an optical fiber cable can be detected.

Wrong IN/OUT insertion for optical fiber cables can be detected.

iQ Works

Programming is simple; installation/replacement are easy!!

By programming with labels, programs can be made in an easy-to-understand manner.

These labels can simply be added and changed without considering a memory map.

13

PAINTING

Faulty part

Error

14

Solution6

Enhanced support for workers

Stamping

Welding

Painting

Final assembly

(1) Quick troubleshooting using a GOT "Ladder monitor function" - Error tracing simply by touching a button

SYNERGY

+ PLC

Power train assembly

Power train machining

Support for workers to reduce mistakes in production Final Shorter downtime assembly High capability for the maintenance

+

Inverter

GOT

A sequence program can be monitored in a ladder diagram.

Supported by XGA/SVGA/VGA models of the GT15 series

<Error occurred at ST2 of the equipment>

Error occurring

ST1 (Normal)

Search factor

ST2 (Error)

Error indicator Y10

When an error occurred, touching the "Search factor" switch automatically activates the ladder monitor screen.

Touch switch to which

Touch the coil Y10 is set as a jump destination

One-touch ladder jump function A sequence program name and coil number can be assigned to a one-touch button, which directly displays the ladder block of the corresponding coil.

A PLC station number, CPU number, program name and coil number can also be assigned to a one-touch button. In the circuit block of the coil displayed with the one-touch button, not only the PLC connected to the GOT but also other station PLC, multiple CPUs, multiple CPU programs, and local devices can be specified.

Search for the error factor by simply touching the screen several times! <Ladder block including Y10 displayed>

<Ladder block including the coil M20 displayed>

ST1 error

Pusher LS error

Error indicator displayed ST2 error

ST2 error Air pressure error Oil pressure error

Touch the NO contact (M20) that is ON (Coil search function)

An error is detected since the oil pressure error (M33) is ON!

Touch

Easier-to-read operating commands greatly reduce operational mistakes!!

The operating commands are clearly shown on the GOT's high-intensity, wide-view angle, and large screen.

By supporting a multilingual environment, GOTs meet the needs of globalization.

Backing up your important sequence programs - "Backup/Restore functions" prevent data loss

Problems are easily resolved on site without a personal computer!!

The error location and countermeasure can be checked on site using the one-touch ladder jump function or document display function of the GOT. With the backup/restore functions, the sequence program can be changed incase of errors.

The data of a PLC CPU such as sequence programs and parameters can be backed up to the CF card of a GOT. Data can be batch-restored (rewritten) to the PLC CPU when necessary. Change the program in a PLC CPU, simply by using the CF card. No personal computer is required at the production site.

Usage example 1)

Usage example 2)

By backing up data in advance, replacement or recovery can be quickly performed when the PLC CPU becomes faulty or the battery runs out.

Data such as a sequence program must be exchanged, analyzed or corrected when an error occurs or the program in the PLC CPU is updated. With this function, those tasks can be completed without an experienced engineer, leading to cost and time reductions.

Backing up data allows...

Replacement of CPU

Server

Ethernet

Patent pending

Factory Sequence program, etc.

Data transmission

CF card

Restoring

Sequence program, etc.

Backup

CPU direct connection

MES Interface module

Restoring

CF card

Office

Analysis/ Correction

CF card

Sequence programs stored in the CF card can be edited.

* The restoring function may not be available depending on the system configuration or connection after the replacement of a PLC CPU.

CC-Link IE

(2) Ease of maintenance and long-life design MELQIC GOT

Long-life design Consumable parts (capacitors, cooling fans) for the inverter 700 series are designed to offer a service life of 10 years.

PLC Geared motor

Components

Guideline of the 700 series

Guideline of JEMA*

Cooling fan

10 years

2 to 3 years

Main circuit smoothing capacitor

10 years

5 years

Printed-circuit board smoothing capacitor

10 years

5 years

* Excerpts from "Periodic check of the transistorized inverter" of JEMA (Japan Electrical Manufacturer's Association)

Inverter

15

ID controller

Service life check

Maintenance costs are reduced by a longer life and life check!!

The degree of deterioration of the main circuit capacitors, control circuit capacitors, and the inrush current limiting circuit can be monitored.

Faults can be prevented thanks to the self-diagnosis alarm that is output when a component is nearing the end of its service life.

Consumable parts (capacitors, cooling fans) are designed to last for 10 years.

Faults can be avoided with a self-diagnostic alarm that is output when the life of an inverter part is near its end.

High reliability and longer life

FINAL ASSEMBLY

Newly-developed oil seals prevent grease leaks.

The a sealing performance is 100 times better than that of our conventional products and realizes high reliability and longer life.

16

Solutions for saving energy Our manufacturing energy use is based on the following factors: When required (year, month, day, hour, minute, second...)

Where required (entire factory, building, division, production line, equipment) Quantity required (technical standards, usage/operation standards) and we pursue a "just-in-time" energy usage.

and the environment Environment where "basic unit" is "visualized" in real time and shared by everyone Exposing of problems by the "basic unit management" Improvement of the basic unit Outline of the energy-saving system

Visualized management Quantity required

Where required

Realization of just-in-time energy usage

FEMS Factory Energy Management System

Six perspectives Air

When required Spiral-up of energy-saving activities

STEP UP

Production control

Lighting, air conditioning, and others

Final assembly

Power train machining

Basic unit management

EcoMonitor II EcoMonitor II

Production line

Amount per hour [pcs]

Air conditioning

EcoMonitor II

Lighting

Basic unit of the self-installed 2nd line basic

Basic unit [kWh/pc]

Painting

Power train assembly

Basic unit of the self-installed 2nd line basic

[o'clock] Basic unit [kWh/pc]

After improvement

Gas

Water

Operation/Management

EcoServer II

Amount per hour [pcs]

Electricity Fuel oil Vapor

Mitsubishi Electric group, your partner for <aggressive energy saving>

Countermeasure

Energy saving is considered as a cycle and realized by our plenty of know-how and actual performance!

Introduction of overall energy control using

Before improvement

Factory Energy Management System (FEMS)

Measurement/Diagnostics

Energy-saving database server software

LAN(Ethernet)

Production equipment Pulse

Just-in-time energy usage

Total solution gives you an effective management power.

Stamping

Welding

[o'clock]

EcoServer II for data management on the Web

Measuring Display Unit MDU breaker for measuring, displaying, and transferring electrical circuit information

IPM motor for realizing the highest level of energy saving and the energy-saving drive FREQROL-FP series

GOT that can perform each

Redundant CPU that realizes highly reliable continuous operation

Inverter with energy-saving operation

processing without paper

Mitsubishi's wide range of products supports those factory utilities that must offer continuous, high-quality operation, such as water purification and air-conditioning equipment.

Ultra-pure water processing equipment 17

Waste water processing equipment

Air conditioning equipment

Energy-saving operation using an IPM or inverter, highly reliable continuous operation using a redundant system, and the improvement of energy usage (efficiency) using EcoMonitor and EcoManager will contribute to reducing the environmental load of the factory overall.

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