Body Shop

Body Shop

  • Maintaining and managing welding quality by monitoring the welding conditions constantly
  • Reducing the defect rate by measuring the width of welded vehicles from both sides
  • Lowering the defect rate by inspecting for welding defects (blowholes, height, misalignments, etc.)
  • Improving an operating rate by monitoring the operations of welding robots
  • Improving energy efficiency of a belt conveyor and reducing cost by eliminating an enclosure
  • Collecting and analyzing data by a PLC for preventive maintenance

Solution overview

Issues Solutions
Maintaining and managing welding quality by monitoring the welding conditions constantlyMonitor the quality fluctuation and alarms with an Xbar-R control chart.
Reducing the defect rate by measuring the width of welded vehicles from both sidesMonitor the quality in real time with an Xbar-R control chart and a histogram.
Lowering the defect rate by inspecting for welding defects (blowholes, height, misalignments, etc.)Detect welding defects with a vision sensor and a laser displacement sensor.
Improving an operating rate by monitoring the operations of welding robotsVisualize the robot operation status and identify the cause of troubles with e-F@ctory starter package.
Improving energy efficiency of a belt conveyor and reducing cost by eliminating an enclosureControl a belt conveyor by a high-performance, energy-saving S-PM geared motor.
Collecting and analyzing data by a PLC for preventive maintenanceCollect the vibration data of fragile reducers and analyze the collected data by a PLC.

Solution details

Maintaining and managing welding quality by monitoring the welding conditions constantly

Collect and analyze the effective current value at welding and visualize the welding condition. Maintain and manage welding quality by monitoring the quality fluctuation or alarms in real time with an Xbar-R control chart.

Collect and analyze the effective current value at welding, and visualize the welding condition on a GOT.

Manage production processes and maintain welding quality by monitoring quality fluctuations in real time with an Xbar-R control chart of e-F@ctory starter package.

Key Point

  • Create a control chat with a control chart (Xbar-R) function of e-F@ctory starter package in real time and send feedback to the shop floor.

Reducing the defect rate by measuring the width of welded vehicles from both sides

Measure the width of a workpiece from both sides with laser displacement sensors.Lower the defect rate by monitoring quality fluctuations with an Xbar-R control chart and quality data distribution with a histogram in real time.

Use two laser displacement sensors to measure a workpiece from both sides, and judge OK or NG by calculating the width by a PLC.

Check where the distribution center of the measured data and how it distributes visually with a histogram.

Key Points

  • Display quality fluctuations visually.
  • Display how the quality data distributes within a specified range.

Lowering the defect rate by inspecting for welding defects (blowholes, height, misalignments, etc.)

Monitor appearance defects such as blowholes and misalignments with laser displacement sensors and vision sensors, and judge pass or fail.Prevent defective products from being shipped to the market since the sensors do not overlook errors that cannot be seen with human eyes.

Enable a stable measurement with the sensors automatically compensating the projecting light quantity according to the reflected light quantity from the target.

Key Points
  • Measure displacement accurately with an automatic correction using a unique algorithm developed by Mitsubishi Electric.

Improving and operating rate by monitoring the operations of welding robots

Collect the axis current value and operation status data by connecting a robot controller to a PLC. Improve the operating rate by analyzing the collected data and visualizing the current condition.

Connect a robot controller to an Ethernet module, collect data required to monitor the operation status (axis current values and errors, operation status) from the controller, and utilize the collected data with e-F@ctory starter package.

Analyze the collected data and visualize the condition to improve the operating rate with e-F@ctory starter package.

Key Points

  • Collect and monitor each axis current value and the operation status data of up to eight robots on a GOT by connecting a robot controller and MELSEC iQ-R series via Ethernet.
  • Detect errors that were difficult to find with a simple threshold monitoring, monitor operation status 24/7, and identify the cause of troubles by monitoring the trouble occurrence status.

Improving energy efficiency of a belt conveyor and reducing cost by eliminating an enclosure

Save energy by using a high-performance, energy-saving S-PM geared motor to control a belt conveyor. Save costs by using an IP 67 model of inverters that can be installed in various environments, including outside of an enclosure.

The S-PM motor is a synchronous motor having a strong permanent magnet (high-performance ferrite magnet) in the rotor.Unlike induction motors, the motor does not show slipping (drop in rotation speed under increased load), and it is suitable for high-accuracy speed control.

An IP 67 model of inverters improves environmental resistance and allows installation in various equipment and environments, including corrosive environments and surrounding air temperatures between -20°C and 60°C.

Key Points

  • The S-PM motor does not cause secondary copper loss and can keep a high motor efficiency. It requires less energy to apply the same force, leading to energy saving.
  • An IP67 model inverter can be installed outside the enclosure, allowing installation in various environments.

Collecting and analyzing data by a PLC for preventive maintenance

Collect the vibration data of fragile reducers, analyze the collected data by a PLC, and detect an abnormal frequency, enabling preventive maintenance

FBs are provided to analyze vibrations by FFT (fast Fourier transform) and digital filters.

Analyze the vibration data and monitor the threshold with quantified vibration data, enabling equipment condition monitoring utilizing vibration data.

Key Points

  • Use any FBs to create a vibration analysis program, and create an original vibration analysis and diagnosis for your equipment.
  • Create a simple vibration analysis with less initial investment.

Product Lineup

La série GOT2000 propose non seulement plus de performance, mais aussi toute une série d’innovations. Elle couvre une large gamme de produits avec 20 modèles disponibles en quatre tailles.
Des applications commerciales à celles de l’industrie lourde, ces variateurs de fréquence sauront vous convaincre au quotidien par leur rentabilité, fiabilité, fonctionnalité et leur flexibilité.