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NJ

NJ Overview

NJ

Motion, Logic, Safety, Vision and HMI in one

Sysmac: A fully integrated platform

Integration and Functionality

Sysmac is an integrated automation platform dedicated to providing complete control and management of your automation plant. At the core of this platform, the Machine Controller series offers synchronous control of all machine devices and advanced functionality such as motion, robotics and database connectivity. This multidisciplinary concept allows you to simplify solution architecture, reduce programming and optimize productivity.

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One Machine Controller

Complete integration of motion and logic sequence

One Integrated Development

Environment software for Configuration, Programming, Simulation and Monitoring

Motion

• Motion Control: Integrated within the IDE, and operating in real-time
• Standard PLCopen Function Blocks plus Omron generated motion FB’s
• Direct Synchronous control for Position, Speed and Torque

Safety

• All safety related data is synchronized with the whole network
• The PLCopen® FBD simplifies and accelerates the development process through structuring safety circuits and enhancing reuse.

Vision

• Higher resolution images available without increasing the vision processing time
• Shape search technology: Provides more stable and accurate object detection for Pick & Place projects

Robot

• Function Blocks in Adept Robot Control Library enable robot control from the NJ/NX/NY Controller using Ladder and Structured Text

Sensing

• Full control of the process parameter setting and predictive maintenance functions
• High precision detection and positioning data synchronized on the network

Integrated Automation Control:

The Sysmac platform is scalable and provides the performance and functionality for a wide range of solutions from simple machines through to manufacturing cells

Information

• Sysmac communicates in real-time with Databases such as SQL
• Secure Data: In the event of a server going down or losing communications, data is automatically stored in internal memory
• Sysmac operates with Databases at high speed [1000 table element/ 100 ms] ensuring realistic Big Data Processing to improve productivity and aid predictive maintenance etc.

One Connection

Seamless machine control and factory automation

One machine control through one connection and one software is how we define the Sysmac automation platform. The Machine Automation Controller integrates logic, motion, safety, robotics, vision, information, visualization and networking under one software: Sysmac Studio. This one software provides a true Integrated Development Environment (IDE) that also includes a custom 3D motion simulation tool. The machine controller comes standard with built-in EtherCAT and EtherNet/IP. The two networks with one connection purpose is the perfect match between fast real time machine control and data plant management.

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EtherCAT - Machine Control

• Fast and precise: Fastest cycle time of 125 μs, synchronization with 1 μs jitter
• 512 slaves
• Embedded in Omron servo drive, inverter, I/O, Safety, Vision and Sensing
• Uses standard STP Ethernet cable with RJ45 connectors
• One connection using Safety over EtherCAT (FSoE) protocol

Ethernet - Factory Automation

• Peer-to-Peer controller communication
• Interface with Sysmac Studio , NA HMI or SCADA software
• Database connection for Microsoft SQL Server, Oracle, IBM DB2, MySQL and Firebird
• FTP server

One Software

One Integrated Development Environment Software

Created to give you complete control over your automation system, Sysmac Studio integrates configuration, programming and monitoring. Graphics-oriented configuration allows quick set-up of the controller, field devices and networks while machine and motion programming based on IEC standard and PLCopen Function Blocks for Motion Control cuts programming time. Smart Editor with On-line debugging helps quick and error free programming. Advanced simulation of sequence and motion control, and data trace reduce machine tuning and set-up.

Design

Reusable programs

Programming with variables

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One Integrated Development Environment software Sysmac Studio is fully compliant with the open standard IEC 61131-3. Programming with variables eliminates the need to learn the internal memory map of the PLC and allows the programs to be reused.

Development by multiple developers

Project version control function *

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When you develop a project at the same time as your colleagues, the Sysmac Studio combined with the version control system (GitTM) merges changes automatically and resolves conflicting changes. This makes merging easier and faster. You can even revert to the previous revision after graphically comparing the current project with a previous one.
* This function can be used by applying the Team Development Option to Sysmac Studio version 1.20 or higher.
  Project version control function is supported by CPU Unit version 1.16 or later.

For advanced machine control

Motion programming

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Advanced motion control applications can be created quickly just by combining PLCopen® Function Blocks for Motion Control.

Model-Based design

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Complex feedback control that is designed with MATLAB®/Simulink® can be imported into programs.

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Verifification

Fast system debugging

Virtual mechanical debugging

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Before the mechanical prototype is completed, motion can be checked and the program can be debugged. This cuts design time.

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3D simulation

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Motion trajectories in 3D can be pre-tested with advanced simulation of sequence and motion control. Simulation of single Function Blocks, POU’s (Program Organization Unit) or the entire program can be performed.
In addition all standard features such as Break & Step are available. Easy tuning and debugging reduce the set-up times of machines and production lines.

Maintenance

Highly efficient maintenance

Troubleshooting

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Troubleshooting in the Sysmac Studio and NA Programmable Terminal can manage errors across the entire system including the controller. You can check details of errors and solutions without reading manuals.

Remote maintenance

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Movement of the machine connected online can be displayed on the CAD in real time, and movement can also be reproduced from the trace data.
Maintenance and troubleshooting can be performed in remote locations.

Collection of software functional components Sysmac Library

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Packed with Omron’s rich technical know-how, the Function Blocks in the Sysmac Library for advanced applications and motion control cut programming time.

One Machine Controller [NJ/NX/NY Machine Automation Controller]

Powerful, yet easy to configure

The NJ/NX/NY Controller is at the heart of the Sysmac platform. One integrated controller is designed to meet extreme requirements in terms of logic sequence and motion control speed and accuracy. Standard programming and open networks make it easy to build your automation system.

High-speed, high-precision control *1

Architecture based on Intel® CoreTM i7 processor significantly speeds up the execution of instructions (basic instructions 0.37 ns, math instructions for Long Real Data 3.2 ns). Command values to send to servomotors and stepper motors can be updated as fast as every 125 μs.
This enables smooth cam motion and high-precision interpolation and phase adjustment between axes.

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Complete integration of motion and logic

One controller integrates logic, motion, vision and information for complete control and management of machines. Position, displacement, and tension information collected from sensors can be quickly and easily fed back to the motion control.

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Integrated safety into machine control*3

The controller integrates safety control into machine control in lines that require fast cycle times. It also integrates two different open networks: EtherNet/IP for safety control in production lines and EtherCAT for safety control in machines.

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Collection of software functional components Sysmac Library

• FB library option for advanced applications (vibration suppression, temperature control, motion control...)
• High quality products with reliable global support

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*1. Performance of NX701-1[]00
*2. Based on Omron investigation in February 2015.
*3. Performance of NX102-[][][][] and NX-SL5[]00
*4. Database connection CPU unit: NX102-[][]20/NJ[]01-[][]20
*5. Performance of NX102-[][][][]/NJ501-1[]00

Case studies of machine innovation by increasing speed and precision

Case 1: High-speed alignment and vibration-free handling

Problems

1. Precisely stacking many sheets increases cycle time because retries caused by mechanical errors increase positioning time.
2. Vibration settling time is required when high-speed handling is stopped. Speed must be reduced to suppress vibration.

1. High-speed, high-precision alignment system

The FH Vision System provides the Shape Search function for fast and accurate shape recognition and Visual Feedback that feeds back the current position to control the motor in every measurement cycle. These increase alignment speed without sacrificing accuracy.

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Visual Feedback Alignment Library

2. Software functional components for vibration suppression

The Vibration Suppression Library facilitate programming for high-speed handling while suppressing vibration. Waiting time is reduced, and positional accuracy is increased.

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Vibration Suppression Library

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Case 2: Packaging machine using electric cam

Problems

1. The PLC and mechanical cam control cannot accurately synchronize axes.
    In addition, low precision, vibration, and noise caused by mechanical cam limit high-speed and high-precision packaging.
2. It takes time to adjust mechanical cam to different packaging materials and settings every time a different type of
   product is packaged.

Electronic cam optimizes packaging speed and precision

Electronic cam motion control realizes machine cam motion. Electronic cam enables 3 axes - “film feeding”, “product feeding”, and “rotary knife” - to be synchronized at high speed. This eliminates following errors between axes even during high-speed operation, leading to higher-speed and higher-quality packaging. Registering settings as a recipe reduces changeover time.

Software functional components for electronic cam control

The Rotary Knife Function Block in the Packaging Machine Library increases the speed and precision of horizontal flow packaging and enables mechanical cam motion without electronic cam table.

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Packaging Machine Library

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