Company : Mitsubishi Electric Corporation

Category : Production Control Equipment and Testing Systems

Key Products : Powertrain, Press, Weld, Paint, Final assembly

With over 90 years of experience in providing reliable, high-quality products, Mitsubishi Electric Corporation (TOKYO: 6503) is a recognized world leader in the manufacture, marketing and sales of electrical and electronic equipment used in information processing and communications, space development and satellite communications, consumer electronics, industrial technology, energy, transportation and building equipment. Embracing the spirit of its corporate statement, Changes for the Better, and its environmental statement, Eco Changes, Mitsubishi Electric endeavors to be a global, leading green company, enriching society with technology. The company recorded consolidated group sales of 4,394.3 billion yen (US$ 38.8 billion*) in the fiscal year ended March 31, 2016. For more information visit: www.MitsubishiElectric.com *At an exchange rate of 113 yen to the US dollar, the rate given by the Tokyo Foreign Exchange Market on March 31, 2016

About Mitsubishi Electric Factory Automation Business Group Offering a vast range of automation and processing technologies, including controllers, drive products, power distribution and control products, electrical discharge machines, electron beam machines, laser processing machines, computerized numerical controllers, and industrial robots, Mitsubishi Electric helps bring higher productivity and quality  to the factory floor. In addition, our extensive service networks around the globe provide direct communication and comprehensive support to customers. For more information please see:

Power Train Production Systems

Power train production is at the heart of any automotive business, and is a complex multi-facetted operation embracing many different processes, such as CNC metal cutting, materials handling, sensing, test and measurement. In order to meet demanding productivity objectives, accuracy, repeatability, consistency and precision must all be to the highest standard.

Traditionally a plethora of technologies have been deployed within power train production – CNC machines, motion control, tracking and tracing, gauging and measurement, sequence control, networked data collection. This makes for a high total cost of ownership and raises risks associated with designing, operating and maintaining multiple systems from different vendors that may not have been intended to work together. This can diminish and slow return on investment. Longer term, a poorly running plant has more difficulty justifying further capital investment making it difficult to remain abreast of changing market demands.

Mitsubishi uses its expertise as a leading developer of control technologies to rationalise these varying forms of production control into a single system. This is based on the iQ Automation Platform, which supports dedicated systems for CNC, motion control, sequence control and information management on a single controller. This in turn is easily applied to plant operation, testing, materials transfers, data collection and analysis, production reporting and management information generation.

Precision Press Components

A press shop combines many different functions, including materials handling and storage, as well as the precision press operations. Data management is critical because absolute traceability of finished panels is vital for efficient operations; inaccurate, incomplete or lost data will reduce productivity massively.

Within Mitsubishi’s solution is every technology required for successful operations. Inverters such as our FR family offer energy saving benefits wherever motors are used, from the high power units running the press itself to the material handling systems taking raw material in and finished panels out.

Precision servos such as the MR-J4 family run automated ASRS cranes for panels in temporary storage, while controllers such as the iQ Platform orchestrate the general operations and provide powerful data management abilities.

A comprehensive open network architecture such as CC-Link reduces wiring costs, simplifies maintenance and insures information is readily available where needed, when needed. This all combines into one highly efficient and flexible production system that is straightforward in its initial set up, reliable in operation and simple to reconfigure as changing market demands dictate.

Automated Welding Systems

In the modern automotive plant, safety and standard control often need to be highly integrated. Stringent safety legislation means manufacturers are under steadily growing pressure to demonstrate that they are doing everything possible to protect personnel. An integrated approach means that manufacturers can address safety requirements and productivity goals without conflict or compromise.

Safety systems must of course stop machinery in response to events where safety of personnel is paramount. Mitsubishi’s integrated approach to machine safety enables the efficiency of automated processes to be increased while still offering the highest levels of safety to protect both operators and the machines themselves.

A portfolio of safety technologies and safety networking covers the whole spectrum of protection requirements that enable effective, integrated safety systems to be implemented simply and efficiently. They make it easy to adopt zonal approaches to safety, where an event on one aspect of the production line doesn’t necessarily have to impact on upstream or downstream production.

Incorporating open communications networks such as CC-Link allows both machine controllers and safety systems to be mixed on a single network. This provides tight coupling of safety and machine control to provide a unified approach to the automation of the whole production line. The CC-Link network architecture can also be extended to increase plant visibility, hence playing a key role in maximising machine availability on a plant-wide basis.

Paint Shop

The paint shop is another critical process area in automotive manufacture. The finish is absolutely critical to the customer’s perception of quality, and the variations in possible colours give manufacturers the opportunity to differentiate themselves.

Environmental compliance in increasingly important, while there is a constant drive to reduce wastage and therefore costs. As elsewhere, traceability has to be 100 per cent.

These combined requirements for high quality and maximum traceability place stringent demands on control systems.

Quality depends not simply on how well the paint is applied, but also temperature and humidity are critical aspects to be considered and controlled.

At the same time, automotive manufacturers must also focus on the impact of potential paint spray related pollution and take steps to neutralise potentially harmful emissions before they reach the atmosphere.

Mitsubishi can offer an integrated solution to address all these issues. Our System Q can combine precise control of paint temperature and booth environmental conditions with emissions compliance monitoring. The FR Family of inverters offers high power models that also offer maximum energy efficiency in air house fans. Our controller and network portfolio provides the necessary coordination between these systems and with the rest of the plant using the e-F@ctory technology of our MES interfaces. This insures the necessary data management capabilities to insure the required levels of process transparency and traceability.

Automotive Final Assembly

Final assembly is the point at which so many of the features that are unique to a given customer’s order are incorporated in the vehicle, from engine variants to trim options to comfort features and more. Mistakes impact the bottom line through reduced productivity and rework. HMIs networked to PLCs and the MES environment can provide operators with a ‘fool proof’ system for final assembly that can dramatically reduce the possibility of mistakes.

The same HMIs can also double as problem-solving terminals, eliminating the need to plug in diagnostic PCs, and enabling operators to diagnose and solve problems on the line as and when they occur. Allowing the operators to take local control and ownership of the line provides a big boost to productivity.

HMIs that provide a window into the process also ease ongoing maintenance efforts, making it simple to implement predictive and proactive maintenance schedules. This holds the key to reducing unscheduled downtime and maximising line availability.

Contact Details

Mitsubishi Electric Corporation
Tokyo Building 2-7-3, Marunouchi, Chiyoda-ku,
Chiyoda-ku,
Kokyo 100-8310
JAPAN
Tel: +81 3 3218 2111
e-Mail: info@mitsubishi-automation.com
URL: www.mitsubishielectric.com

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