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
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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.
11
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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