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Conveyor systems /// Storage and retrieval (AS/RS) /// Automatic guided vehicles (AGVs) /// In line and vertical sorting ///High speed sorting loops /// High speed insertion systems ///
Lean and flexiblesystems that deliver
MATERIAL HANDLINGAutomation Solutions
Lean and flexible /// Material handling solutions /// Lean and flexible ///
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Moving forward together
Material handling solutions /// Lean and flexible /// Material handling sol
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Mitsubishi Electric believes in thestrength of the independent solutionsprovider. Our ultimate goal is to deliverinnovations that empower our customersand allow them to differentiate them-selves while setting higher standardswithin their respective markets.
Mitsubishi Electric has a long history inautomation starting from a ship buildingbackground over 85 years ago. Sincethen we have grown to be a $30Billionmultinational corporation with an esti-mated 100,000 plus employees world-wide. Using a constant progression ofknowledge, we continue to increase thespeed, accuracy, and quality of both ourproducts and business processes. As aresult, many of the world’s top materialhandling solutions providers havealready discovered that Mitsubishi Electric is the performance standard theycan build upon.
Integration is the keyMitsubishi Electric’s principle of integrat-ing automation products into one com-mon platform is a key advantage toapplications for today’s cost drivenrequirements. Every aspect of automationcontrol, ranging from low to high endcontrollers, servos, inverters, and HMIs arebased on our integrated Automation Plat-form. This provides users with the choiceto deliver a PLC, Process, IT or PAC basedarchitecture, using standard componentsfor their chosen solution.
Meeting industry needsWhether your company provides solutionsin baggage handling systems, automatedwarehousing, postal automation or manu-facturing systems; designs single materialhandling machines or entire automatedfacilities, Mitsubishi Electric can deliverthe tools necessary for the right solution.With Mitsubishi Electric’s high function,advanced performance products andtechnical know how, a complete andtruly total solution architecture is easilyrealized.
Material handling solutions /// Flexible manufacturing /// Material handl
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Manufacturing anddistribution systems
MELSECNET/G
ERP/MES
Storage systems require intensive line side data tracking
Getting material from the receivingdocks to the shipping docks as quickly aspossible with the least amount of errorsis critical to any organization’s success.This takes high level logistical coordina-tion and error-proofing of repetitiveprocesses.
Efficient manufacturing and distributionsystems typically result in higher levelsof profitability and increased customersatisfaction. However, lean operationdoes not happen overnight. It’s aprocess of continual improvement thatrelies heavily on having a strong planand even better feedback.
AS/RS
Sliding shoe
Control room
Loading bays
Vertical sorters
Input station Conveyor control
AGV
Merge
Gapper systemtransfer to/ remove from stock
ling solutions /// Flexible manufacturing /// Material handling solutions //
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Bridging IT and automationcontrolHaving vast amounts of data and han-dling, or processing it efficiently hasbeen a hurdle not only for material han-dling applications but automation appli-cations as a whole. Many automationproviders allow for the movement ofdata from one machine to another onthe shop floor. However, moving accu-rate and detailed data from the shopfloor up to IT systems has been over-looked by most, resulting in costly downtime, process inefficiencies and manyother issues.
With Mitsubishi Electric’s e-F@ctorysolution, these problems have beeneradicated. Together with Mitsubishi'srevolutionary integrated AutomationPlatform it can provide a true total solu-tion architecture, not only concentratingon the shop floor but also providing adirect interface to ERP/MES systemswith streamlined real-time data, result-ing in a “visible” system solution.
Flexible manufacturingWith so many products and articles beinghandled in current material handlingprocesses, providing a complete automa-tion platform is paramount to a successfulapplication. Mitsubishi Electric can pro-vide a single centralized automation plat-form that easily interfaces with bar codereaders, pick/place robots, conveyors,weighing machines, scanners and more.The CC-Link device level network providesa high speed method to integrate suchdevices easily and at a low cost. Evenrobots and conveyors can be controlleddirectly from the controller platform,along with interfaces to the GOT1000 HMIseries for real time online control andmonitoring. With all of this cohesiveness,the right product being delivered to theright destination is ensured.
Conveyor systems /// Flexible manufacturing /// Conveyor systems /// Fle
Conveyor systems
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From simple induction systems to themost advanced gapper designs, Mit-subishi Electric delivers with various con-troller performance levels from theQD75P position module to the newQD series with integrated high-speedBUS [back-plane] for fast multiple CPUcommunication. In addition, remote I/Oand interrupt modules range from stan-dard 20msec response times to the faster50microsec QI60 up to the extremely fast10microsec Q172LX devices.
CC-link compatible FR-A700 inverterscoupled with CC-link remote I/O providea very strong baseline that satisfies the majority of induction system require-ments. For gapper conveyors thatrequire an extra boost of performance,the SSCNET III based MR-J3-B servo sys-tem can be easily added into the inte-grated Automation Platform, taking“high speed ” to a new standard.
Merge, gap, slideIn many material handling applications,items are first loaded onto a merge con-veyor which matches speeds with themain conveyor and inserts packageswhenever room is available. Next, aninduction system uses smart conveyorsor gappers to adjust the space betweeneach package and create uniform sepa-ration.
Since placement onto the merge con-veyor can vary significantly along withboth the size and shape of the materialbeing handled, the automation systemmust recognize these differences andrespond accordingly, often with very lit-tle time to do so.
Fast input A gapper system typically consists of asuccession of multiple small conveyors,each conveyor changing speeds in rela-tion to the conveyors in front andbehind it. The key requirement in gap-ping technology is the ability of the sys-tem to sense product and changeconveyor velocity in a very short amountof time.
During ultra fast time intervals, proximitysensors send updates to the controllerregarding the product location, whichthen calculates new speeds to be sent toinverters or servo amplifiers. Even withrapid velocity commands, the conveyorsmust accelerate or decelerate withoutany overshoot or undershoot occurring.
Timing and speed of response govern many conveying applications
Proximity sensors
Sliding shoe diverters
Main conveyor
exible manufacturing /// Conveyor systems /// Flexible manufacturing ///
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SynchronizationOne of the challenges of sorting is how totransfer from one conveyor to anotherwithout stopping or damaging products.Mitsubishi Electric’s communication net-works are optimized for maintaining syn-chronous control of multiple axes. Theservo network SSCNET III is a full-duplex50 mega baud system where data com-munication is both bidirectional andhigh-speed (Synchronous deterministiccommunication) yet has zero possibilityof data collisions which otherwise couldcause timing delays and unwanteddowntime. Furthermore, the networkcycle of SSCNET III is designed to matchthat of the controller and the servoamplifier. Therefore, all critical motiondevices are synchronized and the sys-tem is allowed to perform in real-time.This is a huge performance benefit whenusing electronic gearing or coordinatingthe motion between two fast movingaxes.
CC-Link IE is an ultra high-speed 1Gbpsredundant Ethernet topology com -munication system for inter-controllercommunication, allowing various sub-systems in a material handling system toall communicate deterministically in a peer-to-peer manner. The sorting sub-system can communicate upstream withan AS/RS system or an AGV command sta-tion and prepare those systems for thematerial they are about to receive. Whenthe time comes, the product can be trans-ferred cleanly to its new carrier withoutany delay.
In addition, CC-Link, an open standardfrom the CC-Link Partner Association(CLPA), allows for high-speed access toI/O and other devices over long dis-tances. Unlike other similar networks,
adding I/O and increasing distancebetween devices does little to impedethe performance of the network. Speedsof up to 10Mbps, and bus lengths of upto 1.2km without the use of repeatersare standard.
This is especially useful for diverters,such as sliding shoe sorters that haveremote I/O elements down the entirelength of the conveyor system.
Merge conveyors
Gapper system A
Proximity sensors
Gapper system B
Control panel
ERP/MES
Ethernet
Q BUS
CC-Link IE
Main conveyor Merge conveyor
Gapper system B
Gapper System A
Sliding shoe sorters
Proximity sensor
Proximity sensor
Proximity sensor
QD Motion CPU MES interface
CC-Link MasterCC-Link IE
High speed interrupt I/O
Universal model QnUD CPUPower supply
Automated storage /// Retrieval systems /// Automated storage /// Retrieva
Automated storage/retrieval systems
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Minimize your breaksAutomated Storage and Retrieval Sys-tems (AS/RS) have many advantagesover older warehousing techniques. Theability to store items higher on shelvesreduces floor space and the ability totrack individual boxes or pallets allowsfor easy first in-first out systems. In theBaggage Handling System (BHS) indus-try, Early Baggage Storage (EBS) systemsallow for bags to be temporarily storedand then released at the correct time toget on the same flight as the passenger.Since all of these AS/RS systems are typi-cally large, the speed of the transportvehicle is key as it needs to move items inand out as fast as possible.
ContinuouspowerA single stacker crane in an AS/RS sys-tem typically has up to 4 axes of motion:Lift, extraction and two traverse drivewheels. All of this motion requires a lotof energy. Since the cranes are movinglong distances at high speeds, power istypically delivered via a DC Bus suppliedby our FR-CVL series of line regenerativecommon converters. These convertersallow up to six Mitsubishi Electric invert-ers (VFDs) to be connected in a commonDC Bus configuration and provide ACline regeneration.
Scales
Main conveyor
Stacker crane A
Stacker crane B
DC Bus
Barcode reader
l systems /// Automated storage /// Retrieval systems /// Automated storage
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Advanced auto-tuning AS/RS systems need to be able to moveat maximum acceleration and velocityunder varying load carrying situations.One of the most extreme cases would bean AS/RS that transports heavy, full pal-let-sized loads. If tuned to have the sameset of gains for both loaded andunloaded conditions, the system, whilestable, may still not be optimized for topperformance. The MR-J3 amplifier con-tains advanced real-time auto-tuningtechnology that can automatically sense achange in load and alter the PID gainsaccordingly. This allows for maximum per-formance even with drastically changingload characteristics.
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Power, speed and flexibility are prerequisites for a successful AS/RS solution
ERP/MESEthernet
Q BUS
Stacker crane A Stacker crane B
DC Bus
Reactor PowerRegenerationCommonConverter
FR-CVL FR-CV
CC-Link IE
Lift axis
Frontwheel
Rearwheel
Lift axis
Frontwheel
Rearwheel
Proximitysensors
Barcode reader
Weighing system
Lift axis
Lift axis
QD Motion CPU MES interface
CC-Link Master
CC-Link IE
High speed interrupt I/O
Universal model QnUD CPUPower supply
Automatic guided vehicles /// Automatic guided vehicles /// Automatic gui
Automatic guided vehicles
10
Add flexibilityBeing able to respond to changing cus-tomer demands is a key component of asuccessful material handling installation.For example, the beginning of the holi-day season typically sees a rush of salesand shipments which is followed up by asignificant increase in returns andexchanges. In order to accommodatethis demand, distribution centers typi-cally need to increase flow in one direc-tion or the other.
In these flexible manufacturing environ-ments, Automated Guided Vehicles(AGVs) become increasingly useful espe-cially where conveyor systems are notpractical. Furthermore, they can be usedto remove the risks associated withheavy lift situations and reduce thenumber of forklifts in a factory, thusreducing on-the-job disruptions. Beingable to react to and avoid obstacleswhile maneuvering through a crowdedenvironment is a key element in AGVdesign.
ided vehicles /// Automatic guided vehicles /// Automatic guided vehicles //
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All-wheel drive controlSort floors can be crowded and vibrationintensive environments. Therefore, AGVsmust be completely stable even withchanging external disturbances andhave the ability to make quick and pre-cise movements. Using the phase com-pensation function, all four wheels (ormore) of an AGV can be perfectly syn-chronized. In comparison to two wheeldrive, all-wheel drive can increase accel-eration, deceleration and of course han-dling, making incredibly tight turnspossible.
The phase compensation functionadjusts for time delays in the system andallows multiple axes to move together in perfect synchronization. Robust distur-bance compensation allows the responseto external disturbances to be tuned sep-arately from the main PID loop, thusincreasing overall responsiveness.
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AGV's look deceptively simple but any driverless process requires reliable and repeatablecontrol for safety and task completion
Proximity sensors
Transferarm
Magnetic stripSensor Magnetic strip
Universal model QnUD CPU
Power supply
QD Motion CPU
High speed I/O
Steering Drive wheels Transfer arm
Proximity sensors,magnetic strip sensor
Drive wheels
Baggage handling systems /// Baggage handling systems /// Baggage hand
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Baggage handling systems
Control withredundancyMitsubishi Electric delivers all of the criti-cal components for complete control andvisibility of baggage flow throughout theairport. High performance redundantCPUs, motion controllers, linear androtary servo amplifiers and motors, oper-ator interfaces, distributed I/O and safetyare all available direct from one source.The required high speed characteristicsand performance are easily realized withMitsubishi Electric’s integrated Automa-tion Platform, which consolidates motionand sequence control, reducing cyclelatency, and improving performance.Together with the high performance,high speed characteristics of the Q Seriescontroller, maintaining control and elimi-nating downtime are pre-requisites ofany BHS system. With the Q Series redun-dant system, control is maintained with acontrol and standby CPU. In addition, thenetwork topology is also redundant,therefore ensuring system wide controlin the event of a failure or power loss tothe system.
Stay on schedule In baggage handling, the goal is to havethe passenger and their bag get on thesame plane. Airport expansion along within-line security measures and a decreasein layover times at major hubs has createdthe need for extremely efficient and highspeed baggage handling systems (BHS).Mitsubishi Electric has the completetoolset necessary for a fully integratedsolution. When a passenger takes a high-speed tram between terminals in order tocatch a connecting flight, the person’sbaggage must be delivered equally asfast. This typically requires the use of ahigh-speed Destination Coded Vehicle(DCV) system. On the other end of thespectrum, sometimes passengers check-in earlier than the airline anticipates. If thebag was sent directly to the terminal gate,it might board an earlier scheduled flight.Therefore, Early Baggage Storage (EBS)systems are used to quickly store bags andthen retrieve them at the proper timing.
dling systems /// Baggage handling systems /// Baggage handling systems
13
MELSECNET/G
ERP/MES
Passenger expectations are high and so baggage systems must match and exceedthese on a daily, even hourly basis
RFID-basedtrackingExpanding to fit a system’s requirements isthe specialty of the integrated AutomationPlatform. RFID is becoming increasinglypopular in BHS due to how easy it makesscanning moving baggage and because ofits ability to store information in the tagitself. Successful scan ratios reach close to100% in many new applications, reducingerror and increasing throughput. RFID canbe integrated simply by using the serialinterface module on the Q series, or byinterfacing directly from the CC-Link serialinterface block.
Control room
EBS
Input station
DCV
Inspection points
Baggage claim
Check-in counters
In-line and vertical sorting /// In-line and vertical sorting /// In-line and ver
In-Line and vertical sorting
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Moving while sortingEarlier, sliding shoe sorters were men-tioned. Many applications also use push-er devices and vertical sorting systemswhen heavier items need to be trans-ferred. While these types of machinesare commonly seen in the various mate-rial handling industries, they are particu-larly useful in baggage handlingsystems. An airport typically has check-incounters on one floor with baggageclaim on another. Furthermore, a high-speed loop sorting system is usually run-ning at the lowest level, playing catch-upwith the passengers on high-speedtrams.
Large pusher systems are used betweenconveyors in order to move large piecesof luggage that often differ greatly inshape and size. Vertical sorting systemschange the flow of material to either goup or go down. In this way, a single in-line system can easily redirect productto the correct end-location.
Smoothly does it For applications that are moving verylarge and sometimes fragile objects, it iscrucial that when ramping up or downto various velocities that accelerationand deceleration is accomplishedsmoothly. Mitsubishi Electric’s intelli-gent MR-J3 servo is an obvious choice tomost when it comes to top performanceat all speeds.
What may be unknown to some is thatMitsubishi Electric’s variable frequencydrives (VFDs) are reaching servo-likeperformance. The A700 has many similarauto tuning capabilities as the MR-J3series and is capable of vector controlwith or without an encoder. Conveyorssee sudden load fluctuations every timea product is introduced or removedfrom them. Our A700 VFDs haveextremely high response to thesechanging load conditions and thereforelimit jerking and speed fluctuations.
The Real Sensorless Vector (RSV) motorcontrol system provides unequalleddynamic performance, ensuring a widerspeed range, smoother operation andlower motor currents than ever before.RSV starts with a highly accurate motor‘map’, obtained during an auto-tuneprocedure which applies alternatingvoltage to the motor and determinescritical motor characteristics. At theheart of RSV is the Adaptive Flux Observ-er system which compares actual motorbehavior during operation with the the-oretical model.
Instead of a response to a change in loador speed being fixed, any variationsbetween the theoretical and the actualmotor response measured in operationare analyzed by the Flux Observer,which constantly refines the motor mapas speed and load conditions change.
Each item must be reliably sorted – first time
Pusher control
Proximity sensors
Paddle
tical sorting /// In-line and vertical sorting /// In-line and vertical sorting ///
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Line side processingTracking, collating, updating, interruptingare all actions which happen continuouslyduring the basic sorting operation. All ofthese processes are fundamentally linkedto databases and data manipulation. As each passenger's bags are trackedaround the baggage handling system,information needs to continuously be fedback in to the ERP solution. Reactions tochanges must be instant, reliable and doc-umented.
This need for constant line side process-ing of data is why Mitsubishi Electricdeveloped dedicated MES interfacetechnology which allows the IT andautomation world to meet at the pointof action. In addition, some of these lineside MES modules also allow edge pro-cessing, which means that data can bemanipulated immediately in a databasestored locally within the MES module.This means extreme processing speedscan be realized - often stretching the lim-its of the surrounding legacy automationarchitecture.
Creative solutionsOften engineers are presented with anexisting building or infrastructure inwhich to install a new or upgraded han-dling system. Finding solutions to space,flow and control problems can be taxing,but with flexible automation compo-nents and a flexible attitude comes suc-cess. This is what Mitsubishi Electric callscreating productivity.
Creative solutions come from a flexible attitude
Main conveyor
Conveyor 2
Conveyor 1
Tilt control
Conveyor 3
Ethernet
ERP/MES
CC-Link IE
Paddle pushers Main conveyor
Barcode/RFID
Vertical sortation
Proximitysensor
Proximitysensor
Tiltmotor
Conveyor1
Conveyor2
Conveyor3
Horizontal sortation
Q BUS
QD Motion CPU MES interface
CC-Link Master
CC-Link IE
High speed interrupt I/O
Universal model QnUD CPU
Power supply
High speed loop sorting /// High speed loop sorting /// High speed loop so
High speed loop sorting
16
Run faster and on timeLoop sorters are the highways of materi-al handling. They consist of an endlessloop of segmented carriers (DestinationCoded Vehicles or Sorting Transfer Vehi-cles) that take the product to a specifictarget location.
Since the carriers stay on the loop anddon’t exit with the product, transfer con-veyors or tilt tray sorters are used todivert the product from the carrier. Thisrequires knowledge of what is on theDCV or STV in real-time and having theproduct exit at the required location.Fully electronic tilt mechanisms allow fortrays to tilt through curves to countercentrifugal forces.
rting /// High speed loop sorting /// High speed loop sorting /// High speed
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Solutions on the moveThe Mitsubishi Electric MR-J3 servo sys-tem is compact, yet provides hightorque at high speeds. In our researchlaboratories around the world, scientistsare doing fundamental research in elec-tricity and magnetism. Experiments instator and winding methods, along withchanges to the orientation and shape ofthe magnets has led to breakthroughs inmotor technology. Mitsubishi Electric’srevolutionary design in servo motormechanics has reduced the overall sizeof the motor and resulted in anincreased power efficiency. The low cog-ging design allows for higher velocitiescoupled with higher torque. Like manyof our products, the MR-J3 servo motoris a real-world example of scientificadvancement aiding product designand development.
Realizing a cost efficient solution consist-ing of a Q series universal controller andQD75 positional module is second naturefor the Q series range. Having so muchgeneric modules on offer, realizes a solu-tion fit for the application without sacrific-ing key functional requirements andperformance.
The QD75 offers up to 4 simultaneousaxes that can be utilized for a cost drivensystem requiring high precision control.Advanced features are supported suchas, linear/circular interpolation, speedcontrol, positioning to speed switchoveras standard. The QD75 also supportsconnection to the SSCNET III high speed50MBaud communication network.
Speed and reliability are fundamentals to the sorting process
Sort location B
Sort location A
Proximity sensors
Sort location C
Tilt control
Universal model QnU CPUPower supply
QD75M
High speed I/O
Proximity sensors
Tilt control
Postal automation /// Postal automation /// Postal automation /// Postal au
18
Postal automation
Your customer’stransformation From the latest “Strategic TransformationPlan” created by the United States PostalService, to the “Cap Qualite Courrier” pro-gram of France’s La Poste and Royal Mail’s“Flats Automation Project” in the UnitedKingdom, many major mail servicesaround the world have initiated new pro-grams to directly address their changingneeds. These programs are fundingextremely large investments in new flatsorting machines, mixed sortingmachines and technology that enableslarge-scale, real-time tracking of mail. Uti-lize Mitsubishi Electric’s extensive prod-uct range to offer solutions that meetevery aspect of your customer’s futureplans and goals.
From send toreceiptThe move towards commercialization ofmany public mail services (such as inJapan and France), which are typicallythe largest delivery networks in manycountries, is pushing postal services todifferentiate and add new and uniqueadvantages to their customer base. Thisadded pressure on the postal providersmeans more and more are turning totheir automation providers to help makethe difference. Customers of OEM postalautomation machine makers now desirehigh-speed, high-throughput, highly reli-able systems with flexible network optionsthat allow them to view mail flow through-out the entire delivery process.
Like most other industries, the postalindustry is trending towards higherthroughput at lower costs. With increasedcompetition from online bill generationand payments tied with increasingamounts of email-based advertising, avery large portion of many postal opera-tions’ incomes is decreasing.
At the same time, world population isincreasing and with it, the number ofdeliverable addresses. This creates a verydifficult situation for postal companies.Lower revenue coupled with a moredemanding and larger customer base hasforced a move towards more advancedsorting and tracking techniques that canallow for drastically reduced overhead,decreased delivery time and increasedcustomer satisfaction.
utomation /// Postal automation /// Postal automation /// Postal automation
19
MELSECNET/G
ERP/MES
Automation is helping postal service providers keep up with demand and direct, up to the millisecond data helps them stay in profit
Thankfully, Mitsubishi Electric is in thebusiness of delivering solutions specifical-ly for their customers success. Everyonearound the world right now is talkingabout Industrial Ethernet but only Mit-subishi Electric has delivered an Ethernetsolution that truly connects all levels of theprocess. By simply adding an MES moduleto a machine’s PLC configuration, the abili-ty to obtain data from every sensor, ampli-fier and motor becomes instantlyobtainable via a standard Ethernet con-nection. Track mail down to the latest sen-sor in the system, follow it throughmultiple passes, see instantly if it’s about tobe returned due to an unreadable addressor change its destination on the fly.
Control room
Receiving
DCV system
High speed insertion
Letter/flat mail sortation
In-line sortation
Shipping
High speed insertion /// High speed insertion /// High speed insertion ///
High speed insertion
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Seal the envelopeHigh speed insertion deals with insert-ing flat material into envelopes. This canbe anything from single to multi-foldadvertisements, magazines and evenCD’s and DVD’s. The technology is quick-ly getting more advanced and has tend-ed towards extremely high throughputmachines. While insertion systems arenot typically found in major postal sort-ing hubs, they are used frequently atprinting, marketing and advertising, anddirect-mail services companies.
Ensure alignment By utilizing an external master encoder,the entire insertion system can be syn-chronized to one axis. This means that assensors either upstream or downstreamobtain new information about the loca-tion of inserts, conveyors and diverters canbe adjusted for variations in product posi-tion all the while maintaining knowledgeof their relationship relative to the masterencoder.
In fact, utilizing data from various sen-sors is key to the success of a high speedinsertion machine. Not only does thesystem need to track the location ofmaterial, it also needs to continuallycheck for misfeeds, doublefeeds, paperjams and should notify employees whenpaper needs replacing. CC-Link offers anOpen Network standard for interfacingwith all of these sensors. It is alsoextremely easy to deploy and is capableof handling large numbers of I/O with-out degradation in performance.
Match your customer’s needsSince SSCNET III is a multi-drop servonetwork, additional axes can be addedto insertion machines on an as-needbasis. As the customer’s requirementsand demands grow, so can the system.Even in-field retrofits are made easy. Ifneeded, an extra motion CPU can beadded for an additional 8 to 32 axes upto a total of 96 axes from one PLC rack. Inaddition, CC-Link IE can be utilized tonetwork multiple insertion machinestogether. Thus, high levels of job coordination between machines can be accomplished.
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High speed insertion /// High speed insertion /// High speed insertion /// H
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Information andtrouble-shootingDue to a Mitsubishi Electric designedgraphics chip, the GOT1000 series ofHMIs is capable of producing 2D data(graphs, pictrograms, etc.) at a rate near-ly 4x as fast as competitive products.This means that job data can bestreamed straight to the system’s HMIand provide the user with up-to-dateinformation in an easily understood for-mat. The high-color, high-contrast dis-play along with the ability to displaydocuments and images, such as JPEGs,allows for trouble-shooting screens thatactually use photos of the system to showthe user where attention may be needed.
In addition, the GOT1000 gives usersmultiple ways to trouble-shoot the sys-tem. View ladder programs right on theHMI without any additional software orcomputers. In fact, the One-Touch Lad-der Jump function allows users to jumpstraight to ladder program steps thatmay have led to a system error. Thismeans that initial trouble-shooting canbe started immediately thus reducingdowntime and increasing productivity.When more advanced tactics are re -quired, a USB port embedded in thefront of the panel allows users to trans-parently access the controller withoutneeding to open any shop floor enclosures.
Insertion machines rely on precise co-ordination, often from a single reference axis
Input bin
Feed conveyor
Filler station
Exit conveyor
Envelope feed conveyor
Ethernet
ERP/MES
CC-Link IE
Q BUS
QD Motion CPU
MES interface
CC-Link Master
CC-Link IE
Ext. Encoder input module
Universal model QnUD CPU
Power supply
Exit conveyor
Filler station
Feed convey-or
Input bin 3
Input bin 2
Input bin 1
Envelope feed conveyor
Proximitysensors
Misfeed sensors
Jam detection sensors
External masterencoder
Letters and flat mail sorting /// Letters and flat mail sorting /// Letters and
Letters and flat mail Sorting
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Deliver yourmessageWithin the postal automation industryare a variety of markets. Large postoffices and airport airmail centers arecertainly two examples but even insur-ance companies, universities, printshops and financial institutions havematerial handling needs for either theirincoming or outgoing mail. Therefore,when it comes to automating the sortingof letters, flat mail and parcels, flexibility iskey. Mitsubishi Electric’s modular systemand various communication networksallow integrators and machine builders todesign a system with a base configurationthat can expand to meet each of their cus-tomer’s different needs.
Reduce the number of passesOne challenge in postal automation is inattempting to separate letters and flatmail and read various styles of handwrit-ing without the need to slow the systemdown or send mail back through the sys-tem for multiple passes. A high speed,distributed system is essential for creat-ing a flexible and high-performance sys-tem. For instance, MES modules allowfor real-time monitoring of data, provid-ing insight into process efficiency. Per-haps a specific barcode reader ismisreading too many envelopes and thusan excess of multiple passes is occurring.Identifying these bottle-necks is critical tocontinual improvement, happier cus-tomers and higher profits.
d flat mail sorting /// Letters and flat mail sorting /// Letters and flat mail /
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Presort and track In some countries, companies that pre-sort their mail prior to delivery to the postoffice receive large price discounts. Forexample, in the United States, presortingletters and flat mail down to a 5-digit zipcode can have dramatic cost savingresults. This is all part of the US Postal Ser-vice’s new strategic plan which alsoincludes the incorporation of CONFIRM,which uses passive barcode scanning toobtain in-process information about mail,such as current location and expecteddelivery dates.
These advancements, are more than justabout decreasing costs though. It is alsoabout increasing customer satisfactionand creating more reasons for business tocontinue using paperbased mail. Sowhether you want to couple machinestogether with CC-Link IE or bring themonline using an MES module, MitsubishiElectric can bring greater visibility to yourprocess.
Speed andexpandabilityMitsubishi Electric has a proven trackrecord in postal automation and ourproducts can be found on the highestperforming machines in the market.
Paving the way for this success is theability to mix and match technology tobest suit the application’s requirements.CC-Link is often used for interfacing withdownstream sensors and diverters in flatmail sorters. Servo motors and variablefrequency drives can also both beinstalled on the same multi-drop net-work allowing for easy wiring and opti-mum price-to-performance ratio.
Whether linking machines or monitoring performance Mitsubishi Electric's automation solutions increase your visibility
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Envelope feeder
Gapper sub-system
Diverter sub-system
Mail bin conveyor
Bin de-stacker
Ethernet
ERP/MES
CC-Link IE
Q BUS
QD Motion CPU MES interface
CC-Link Master
CC-Link IE
Universal model QnUD CPU
Power supply
Envelope feed conveyor
Gapper toproller
Mail bin conveyor
Gapper bottom
Remote I/O Barcode readers Photo eyes
Mail bin divertersAxis 1 Axis 2 Axis 3
Low cost solution /// Low cost solution /// Low cost solution /// Low cost /
A simple and low cost solution
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MESInterface
Shopfloor
Industrial robots
Motion controllerCNCs
EDMs Laser processing
Many companies today must survive inthe face of tough competition. Customersexpect perfect performance, high qualityand fast, punctual delivery, all for the low-est price. How can automated processesbe further enhanced cost effectively? Mitsubishi Electric's solution to this question is e-F@ctory – a concept basedon integrated system solutions and thecontinuous flow of information throughall levels. This allows the user to implement steady and continuousimprovement processes, reducing leadtimes, improving quality and reducingwaste – delivering a reduced total cost ofownership (TCO).
Integrated information flowThe seamless flow of informationbetween operations and management isno longer a dream for the future butdaily reality.
Thanks to e-F@ctory, company manage-ment can rely on up to date and meaning-ful information. This simplifies, improvesand speeds up decision making.
The MES interface product groupenables direct connection between theMES (Manufacturing Execution System)database and shop floor equipment,without a communication gateway suchas a PC. The information collected on theintegrated Automation Platform is linkedby the PLC MES interface module, and theinformation from existing equipment and3rd party controllers is linked by theGOT1000 MES interface function. TheMES interface product series links shopfloor equipment and MES informationsimply, with minimum cost.
Quality management
scheduling
Production planningcost management,
inventory management,task management, etc.
// Mitsubishi Quality /// Mitsubishi Quality /// Mitsubishi Quality /// Mits
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The MES Interface■ Provides accurate information in
real-time through direct utilizationof internal device information.
■ Simplifies system implementation bydirectly connecting to database(s).
■ Eliminates the need for PCs and programs, greatly reducing costs.
■ Improves reliability by changing thegateway PC to a PLC.
No PC programmingThe MES interface module is easily set-up using simple drag and drop configu-rations. This means both engineeringstaff and IT staff can quickly configurethe units to their needs without addi-tional programming skills.
65% decrease inimplementationcostImplementation costs can be reduced inmany ways including the removal ofmany interfacing PCs, their associatedsoftware platforms and the engineeringtime and effort involved. In addition,because Mitsubishi's MES solution is astandard module it can be added in ret-rospect to many existing System Qapplications as long as the standard con-figuration rules are not broken.
MES (Manufacturing Execution System)
database server
MES (Manufacturing Execution System)
database server
Control network (MELSECNET/H etc.)
Control network (MELSEC-NET/H etc.)
Overall controlling
PLC
Results manuallyentered or processingprogram executed by
operator
Gateway PC
Operation performance result data.Equipment management data.Quality control data.Traceability data, etc.
Accurate identification of System construction simplificationSystem construction simplificationSystem construction period and cost reductionStable operation.MES interface
After MES interface introduction
Standard
Guaranteed Mitsubishi qualityIntegrating allaspects ofautomationThe automation control system is basedaround the Automation PlatformSystem Q series integrated automationplatform which is an extensive range ofrack mounted controllers ranging fromentry level CPUs to high performancelogic, motion controllers, numerical control, and robot controllers, all availableon a consolidated high speed backplane.
Together with this, a range of digital I/O,high resolution analog, and intelligentfunction modules are available, providingan effective means of interfacing the con-trollers with external equipment andcomponents. In addition to the controllerseries, various networks are available toenable efficient data handling betweencontrollers or devices to save wiring andreduce costs. These are state of the art enterprise level Gigabit Ethernet (CC-Link IE), controller level (MELSECNET/H),device level (CC-Link).
Highly accuratehigh speed servodrive systemsThe MR-J3 has raised the bar for servospeed and performance. The capacityranges from 50W to 55kW and includes afull line up of linear motors as well. High resolution encoders (262,144ppr),advanced auto-tuning and vibrationcontrol are all standard and help to pro-vide stability at all speeds.
Set-up, diagnostics, and tuning are alleasy, thanks to MR Configurator, a Win-dows-based software package. MR-Con-figurator has many improved diagnosticfunctions, such as an advanced machineanalyzer, software oscilloscope, and highspeed monitor. A parameter setting win-dow makes start-up simple, and a USBinterface enables highspeed samplingand long-term wavelength measure-ment.
Intelligent energy saving AC drivesThe FR-A700 series of intelligent inverterAC drives are ideal for pump, fan, andconveyor type applications. Rangingfrom 200V to 400V series, from 0.4KW upto a maximum 500KW drive, the FR-A700can provide the best solution for manykinds of applications. With the highestperformance and VFD functions, such asReal Sensorless Vector control and inte-grated EMC filter.
The newest addition to the 700 series isthe FR-E700 compact intelligent drive,known for its high performance with itssmall footprint. This drive can be appliedto a whole range of applications wherespace is of concern without limiting onhigh performance functionality. Thesedrives are very easy to use having anextensive parameter setup architecturethat can be setup on board, by using util-ity software. Providing economical per-formance is second nature for both theFR-A700 and FR-E700 series, using mag-netic flux control to ensure optimummotor operation and ensuring efficientexcitation control minimizing motor lossand reducing the overall power con-sumption of the drive.
Mitsubishi quality /// Mitsubishi quality /// Mitsubishi quality /// Mitsubish
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High resolutionhuman machineinterfacesMitsubishi Electric manufactures adiverse range of Human Machine Inter-faces or Graphic Operation Terminals asthey are sometimes known. TheGOT1000 range starts from the GT115.7 inch compact GOTs, up to the large15 inch GT15 series. These terminals useTFT display technology and are solelydesigned on high performance withclear true color high resolution displays.
They also include a handy front mount-ed USB programming port to enableeasy access without having to open upthe cabinet to access the back of theGOT. The GOT can also be connected toexisting Mitsubishi networks such asMELSECNET/H and CC-Link, but can alsointerface directly with the Q series back-plane bus, resulting in very high com-munication speeds. A memory card canalso be inserted enabling storage of doc-uments, trend, and recipe data, alongwith CSV files, etc.
MELSOFT, a complete engineeringenvironmentThe MELSOFT engineering suite is anextensive range of software for program-ming, configuration and maintenance ofall Mitsubishi automation system ele-ments. Starting with the GX series whichconsists of a sophisticated ladder pro-gramming tool, debug, and maintenancesoftware combined with utility configura-tion software which helps when settingup intelligent function modules, withoutthe need for extra programming. Movingup a step is the MX series of softwarewhich provides a middleware for con-necting and monitoring external 3rdparty software with the Q series, i.e., datalogging spreadsheets, which can be asimple alternative to high end SCADAsoftware.
Leaving the controller series aside, theGT series provides a detailed graphicaltool for designing screens for theGOT1000 series, with embedded editingtools. MR Configurator is a simple programming and virtual debuggingenvironment for the motion controller.Programming and setting up parametersfor the FR-A700 series of intelligent drivescouldn’t be simpler with the FR Configu-rator software. In addition to parameter-izing the inverter drives on board, thisutility software enables parameterizationfrom your desktop PC. In addition to theMELSOFT programming software series, adiverse range of simulation software isavailable enabling you to debug yourprogram without the need for the actualhardware. MELSOFT is a key essential fortoday’s needs.
hi quality /// Mitsubishi quality /// Mitsubishi quality /// Mitsubishi quality /
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Global Partner. Local Friend.
Mitsubishi Electric Europe B.V. /// FA - European Business Group /// Gothaer Strasse 8 /// D-40880 Ratingen /// GermanyTel: +49 (0) 2102 4860 /// Fax: +49 (0) 2102 4861120 /// [email protected] /// www.mitsubishi-automation.com
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Customer Technology Centre,HatfieldPhone: +44 (0) 17 07 / 27 89 90Regional Automation Center,Wakefield Phone: +44 (0) 1924 255 628
IRELANDMITSUBISHI ELECTRIC EUROPE B.V.Irish branch, Westgate BusinessPark, BallymountIRL-DUBLIN 24Phone: +353 (0)1 41 98 80 0
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© Mitsubishi Electric Europe B.V. /// Specifications subject to change without notice /// Art.-no. 214519-B /// 07.2008All trademarks and copyrights acknowledged
For more information about our partners across Europe, please visit the contacts page of our internet site at www.mitsubishi-automation.com
