OMRON has launched the NJ501-R Robotic Integrated Controller, a world first and based on OMRON’s industry leading NJ series of machine controllers for industrial automation. With the integrated controller, it is possible to automate advanced and complex manual work, simulate the design and modification of production facilities in a virtual environment, and conduct maintenance remotely.

Integrated controller for robotic production systems

The new robotic integrated controller offers real-time synchronisation across all automation equipment.

The new machine controller offers real-time synchronisation across all automation equipment, including robots, vision components, drives, and safety equipment.

Improving the speed and accuracy of production, users can simulate entire production lines without having to deploy physical equipment. This will simplify maintenance and reduce time-to-market in the design, planning, commissioning, and changeover processes.

The world over businesses are experiencing a major turning point in how they conduct their operations in the context of global health concerns. As a result, the demand for more advanced automation with robots has increased across many industries, along with a growing demand for digitalisation.

Traditionally, automation equipment for production facilities has been controlled by a number of different controllers – presenting a major challenge to set up and coordinate the speed and timing between various devices. This also makes it difficult to verify a process design in advance with a high level of accuracy, prior to construction of a machine or larger production line. Once the equipment is commissioned, adjustments need to be made on-site and this can prove time demanding.

As a manufacturer of motion sensors, robotics and safety equipment for fully automated production lines, OMRON has addressed these issues by integrating the control equipment.

The Robotic Integrated Controller automates inserting and assembling processes that require delicate and skillful processing. The robots and equipment are controlled and fully synchronised in real-time by a single controller, improving device performance and, according to Omron research, achieving the world's highest level of throughput.

OMRON has also unified the programming languages for robot and machine control, making it easy to simulate a production line with single programming software. The system visualises the process, reducing man-hours required for process design and operational verification by up to 50%. Furthermore, all of this can be done remotely. Through Sysmac Studio’s user interface, users can design, program, troubleshoot, operate and maintain future automation systems remotely from anywhere in the world.

Key features

  • By integrating the PLC, motion and robot control in a single controller, complex manual work that previously could be conducted only by people can now be completed by robots.
  • The programming language for the PLC and robot is unified in the generic IEC language, which allows engineers who usually manage PLCs to manage robots as well.
  • With OMRON’s simulation technology, users can verify equipment performance at the early stage of equipment design, allowing mechanical designers and electrical designers to work in parallel. As a result, equipment commissioning can be completed in a shorter period, higher production capacity can be achieved, and mistakes and setbacks during equipment commissioning can be avoided.
  • The user can run the simulation using the emulation function in Sysmac Studio. The system does not require a connection to the actual machine for operation verification. The production capacity of the robot equipment can also be monitored digitally.
  • By re-using previously digitalised assets, it is easier to establish the next facility.

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