Product category:
Process Controllers: PAC, PLC, Loop control
News Release from: SPECIAL REPORT by the Editor | Subject: Mitsubishi iQ Platform
Edited by the Processingtalk Editorial
Team on 23 July 2007
iQ Platform: PLC, PAC or automation
system?
Mitsubishi Electric presented their latest PLC (or PAC) to the UK press last month, as part of a world-wide roll-out, and started by trying to identify what the product now represents
The Mitsubishi Q Series, from the year 2000, was a PLC, but with added email and SMS messaging for alarms, and then web server functions, it grew in capability It was said that originally the ARC Advisory Group coined the term "PAC", which possibly means Programmable Automation Controller, or might also mean Process Automation Controller, depending on your point of view
But the PLC had grown up into a PAC to provide many of the functions of a DCS, or Process Automation System, becoming scale-able and flexible.
The latest top of the range Mitsubishi Q Series still provides the basic functionality of the PLC, but is able to operate in multiple domains, which to me means it can talk to different levels of the business in a language and functions they will all understand.
So for Mitsubishi, the next generation after the Q Series is even more difficult to define, because it now talks several steps further up the business automation ladder, yet still provides the PLC function that is based on the plant floor, providing machine control.
This next generation Mitsubishi is launching is now called the 'iQ Intelligent Automation Platform'.
Just out of interest it is a PAC, but this time PAC is defined as a Programmable Application Controller.
Before going into the hardware detail, lets look at what Mitsubishi see as the possible problem area in existing business automation systems.
In a business meeting at any level, the latest data is needed from many departments, control systems and networks.
So each manager comes with his own print-out.
The information comes from a number of non-compatible hardware platforms, each requiring interfacing or protocol conversion to work with other levels of the business system.
Mitsubishi see a problem, and unnecessary cost, in this intermediate level of process control, SCADA and sales order input/accounts data processing, the PC based operating systems, which talk down to the PLCs and talk up into the ERP/MES application.
So the iQ Platform sweeps that away, and allows the machine controller to talk directly to the intermediate level people and then also straight up into the MES level, so all the staff are working on the same system, on the same data.
Mitsubishi advise that "iQ Platform strategy revolves around the Mitsubishi Qn series of PACs, along with powerful extensions and option modules, designed to sit at the heart of a control system or manufacturing process.
This enables total integration of control and communications from a single hardware platform".
This single hardware platform is then described as a combination of four processors, each running independently, yet sharing the same data highways, residing on a single back-plane to give fast data transfers between processes.
So it's four bits of hardware really, in each PAC, and there can be multiple PACs.
The four processors allow typically one unit dedicated to IT, one for motion control, one for logic functions, one for process control.
Plus the iQ Platform has a selection of network interfaces, with, just in case there are any old systems, a protocol converter to provide data access to legacy networks.....
Lets concentrate on the broader advantages of the iQ platform: the approach aims to flatten the plant architecture, directly link the plant floor to the MES database, saving plant hardware costs and time delays in gathering data: and the data is real live data, not a yesterday's summary.
It simplifies system configuration: cuts system set-up times, interfaces between MES database and the process plant via SQL without programs.
What Mitsubishi have then added is a further set of software and hardware modules to link their iQ Platform to each business discipline.
* HMI INTERFACE: the normal operator display panel is rolled into a GOT: 'Graphical Operator Terminal', a screen that can show process plant operating conditions, provide push buttons for control, and because the MES system is directly linked can also show production line output, speed compared to other lines, and efficiency: the operator, and the manager on the shop floor can see directly the business results of their actions, and so can the MD.
* MES MODULE: this is the link between the PLC functions and the MES, traditionally the data collected by a SCADA system.
The MES block can interface to database platforms like Microsoft SQL or Access, and Oracle.
* PLANT iT: this is the Mitsubishi system that offers everything needed for consistent solutions: from production data acquisition, process control and batch systems to integration of ERP (eg SAP R3) and LIMS.
* MX4 BUSINESS: to complete the business package Mitsubishi have incorporated some imported proprietary business tracking and reporting software for monitoring OEE, Operational Equipment Efficiency, and other Key Performance Indicators, which provide real-time and historical reports.
This system has been proved in over 1000 installations over 7 years, and was presented on behalf of Mitsubishi by Geoff Tripp of Gemba Solutions.
With over 300 report formats built into the system to track the performance of people/operators, lines/assets, WIP tracking, Kanban items, QC/QA reports, all on an SP95 database model, MX4 allows everyone in the organisation access to the same data, making the round table business meetings more meaningful, with real live data to discuss, (on a GOT screen in the meeting) with what should be no data interface problems between departments! MX4-Business also provides a deployable platform to act as the data centre for Six Sigma projects, and provides failure analysis screens for maintenance/TPM teams, if your business is adopting those routes.
In the wide automation DCS/PAC/PLC supply environment, that is currently more confusing than ever, Mitsubishi have assembled an intelligently integrated total package, that is claimed to be cost effective, scale-able and flexible.
FURTHER INFO: The iQ Platform hardware CPUs will be available in the Autumn, and further developments, like integrated (but separated) safety systems are planned to follow.
Currently there does not seem to be much data available about the new iQ Platform features on the Mitsubishi English language websites, but the launch release is available on Processingtalk on http://www.processingtalk.com/news/mit/mit127.html .
The stand-alone versions of the OEE and other business software from Gemba Solutions can be seen on http://www.processingtalk.com/news/gmb/gmb000.html.
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