New controllers help achieve high production quality

Omron has announced that it will release the NX-series NX502 CPU automation controllers with advanced information control and safety control, simultaneously with the new NX-EIP201 EtherNet/ IPTM units.

This launch responds to the increase in efforts towards carbon neutrality at manufacturing sites that are starting to prioritize ESG (Environmental, Social, and Governance) management. Production lines for rapidly evolving high-tech products such as xEVs (electric vehicles with extended range) and digital devices need to be able to handle sudden changes in demand and have equipment that can easily adapt to these changes.

The new NX502 CPU and NX-EIP201 EtherNet/IP units utilise Omron’s advanced information processing, communications technologies, and large-capacity memory to achieve real-time analysis and process modularisation. This approach contributes to improving sustainability and minimising waste at production sites and shortening lead times when changing lines.

The high-precision data collection capability of the NX502, with a jitter of 1 μs or less, and data transfer capacity claimed to be approximately four times that of equivalent-class controllers, allows real-time analysis of production-related data, such as temperature, pressure, and flow rate, which can be reflected in processing conditions. This feature enables rapid process improvement and reduces loss of resources at various production sites.

As an application example, Omron points to the production of high-quality crystals which requires real-time monitoring and fluctuation of production-related data based on varying conditions. Communication performance limitations are a bottleneck to stable manufacturing quality. The high information processing capability of the NX502 enables early identification of the causes of process issues, leading to improvements in production conditions and stable mass production of crystals, for example for solar cells.

The NX502 and NX-EIP201 feature integrated control technology, allowing control of large-scale production lines with module division through up to eight network system separations and up to 254 safety connections4. This approach enables adjustment and checking of partial processes with minimal impact on overall operations, even on large lines. It also helps maximise energy productivity and significantly reduces lead times when changing lines.

In another application example, Omron points highlights a body frame welding line handling a wide variety of products. As market needs diversify, it may be necessary to add or change processes while mixed production of various vehicle models is ongoing. To minimise lead times by stopping only the relevant parts, the NX502 and NX-EIP201 separate network systems, including safety, allowing flexible responses to detailed changes in manufacturing sites, such as the addition of welding processes. This feature contributes to improving production efficiency.