1. Omron AI Controller: Introduction
Updated: 10/17/2018
CUSTOMER

3. Product Specifications
New
Model
NX102
NX1P2
NJ101
NJ301
NJ501
NX701
Instruction execution time
LD instruction
3.3ns
2.0ns
1.1ns
0.37ns
Arithmetic instruction
70ns
70ns~
42ns~
26ns
3.2ns~
Control cycle
1ms~
2 ms~
0.5ms~
0.125ms~
Program capacity
5MB
1.5MB
3MB
20MB
80MB
Variable capacity
Non-Retained
32MB
2MB
4MB
256MB
Retained
32kB
0.5MB
Motion control axis
4/6/8/12
4/6/8
0/2
4/8
16/32/64
128/256
Synchronous control axis
0/2/4/8
0/2/4
PTP control axis
4/4/4/4
4/4/4
0/0
Ethernet/IP port
2 ports
1 port
2 port
EtherCAT port
# of slaves
Up to 64
Up to 16
Up to 192
Up to 512
# of NX units
Up to 400
Up to 16
Up to 4000
Up to 4000
Built-in I/O
n/a
24/40/40
Total Local NX I/O Capacity 32 8
Enterprise Connectivity
OPC UA/ SQL
SQL
OPC UA/SQL

4. Sysmac IPC – High Reliability & Performance
Split-core Windows® & Sysmac Controls
Flexibility and expansion of a PC
Network port isolation
Reboot Windows® from Controls side
Full Sysmac controller with EtherCAT Master
7th Generation Intel CPU
Higher performance
Cache allocation technology
Improved security

5. So what?
Detect an issue has happened and do something about it immediately, reducing risk of bad parts or equipment damage
Leverage Omron’s proven controls technology and Data Scientist team instead of researching & developing on your own
No extra infrastructure/connectivity cost for Fog or Cloud based solutions (typically managed by IT Department)

6. AI Application Component
What is the Omron AI Controller?
New solution that is uniquely able to Collect  Analyze  Utilize data on the Edge within a Sysmac controller, for the purpose of extending equipment lifecycle
Hardware, Software, and Service (People)
Hardware: based on NY5 IPC as well as NX7 Sysmac CPUs
Software: two new utilities AI Operator and AI Easy Modeler, as well as Sysmac Library of Function Blocks called “AI Application Components”
Service: Omron members deployed for Start-up and Periodic support at a charge
NY-Series
NX-Series
AI Application Component
Configure & Startup

7. ✔- ✔+ ✔ What is an “Edge” device? Cloud Fog Edge
Within the Machine or Production Line, without any separate Windows® PC or remote server (Cloud) or Internet
Fog
Computing
Collect
Data Collection  Processing
Analyze
Storing  Modeling
Utilize
Real-time Monitor  Control FB
Long-term Monitor  Visualize
Cloud ✔- ✔+
Real-time Monitor  Control FB ✔-
Long-term Monitor  Visualize ✔+
Fog ✔
Edge
Real-time Monitor  Control FB ✔+
Long-term Monitor  Visualize ✔-
Edge
Omron is focused on bringing value to customers with Edge level solution.
Relative advantages and disadvantages are indicated as ✔+, ✔, and ✔-
Against Cloud, Edge, and Fog between Edge and Cloud are defined as edge computing.
Each of them has advantages and disadvantages for gathering, analyzing, and using data.
Edge is better to gather sensor data near the factory than Cloud.
On the other hand, Cloud is better to analyze data than Edge because higher computer resources are required.
The upper levels are better to monitor massive data with ERP design data and material data for long term. Edge is better to use real time performance for feeding data back to controllers.

8. What does the Omron AI Controller do?
Detecting outliers (failures, defectives) by learning from historical data in the machine
1) Issue definition
2) Cause identification
3) Prepare sensors
Human
Based on failure impact and feasibility study of AI Controller utilization, define issue
Based on Cause and Effect Diagrams,
identify cause of machine defect
Based on the cause, add necessary sensors to machine
Machine defects
B occurs
Human
Method
Material
Machine
Machine
Omron AI Controller fully covers the data collection, analysis, and utilization.
　Omron also offers startup support for the entire process.
4) Collect
Data collection
Pre-processing
Causal analysis, modeling
5) Analyze
Storage
Monitoring
Visualization
6) Utilize
Control FB
All data-based solutions will require 6 steps, some Human, some Technology.
First 3 steps are all Human steps, leveraging Subject Matter Expertise and real-world experience
Omron AI Controller only solves Steps with technology
Collect the raw data of machine
Eliminate noise, create and collect the features of normal/abnormal state
Store the characteristics data
Create model data
after causal analysis
Status monitoring and control FB
based on model data X1 X2 X3 X4 X5

9. Learn without being explicitly programmed
Machine Learning
Anomaly Detection
Omron AI Controller addresses narrow scope of AI – only Machine Learning for Anomaly Detection
This is still very powerful for manufacturers and machine builders
Learn without being explicitly programmed

10. AI Application Components
First Release
AI Application Components
Pre-made Sysmac Library Function Blocks (FB) for…
Mechanism
Failure Type
Machine event (failure causes)
Air Cylinder
Operation stop
Rubber Gasket broken (Rod/Piston)
Over speed
Speed Controller broken
Over vibration
Air Cushion broken
Contamination
Ball Screw
Guide broken
Ball Bearings falling out
Conveyor Belt or Pulley
Vibration and low accuracy
Belt loosen
Belt broken
Pulley broken
First release – 3 mechanics, but library will grow with continued research & development
Anything outside of these AI Application Components (inside Sysmac Library) would be a custom model, still possible but requires additional clarification and time

11. Overall Equipment Effectiveness=
Availability x
Performance
Quality
Value of Omron AI Controller
OEE
Overall Equipment Effectiveness
Helps improve OEE at the machine level by increasing uptime
Uptime
Downtime
Operating time
Stoppage Loss
Net operating time
Performance Loss
Value
operating time
Defect Loss
Loss types
Improved by AI Controller
1: Equipment failure
2: Changeover
3: Part replacement
4: Waiting for material
1: ✓ 2:
3: ✓ 4:
5: Minor stoppage/idle
6: Deceleration/slowing
5: ✓ 6:
7: Defect/modification
7: ✓
The AI controller will improve overall equipment effectiveness (OEE)
As you know, the key of improving OEE is how to improve availability, performance, and quality

12. Thank you
Expected Americas Launch: Dec 2018