Omron's Tailored Solutions for Modern Manufacturing
In today's globalized and rapidly changing manufacturing environment, companies face diverse challenges. Omron's industrial automation solutions, powered by the Sysmac platform, enable efficient, flexible, and cost-effective manufacturing by addressing these complexities.
Sysmac is designed to meet the demands of modern production by focusing on key pillars:
- Innovation: New technology for smart manufacturing, human-machine collaboration, and environmentally safe products.
- Productivity: Integrated systems for optimized manufacturing, real-time production data, and in-line quality inspection for zero defects.
- Flexibility: Quick product changeovers, open connectivity, and scalable systems.
- Reliability: Non-stop processes (24/7 operation) and extended product lifecycles.
- Globalization: Products meeting global standards with local support for training, repairs, and spare parts.
The Sysmac technology platform supports flexible and integrated production business models, benefiting manufacturers, panel builders, system integrators, and parts manufacturers.
Integration and Functionality
Sysmac provides complete control and management of automation plants. At its core, the Machine Controller series offers synchronous control of all machine devices, incorporating advanced functionality like motion, robotics, and database connectivity. This multidisciplinary approach simplifies solution architecture, reduces programming effort, and optimizes productivity.
Machine Control
The platform integrates motion and logic sequence control. It supports standard PLCopen Function Blocks and Omron-generated motion Function Blocks for direct synchronous control of position, speed, and torque.
Safety
Seamless integration of safety features enhances both productivity and safety. PLCopen safety Function Blocks simplify and accelerate development.
Information
Sysmac communicates in real-time with databases like SQL, ensuring data security with internal memory storage during server outages. It supports high-speed database operations for Big Data processing, predictive maintenance, and productivity improvements.
Vision
Higher resolution images are available without increasing processing time. Shape search technology provides stable and accurate object detection for Pick & Place applications.
Robot
A single controller can integrate different control engines, including cyclic scanning (PLC) and procedural programming (robot features), enabling direct robot control.
Sensing
Full control of process parameters and predictive maintenance functions are available, with high-precision detection and positioning data synchronized on the network.
One Connection
Sysmac defines its approach as one machine control through one connection and one software. The Machine Automation Controller integrates logic, motion, safety, robotics, vision, information, visualization, and networking under the Sysmac Studio software. This true Integrated Development Environment (IDE) includes a custom 3D motion simulation tool.
The machine controller comes standard with built-in EtherCAT and EtherNet/IP. These networks, used together, facilitate fast real-time machine control and plant data management. EtherCAT offers high-speed, precise control (125 µs cycle time, 1 µs jitter) with up to 512 slaves and embedded support in Omron drives, I/O, safety, vision, and sensing. EtherNet/IP supports peer-to-peer controller communication, interface with Sysmac Studio and HMI, database connectivity (SQL, Oracle, etc.), FTP server functionality, and secure cloud connection via MQTT.
One Software
Sysmac Studio is the integrated development environment for configuration, programming, and monitoring. Its graphics-oriented configuration allows quick setup of controllers, field devices, and networks. Machine, motion, and safety programming adhere to IEC standards and PLCopen Function Blocks, reducing development time. Features like the Smart Editor with on-line debugging, advanced simulation, and data trace capabilities further streamline the engineering process.
Key Sysmac Studio Features:
- Design: Reusable programs, programming with variables, model-based design, and import of Electrical CAD data for efficient setup.
- Development by multiple developers: Project version control (Git integration) allows merging and resolving changes efficiently.
- Advanced machine control: Utilizes PLCopen Function Blocks for Motion Control and supports importing complex feedback control designs from MATLAB®/Simulink®.
- Verification: 3D simulation options allow virtual environment testing. Debugging with third-party simulators is also possible.
- Maintenance: Efficient maintenance and troubleshooting through system-wide error management in Sysmac Studio and NA Programmable Terminal. Remote maintenance is supported.
The Sysmac Library provides pre-built Function Blocks for advanced applications and motion control, leveraging Omron's technical expertise to reduce programming time.
One Machine Controller
The NJ/NX/NY Machine Automation Controller is central to the Sysmac platform, designed for extreme requirements in logic sequence and motion control speed and accuracy. It integrates logic, motion, vision, and information for comprehensive machine management.
High-speed, High-precision Control
Architecture based on Intel® Core™ processors enables fast instruction execution (basic instructions 0.37 ns, math instructions 3.2 ns). Command values for servomotors can be updated as fast as every 125 µs, ensuring smooth cam motion and precise interpolation.
Integrated Safety
Safety control is integrated directly into machine control, supporting fast cycle times. It utilizes both EtherNet/IP (for production lines) and EtherCAT (for machines) for safety communications.
Fast Machine Data Storage
Controllers connect directly to databases (Microsoft SQL Server, Oracle, IBM DB2, MySQL, PostgreSQL, Firebird) without gateways, enabling real-time data collection for productivity improvement, predictive maintenance, and quality traceability.
Secure Host Connection
Equipped with an OPC UA server interface, the controller provides secure connections to IT systems like MES and ERP, aligning with Industrie 4.0 recommendations. It also supports secure cloud connections via MQTT.
Standard Programming
Fully compliant with IEC 61131-3 standards and PLCopen Function Blocks for Motion Control, simplifying development.
Global Standard Networks
Supports standard machine networks like EtherCAT and factory networks like EtherNet/IP.
Driving Machine Innovation
Sysmac enables advancements in speed, precision, and data utilization:
Case 1: High-speed alignment and vibration-free handling
The FH Vision System's Shape Search function and Visual Feedback Library enhance alignment speed and accuracy. The Vibration Suppression Library reduces waiting times and improves positional accuracy during high-speed handling.
Case 2: Data utilization improves yield
The NX5 controller, with its high data transfer capability, sends high-resolution data to databases at high speeds. Real-time feedback of database analysis results optimizes processing conditions, preventing defects and improving yield.
Case 3: Increase equipment availability through integrated safety
Integrated safety controllers and modular network configurations (up to 10 separate CIP Safety networks) allow localized process adjustments without stopping the entire production line, reducing lead times for line changes.
Case 4: Redundancy minimizes downtime
Cable Redundancy on EtherCAT networks ensures continuous connectivity even with disconnections, allowing for repairs without stopping production. This ensures safety by only stopping the line when operators are in danger.
Sysmac Family
The Sysmac platform comprises a comprehensive range of controllers, software, HMI, motion components, I/O systems, safety solutions, vision systems, sensors, and robots.
Controllers
NX Series:
- NX7: High-speed, high-precision control for large-scale systems (up to 256 axes, 0.37 ns instruction execution).
- NX5: Integrated control, information, and safety for fast-cycle, high-precision processing (up to 256 axes, 250 µs cycle time). Supports SQL, MQTT, OPC UA.
- NX1: Compact controller for small systems, integrating control and information (3 Ethernet ports, OPC UA).
- NX1P2: Compact controller with up to 4 axes motion control and built-in I/O.
NJ Series:
- NJ5: High-speed, high-precision control for large-scale systems (up to 64 axes).
- NJ501-R: Robot integrated CPU unit, combining logic, motion, Omron Robot, and kinematics for integrated control of different engines.
- NJ3: Ideal for small control systems (up to 8 axes).
- NJ1: Ideal for simple machines.
NY Series:
- NY5: High-speed control (0.33 ns instruction execution), 16-64 motion axes, 192 EtherCAT slaves.
Specification Table for Controllers (Simplified representation of key specs):
| Series | Model | Key Features | Motion Axes | Instruction Execution (LD) | Program Capacity |
|---|---|---|---|---|---|
| NX Series | NX701 | Large-scale, fast, high-accuracy | 128, 256 | 0.37 ns | 80 MB |
| NX Series | NX502 | Fast-cycle, high-precision, integrated info/safety | 128, 256 | 0.53 ns | 80 MB |
| NX Series | NX102 | Compact, control & info integration | 16, 32, 64, 128, 256 | 0.53 ns | 80 MB |
| NX Series | NX1P2 | Compact, built-in I/O, up to 8 axes | 0, 2, 4, 8 | 3.3 ns | 5 MB |
| NJ Series | NJ501 | Large-scale, fast, high-accuracy | 16, 32, 64 | 1.1 ns | 20 MB |
| NJ Series | NJ501-R | Robot integrated CPU | 16 | 1.1 ns | 20 MB |
| NJ Series | NJ301 | Small control, up to 8 axes | 0, 2, 4, 8 | 1.6 ns | 5 MB |
| NJ Series | NJ101 | Simple machines | 0, 2 | 3.0 ns | 3 MB |
| NY Series | NY5 | High-speed, compact | 16, 32, 64 | 0.33 ns | 40 MB |
Software
Sysmac Studio: The integrated development environment for configuration, programming, simulation, and monitoring. Fully compliant with IEC 61131-3.
Sysmac Library: Provides Function Blocks for advanced control applications like vibration suppression and temperature control.
HMI (Human Machine Interface)
NA Programmable Terminal: Transforms machine data into information, offering intuitive control with rich media and 16 million display colors. Connects seamlessly with Sysmac products.
Soft-NA: NA functions available on Windows PCs.
Motion
1S Series Servo System: Offers higher productivity and a safer environment with features like one-cable connection (power, encoder, brake), 20/23-bit high-resolution encoders, integrated safety functions (STO, SS1, SLS, etc.), and EtherCAT communications.
MX2-V2 Multi-function Compact Inverter: Provides torque control in open loop, quick response to load fluctuation, and integrated safety features (ISO 13849-1 Cat. 3/PLe). Supports up to 15 kW motor capacity.
RX2 High-function General-purpose Inverters: Energy-saving and high-performance with triple rating, PM motor control, safety function (STO), and optional EtherCAT communication.
I/O Systems
NX I/O System: High-speed and accurate I/O response (sub-microsecond accuracy, nanosecond resolution) synchronized with EtherCAT. Offers over 100 models including digital, analog, position, temperature, and safety I/O. Features NsynX technology and Push-In Plus terminals.
GX Series: Block I/O with EtherCAT communication, featuring detachable screw terminal blocks and e-CON connectors for easy setup.
Safety
NX Safety Control Units (NX-SL5/SL3/SI/SO): Integrate safety into machine automation. Support Safety over EtherCAT (FSoE) and EtherNet/IP (CIP Safety). Programming follows IEC 61131-3 and PLCopen Function Blocks for Safety. Modular design allows flexible mixing of safety and standard I/O.
Vision
FH Vision System: Optimized for high-speed, high-accuracy object detection. Features advanced shape search technology, AI Scratch Detect Filter, and a lineup including high-resolution cameras (up to 20.4 Mpix).
FHV7 Smart Camera: An all-in-one, compact, robust camera with FH Series vision functionalities, including autofocus and advanced shape search. IP67 protection for wet environments.
Sensing
Confocal Fiber Displacement Sensors (ZW-8000/7000/5000 Series): High-precision in-line measurements for various materials and surfaces using white light confocal principle. Supports measurements of shiny, thin, or minute parts, and diffuse reflective objects.
N-Smart Series: Next-generation fiber, laser, and contact sensors that connect to EtherCAT. Features include easy tuning, stable detection, predictive maintenance, and network connectivity for multiple sensors.
Robots
Omron offers Parallel, SCARA, and Articulated robots designed for direct control by the NJ501-R Robot Integrated Controller via EtherCAT. These robots are suitable for various applications like Pick & Place, assembly, material handling, and palletizing, offering high speed, precision, and payload capacities.
- Parallel Robots: iX3, iX4 (e.g., for food, pharmaceutical industries).
- SCARA Robots: i4L, i4H, eCobra (for assembly, material handling, screw driving).
- Articulated Robots: Viper (6-axis robots for assembly, palletizing).
Service and Support
Omron provides comprehensive service and support through a global network of technical offices and Automation Centers. This includes expert consultation for design and proof-of-concept, flexible technical support during prototyping, and on-site assistance for commissioning and serial production worldwide.
Omron's commitment extends to fast supply (within 24 hours) and repair (within 3 days) for its global products, which meet international standards such as CE, cULus, NK, and LR.
