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| OGN Co., Ltd. (Representative Director: Tomoaki Sugiura) provides control verification services that utilize the latest “virtual control debugging” technology (debugging: discovering and correcting bugs and defects in computer programs and electrical equipment, work to ensure that the operation meets specifications). This service is an innovative solution that makes full use of 3D CAD to efficiently debug control software. By linking with the design process using 3D CAD, it is possible to significantly shorten lead time compared to traditional on-site debugging work. |
| In particular, this “virtual control debugging” provides a powerful solution and greatly streamlines the control verification process for automotive parts manufacturers and production engineering departments and machine tool departments responsible for equipment design. |
| Virtual control debug service details |
 | | *Virtual control debugging machine: Creates an environment where you can debug as if you were using a real machine using virtual (3DCAD) equipment data using an actual PLC and operation panel. |
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| Our “virtual control debugging” is an innovative technology that allows you to move a 3D CAD model in VR (virtual space) and verify control software without the need for actual equipment. This allows trial and error of mechanical and electrical control to be completed in virtual space, making it possible to complete debugging before operating the equipment. |
| This technology eliminates many of the challenges faced in traditional debugging efforts. In particular, the process of manually (in your head) checking a large amount of control software and the time loss caused by debugging the equipment for the first time after it arrives at the site are reduced. Introducing virtual control debugging has the advantage of reducing debugging lead time by up to 30%. |
| Specific issues solved by virtual control debugging and their benefits |
| Virtual control debugging technology is a solution that innovatively solves many problems in conventional debugging work and dramatically improves work efficiency. Below, we will explain in detail the specific challenges, how to solve them, and the benefits that can be obtained. |
| 1. Reducing the burden of managing a huge amount of control software and detecting errors |
| In conventional control program debugging (without equipment), it was necessary to manually check thousands to tens of thousands of lines of control software. This was very time consuming and there was always a risk of human error. Even the slightest error in the control software can cause the control device to malfunction, so debugging requires careful and delicate work. However, manual checking makes it difficult to scrutinize the entire program, and errors often occur on site due to oversights. |
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| However, in virtual control debugging, a model created using 3D CAD communicates with the PLC and operates according to the actual control program in virtual space. It is also possible to check real-time operation according to input from the operation panel. This allows you to quickly discover errors and inconsistencies hidden in control software, and by visualizing the operation of the entire system, you can intuitively identify problems and make efficient corrections. |
| Benefits : |
| Minimize the risk of human error and improve the accuracy of control software verification. |
| Large-scale control software can be debugged in a shorter time than conventional manual checks. |
| You can check the overall picture of the program from a bird's-eye view, eliminating oversights. |
| 2. Reduce debugging time and costs in the field |
| In conventional debugging work, it is not possible to check the operation of the control software until the equipment is actually installed on-site, so a lot of time is spent on troubleshooting on-site. When a defect in control software is discovered on-site, correction work is carried out on the spot, which typically lengthens the lead time significantly. In particular, when debugging was performed after equipment assembly was completed, there was always the risk of delays in production planning due to work costs and time loss associated with corrections. |
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| However, by introducing virtual control debugging, it is possible to perform preliminary verification of control software in virtual space before the actual equipment is assembled. This allows most defects to be corrected before the actual equipment is assembled, greatly reducing on-site debugging work. For example, by completing control system operation checks in virtual space, the time required for on-site corrections and adjustments can be dramatically reduced. In addition, virtual control debugging allows equipment to be ready for operation as soon as it is assembled. |
| Benefits : |
| Reduce lead time for on-site debugging work by up to 30%, shortening overall lead time. |
| Smooth project progress by reducing costs associated with repairs and adjustments. |
| Prevent problems on-site and speed up equipment startup. |
| 3. Improve efficiency of trial & error and avoid the risk of equipment damage |
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| When debugging control software, it is common practice to perform trial and error using actual equipment, but this process carries the risk of physically damaging equipment. For example, in rare cases, a malfunction can cause a slider or actuator to collide, resulting in component damage. Such damage could be expensive to repair and could delay the entire operation due to the time required to repair the equipment. |
| However, with virtual control debugging, even if there is a mistake in the control software, you can safely debug as many times as you like without worrying about physical damage to the equipment. For example, if a slider breaks down, it will cost around 100,000 to 200,000 yen to repair or replace it, but since trial and error can be confirmed in virtual space, the risk of damage on site can be avoided and loss costs can be reduced. You can save money. |
| Benefits : |
| Since no actual equipment is used, the risk of equipment damage is completely avoided. |
| Reduce project costs by eliminating physical repair and replacement costs. |
| Control verification can be completed in a short period of time by proceeding with a trial and error process safely and efficiently. |
| The safety of people (workers) can be ensured. |
| 4. Control verification in remote areas and strengthening international response capabilities |
| When debugging the control of equipment installed in a remote location, it was necessary for engineers to go to the site and confirm on-site operation. In particular, in the case of equipment installed overseas, travel costs and travel time were required, which placed a significant burden on the progress of the project. Additionally, delays in responding to problems on-site could have a negative impact on overall progress. |
| However, by using virtual control debugging, control verification can be performed in virtual space, regardless of where the equipment is installed. For example, it is possible to perform control design in Japan and debug equipment located in remote locations or overseas from within Japan. This reduces the hassle and expense of traveling and allows us to respond quickly to international projects. Virtual control debugging greatly resolves issues in cross-border project management and supports smoother project progress. |
| Benefits : |
| Control verification can be performed in virtual space even in remote locations, reducing the need to travel to the site. |
| Reduce travel costs and travel time and reduce the cost burden of international projects. |
| We can respond to overseas facilities in real time, accelerating project progress. |
| By solving these specific issues, virtual control debugging can streamline a company's entire production process, reducing costs and improving work accuracy. Particularly for companies and departments that design and manufacture equipment, virtual control debugging is a powerful solution that can significantly improve productivity. |
| Service pricing |
| Virtual control debugging requires separate fees for 3D CAD data operation settings and PLC connection settings in addition to normal debugging work. The average setup cost is 200,000 to 300,000 yen, depending on the scale of the equipment. Compared to traditional debugging work, it is expected to reduce lead time, making it highly cost-effective and especially useful for companies and departments that design and manufacture equipment. |
| Background of the announcement and necessity of introduction |
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| With a shortage of electrical control designers predicted in the future, there is an urgent need to introduce technology that reduces the burden of long working hours in equipment production and the risk of machine failure. Major companies are already introducing virtual control debugging technology, and OGN is following this trend by providing solutions to support efficient control verification. The introduction of virtual control debugging is expected to contribute to human resource development and reduce the burden on engineers. |
| Media Contact |
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| OGN Co., Ltd. |
| Representative: Tomoaki Sugiura |
| Person in charge: Kuniaki Takeuchi |
| Phone number: 0564-53-1013 |
| Email address: |
| Homepage: https://www.ogncorp.com/ |
