MELSEC iQ-R Series Broadcast

Story

Extensive data handling from shop floor to business process systemse-F@ctory is a solution from Mitsubishi Electric helping to optimize production systems through its direct connectivity between an IT system and the shop floor reducing cost over the entire product life cycle. Production data management, analysis and planning utilizing IoT* can be realized, improving productivity through preventive maintenance, operations management, traceability, and energy management. The MELSEC iQ-R Series includes a range of products that fulfill these various needs as part of the “Intelligence” lineup of interconnected e-F@ctory advanced information products.

Direct access to IT system databaseRealize improved production management and reduce overall system costs through real-time direct access to IT system database servers without requiring additional programming and gateway computers.

Highlights

• Direct access to IT system database • C/C++ based programming • Installation of various communications protocols • High-speed collection of shop floor data in real-time • Utilize third-party partner applications

* Internet of Things

C/C++ based programmingProvides a robust and cost-efficient alternative from computer-based analytical and testing systems, enabling custom applications to be executed directly on the control system. In addition, various communications protocols can be installed directly.

High-speed data logging simplifies troubleshootingManaging production line data, accurate identification of failures and keeping daily/monthly records can be realized at a low cost.

C Controller module

C intelligent function module

MES Interface module

High-speed data logger module

iQ Platform-compatible PACe-F@ctory Advanced Information Modules

Fail

Pass

Ethernet

C Controller Module

Inspection data in the CCPU

High-speed Data Logger Module

C Intelligent Function Module

MES Interface Module

Mitsubishi Electric PAC MELSEC iQ-R "Intelligence" Movie

Utilize various partner applications

CustomizationA dedicated functions and communications library

is provided, enabling access to the control system

modules. In addition, various partner applications are

available, helping to reduce development time and

cost as the additional development of applications and

drivers are not required.

Ideal for harsh industrial environments

RobustPart of the MELSEC iQ-R Series, high-quality and

reliability is ensured with fewer chances of product

failure, as is associated with computer-based hardware.

In addition, designed without an additional fan, the

products can be used in clean fab-based applications.

High-speed production data collection

Data loggingEnables high-speed data logging that can be

synchronized with the controller scan time, as an

alternative to a dedicated logging client computer.

Includes features such as triggering and reporting that

improve troubleshooting of the manufacturing process.

SD memory card • Excel® file

• Unicode text file

• CSV file

• Binary file

File server

Possible to install various communications protocols • Wind power generation plant systems

• Building automation

• Various industrial open fieldbus networks

1

Fail

Pass

Ethernet

C Controller Module

Inspection data in the CCPU

High-speed Data Logger Module

C Intelligent Function Module

MES Interface Module

i Intelligence

Extensive big data handling from shop floor to

business process systemsThe “Intelligence” lineup is comprised of interconnected advanced information

products that handle, collect, and process various data enabling improved productivity,

maintainability, and reduced system downtime and asset costs. The lineup includes

direct IT system database connectivity via the MES Interface, C/C++ level programming

for processes requiring high-level analytics such as in-process testing and

application-specific communications protocols. In addition high-speed data logging,

which simplifies troubleshooting and promotes low-cost maintenance solutions.

C/C++ based programming

FlexibilityBased on the ARM® dual-core Cortex A9 processor,

the real-time OS VxWorks® C Controller CPU is ideal

for high-end analytical requirements where raw data

has to be processed, such as for in-line manufacturing

quality testing. The C Intelligent Function Module, based

on the same processor, is a versatile programmable

module that can be used for installing industry-specific

communications protocols; for example, plant-wide

monitoring of wind power generation farms, building

automation and industrial open fieldbus networks.

Direct access to IT system database servers

Information connectionImprove production management and recipe data

handling via real-time direct access to IT system

database servers such as Oracle® and Microsoft®

(SQL Server®, Access®). Overall system cost is also

reduced as additional programming, which can increase

engineering time, and gateway computers are no longer

required.

IoT server

IT systemdatabase server

2

System configuration costs reduced by 65%*2

MES Interface modules enable direct connectivity between IT database servers and programmable controllers on the shop floor, eliminating the need for gateway computers or specified programs. Being much more reliable than computers, the MES Interface saves on maintenance costs typical of computers.*2. Assumption based on a typical control architecture.

MES Interface module specificationsItem RD81MES96

Database connection

Supported database*3 Oracle® Database, Microsoft® SQL Server®, Microsoft® Access®, MySQL®, PostgreSQL

SQL text SELECT, INSERT, UPDATE, DELETE, Multi-SELECT, STORED PROCEDURE

Database communication action field 65,536

Accessible CPU module*3 iQ-R Series (Direct, Remote), Q Series (Remote), L Series (Remote)

Data sampling interval

High speed data sampling (ms) Sequence scan time synchronization, 1…900 (up to 8K points)

General data sampling (s) 0.1…0.9, 1…3600

Function

DB record read/write Reads/writes data in the database of the host information system

Device memory read/write Reads/writes device memory data of the CPU module

Trigger condition monitoringMonitors values of the time or device tag components etc., and starts jobs when a trigger condition changes from

false to true (the condition is satisfied)

Data operation and processing Performs four arithmetic operations, obtains remainder, performs character string operation, etc.

Program execution Executes a program on the server through a MES Interface module

DB bufferingBuffers the data sent to the database, and resend it after recovery, when the data cannot be linked due to the

disconnection of the network between MES Interface module and the database or failure of the database etc.

REST server*4Enables job-related operations and job information acquisition from the REST client

(Also supports the XML process function for the MELSEC-Q Series MES interface module)

Setup software

MES Interface function configuration tool SW1DND-RMESIF-E

*3. For details, please refer to the relevant manual (for support related to the database, please contact the relevant database software company).

*4. REST: Representational state transfer

■ MES Interface ModuleRD81MES96

Along with ever-changing manufacturing trends, improving machine productivity and maintaining manufacturing quality through meticulous traceability have become a fundamental part of manufacturing. MES Interface modules address these requirements by providing direct database connectivity for IT systems and facilitating automatic SQL*1 text generation using intuitive configuration setup software. Modules allow production data from the shop floor to be inserted into database records directly; for example, providing real-time production status that enables quicker response to production-related problems.*1. Structured Query Language is a programming language designed for managing data in a relational database.

• Shop floor data acquisition in real-time

• Direct access to database without programming or gateway computers

• High reliability • Reduce system costs by 65%

IT system database server

Research and development

System development

Commissioning and testingHardware cost

Gateway computer • Requires dedicated

applications program

MES Interface System

Conventional System

Conventional System

MES Interface System

Reduce system costs

by 65%

Direct access to database without requiring additional

programming or gateway computers

3

Data logging synchronized with control system scan timeAcquired data can be synchronized with the control system scan time and achieve sampling rates up to 0.5 ms, realizing a higher resolution that enables changes in control data to be captured.

0 200 400100 300

High-speed data sampling function: 0.5 ms (max.)

These areas are not captured

with slower sampling rates

Normal

range

Time (ms)

High-speed data logger module

Computer

Easier route cause analysisEvent-driven data can be acquired right before and after the trigger occurrence, improving the recovery time of the control system.

Data(machine

status)

Only this range is saved as logging data

Only the data required for analysis is saved, enabling faster troubleshooting

Uses minimum storage capacity

Time

Trigger occurs

Utilize data for various analysis and maintenance processesVarious data, such as the frequency and duration of a specific operation that has been satisfied, can be utilized for preventative maintenance and machine operation/trend analysis.

High-speed data logger module specificationsItem RD81DL96

Accessible CPU modules iQ-R Series (Direct, Remote), Q Series (Remote), L Series (Remote)

Data sampling interval

High-speed data sampling (ms)

•Sequence scan time synchronization

•0.5...0.9, 1...32767 (for trigger logging)

•2...32767 (for continuous logging)

General data sampling (s) •0.1...0.9, 1...32767

•Time interval specification (specify hour/minute/second)

Amount of sampled data

High-speed data sampling •Overall amount of data: 32768 (per setting: 1024)

•Overall number of device points: 32768 (per setting: 4096)

General data sampling •Overall amount of data: 65536 (per setting: 1024)

•Overall amount of data: 262144 (per setting: 4096)

Function

Data logging Logs CPU module device values at specified data sampling intervals.

Event logging Monitors sampled device values from the CPU module, and logs events that occur.

Report Outputs the data sampled by the high speed data logger module as an Excel® file.

Recipe

Executes the following operations using recipe files stored in the SD memory card:

•Transfer device values written on the recipe files to devices in the CPU module.

•Transfer device values in the CPU module to the recipe files.

Setup software

High-speed data logger module tool SW1DNN-RDLUTL-E*1

*1. For information on how to obtain the software, please contact your local Mitsubishi Electric sales office or representative.

■ High-speed Data Logger ModuleRD81DL96

The production process data acquisition feature of this high-speed data logger module contributes to improving production quality and efficiency, thereby realizing optimal production processes. The module enables logging of various data such as Unicode, CSV, and BIN text formats, which can be utilized for spreadsheet reporting owing to the automatic report generation feature: BIN text format data can be ported directly to Microsoft® Windows® Excel®. Logging files can also be automatically sent to a FTP server or directly into a Microsoft® Windows® share folder.

4

100

150

200

Reduce long-term tangible costsExtremely robust, the MELSEC iQ-R Series C Controller is designed for use in industrial automation environments. Unlike computers, which are mainly used for non-industrial applications, the C Controller reduces the need for multiple maintenance cycles and purchasing newer equipment as components and software become obsolete or faulty, which can drastically add to the total cost over the long-term.

Realize complex arithmetic equations in C/C++The C Intelligent Function module enables the execution of C/C++ programs when paired with a standard MELSEC iQ-R Series Programmable Controller CPU, emulating the same features as a standalone C Controller. Representing complex arithmetic and string equations in C/C++ programs is much easier than implementing in ladder form, thereby reducing overall development time and program size. Additionally, Intellectual property is simplified as the result of separating it from the ladder program.

■ C Controller ModuleR12CCPU-V

■ C Intelligent Function ModuleRD55UP06-V

The C/C++ module series is available in two types, with both modules having a multi-core ARM®-based controller pre-installed with VxWorks® Version 6.9, which realizes simultaneous execution of programs, thereby providing a robust and deterministic alternative to computer-based systems. Utilizing a fan-less hardware design, the C Controller and C Intelligent function modules are ideal for clean fab-based environments, where dust circulation can be detrimental to the production environment, and can be used for applications such as in-line production quality testing or as a gateway for various industry-specific communications protocols.

◼ Maintenance cost over time

Cost

Date of purchase

Cost parity

Computer

MELSEC iQ-R SeriesC Controller

Years

Roughly 50% difference in initial cost

Substantialcost difference

I/O control I/O control

C/C++ program call operation

Arithmetic, string processingComplex processing executed directly in C/C++ program

Call execution command

C/C++ program

Processing result

Programmable Controller CPU moduleC Controller or Programmable Controller CPU plus C Intelligent Function module

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Versatile low-cost programmable module utilizes various communication protocolsA versatile programmable module that supports the use of various communications protocols required for specific applications, such as plant-wide system interfacing for wind power generation and dedicated building automation communications. These modules allow custom protocols to be installed, enabling control systems that can manage data plant-wide to be integrated into the application.

Ethernet

Wind power generation systems

Supports various application-specific communications protocols:• Wind power generation systems• Building automation • Various industrial open fieldbus networks

Building automation

Application development in simple stepsDeveloping applications with the MELSEC C Controller is easy as no additional driver development is required, thereby providing a full-scale embedded development environment at a relatively low cost. CW Workbench is the main programming software, and uses C/C++. CW-Sim/CW-Sim standalone is a VxWorks® emulator, which enables debugging without requiring any hardware.

No need to generate OS or drivers.This program does it all.

Engineering tool for C Controller CW Workbench

Easier to configure various control systemsDedicated functions and communications library are provided, enabling access to the control system modules. In addition, various partner applications are available, supporting different manufacturing equipment features.

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110101001010100

101011010100010

111011101110101

111010010101110

CCPU functions

C/C++

MD functions C Controller

C Controller

Access to modules using dedicated functions

Third-party partner applications

C Controller module, C intelligent function module specificationsItem R12CCPU-V RD55UP06-V

Hardware

Endian format Little endian Little endian

MPU ARM® Cortex-A9 Dual Core ARM® Cortex-A9 Dual Core

Working RAM 256 MB 128 MB

ROM 12 MB 12 MB

Backup RAM 4 MB –

Software

OS VxWorks® Version 6.9 VxWorks® Version 6.9

Programming language C/C++ C/C++

Programming development environment CW Workbench/Wind River Workbench3.3 CW Workbench/Wind River Workbench3.3

Setting/monitoring tool CW Configurator (SW1DND-RCCPU) GX Works3 (SW1DND-GXW3-E)*1

Communication interface

USB ● –

Ethernet (1000BASE-T/100BASE-TX/10BASE-T) 2CH 1CH

RS-232 (9600...115200 bps) 1CH –

SD memory card slot ● ●

*1. Setting and monitoring of the module is integrated within the GX Works3 engineering software.

SoftwareType Model Outline

CW Workbench

SW1DND-CWWR-E Engineering tool for C Controller module, C intelligent function module

SW1DND-CWWR-EZ Additional license for R12CCPU-V, RD55UP06-V

SW1DND-CWWR-EVZ Update license for R12CCPU-V, RD55UP06-V

CW-Sim

CW-Sim Standalone

SW1DND-CWSIMR-EZ VxWorks® simulation environment for CW Workbench, additional license

SW1DNC-CWSIMSAR-E VxWorks® simulation environment for CW Workbench, standalone type

MELSOFT CW Configurator SW1DND-RCCPU-E Setting and monitoring tool for C Controller module

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Big Data handling across the plantAs production management, analysis and planning have become more mainstream, the MELSEC iQ-R Series advanced information modules enable large amounts of various key data to be handled easily across the manufacturing plant. MES Interface modules help improve traceability and production planning by enabling manufacturing data to be processed directly in the IT server, thereby saving time in operations management and providing a real-time overview.

Utilizing the power of C/C++ programmingImprove quality in manufacturing processes by incorporating the C Controller or C Intelligent Function Module in production control systems. Inspection results can be obtained immediately, eliminating the need of a separate standalone computer. Existing program assets are also maintained without having to re-engineer the entire inspection system.

High-speed logging of production dataUse High-speed Data Logger modules to collect high-resolution processing data, and visualize minor changes in processing parameters before a fault develops, thereby improving preventive maintenance and reducing system downtime. Data can be used for post-maintenance analysis as well.

Minimize overall cost of assetsIntegrating these various advanced information modules will contribute to improving overall factory operations. Additionally, hardware costs can be reduced by eliminating the need for separate computers, which were previously required for high-speed, large-volume data processing.

IT system

database server

Post-soldering inspection

SMT pick and place

Reflow oven

Final assembly

Packaging

Central control room

MES Interface Module • Traceability • Preventive maintenance • Operations management • Production control

C Controller Module • In-line quality testing • Traceability • Communications interface

High-speed Data Logger Module • Production process data acquisition • Traceability • Route-cause analysis • Preventative/Corrective maintenance

C Intelligent Function Module • Communications interface • Production process data acquisition

HEAD OFFICE: TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN

www.MitsubishiElectric.com

R005ENG-B 1710[IP]New publication, effective Oct. 2017.

Specifications are subject to change without notice.

For safe use• To use the products listed in this publication properly, always read the relevant manuals before use.

• Company names and product names used in this document are trademarks or registered trademarks of their respective companies.

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