New CNC controller integrated with PLC controls complex production lines.

Mitsubishi Electric has launched a hyper fast CNC controller that sits on the high-speed rack used by its powerful iQ-R Series PLC platform. Offering nanometre scale control over machine tool functions, the new C80 CNC controller and integrated iQ-R platform manages complex production lines with a single control platform.

The advantages of integrating a powerful CNC controller with Mitsubishi’s most advanced modular iQ-R PLC, is the performance gain from having both devices communicating via a high-speed bus. Together they can coordinate and manage a complete production line from the robots and machine tools to the HMIs and overhead displays. Fast data management and perfectly synchronous operation not only speeds-up production, but improves quality and allows for more operations to be packed into a smaller space.

Not only does this improve overall performance, but due to ease of integration and a common programming environment Mitsubishi’s GX Works3, it can save a considerable amount of time in the design and commissioning phase. Being faster to install and commission reduces set-up costs, while replacing on-machine controls with the unified system reduces hardware costs for controlling a CNC production line for example.

Originally developed for the automotive industry, the combination of the C80 CNC controller and iQ-R PLC the systems applies equally to other complex automated manufacturing applications that would otherwise have employed several different CNC solutions and controllers. Configured with up to 3 CPUs (21-part systems and 48 axes) for example, the C80 can control highly complex machines.

Retrofitting

The C80 and iQ-R control platform is suitable for retrofitting into existing machines to give a capacity beyond any existing CNC or PLC solution. With the common control platform established, future changes and upgrades are faster to implement and less costly, as adding modules to an existing PLC rack is simpler and cheaper than purchasing and integrating a new controller.

Improving machine performance and safety

A reduced cycle-time for commands within the control platform is the key to increased system speed and performance. By using one single automation platform that is communicating via high-speed data bus, optimal communication is achieved between the servo-drives. In addition to the added speed and precision, the C80 Series provides a range of safety features collectively called the Smart Safety Observation Function.

The new lower cost combination enables a full production line control system to increase its added value and reduce its Total Cost of Ownership (TCO) in five key areas: improvements in productivity, ease of use, connectivity, functional safety and reliability.