Software Solutions

Build & verify layouts from the eCatalog

Layouts can be built and verified by simply dragging and dropping the necessary parts for line verification from the library and performing easy settings.

Visualize & analyze using a chart/statistics function

Simulation results can be visualized and analyzed to identify bottlenecks and changes in operating ratio.

Operations can be set up by importing 3D CAD data, setting up the mechanism, then using the script in MELSOFT Gemini. This makes it possible to create and simulate machine operations even if ladders and other programming are incomplete. This streamlines the task of alignment conventionally using 2D drawings and timing charts.

Direct connection to various simulators and FA equipment made by Mitsubishi Electric improves the accuracy of mechanical collision checks. Through connection to other companies’ equipment and simulators via an OPC Server, control logic verification is possible regardless of the equipment or machine

When proposing in-house developed machines and systems to customers, utilizing a 3D Simulator to demonstrate product functionalities ensures clear and precise information exchange. By showcasing products through diverse mediums such as 3D models, Virtual Reality (VR), and animations, we foster smooth mutual understanding and expedite business discussions.

Users can take 3D models of equipment, etc. from the abundant library to build any line they wish to verify. Upon purchase of this product, the 3D model of the equipment line is pre-set with conveyor systems, AGVs, and worker movements. Users can identify areas requiring improvements during the concept design phase and compare results by individual improvement measure. Operating conditions can be simulated with ease.

1. Planning

We wanted to increase the number of work stations from the current five to six and achieve a cycle time of 103 minutes/unit. However, it was difficult to conduct preliminary verification, including detailed loss analysis, and using conventional Excel®-based calculations.

2. Preparation

MELSOFT Gemini was used to reproduce the current line based on line specifications (station layout, individual work time, etc.) Current model construction was completed in around two days due to the abundance of 3D models already set up in the eCatalog.

3. Verification

Cycle time was reduced to 99 min/unit with one additional work station and one additional operator. A graph function detected idling losses that were previously unnoticeable, and the installation of an intermediate work station eliminated these losses. In actual operation, cycle time was reduced to 92 min/unit, thus increasing production capacity.

4. Operation

Based on the simulation results of MELSOFT Gemini, the target production volume of 80 unites/month was achieved. In addition, idling loss was eliminated by installing an intermediate work-in-process stand which saved approx. JPY600,000 annually. Due to the high accuracy of the preliminary verification, rework was reduced by redesign and additional work.

By connecting with programmable controllers and other control devices, it is possible to confirm control logic via 3D motions. Users can identify problematic locations upon control execution, such as mechanical inter-reference or robot motions. Significantly reduces on-site engineering labor time. Smooth linkage between Mitsubishi Electric’s devices and engineering tools.

1. Control program debugging

Operations of the control program can be visually confirmed with a 3D model, and defects that were difficult to notice only in the program can be identified. Debugging of control programs without the use of actual equipment is now possible.

2. Teaching + collision check

MELSOFT Gemini is used to perform teaching work and faithfully simulate actual robot operations such as paths and range of motion.This means that teaching and collision check can be completed in advance without actual machine.

3. Program verification for cycle time reduction

Carrier transfer is performed in parallel with robot operation, preventing operation loss. Because wasteful movements were identified and improved at the design stage, the cycle time was reduced by 30 seconds, from 1 minute and 20 seconds to 50 seconds.