Application Scenarios

At a leading automotive battery cell manufacturing plant in Germany,production throughput was bottlenecked by mechanical cam-based electrode slitting machines that couldn’t maintain cut-length consistency at high speeds.Engineers replaced the legacy PLC with a MITSUBISHI BN624A960H03B motion controller driving eight synchronized servo axes over CC-Link IE TSN.The result?Cut accuracy improved to±0.02 mm at 120 m/min line speed,and changeover time dropped from 45 minutes to under 5 minutes via recipe-based electronic gearing.In this transformation,the BN624A960H03B didn’t just automate—it redefined what was mechanically possible.

Parameter

Main Parameters Value/Description

Product Model BN624A960H03B

Manufacturer Mitsubishi Electric Corporation

Product Category Motion CPU Module(MELSEC iQ-R Series)

Control Axes Capacity Up to 96 axes(via network expansion)

Motion Control Cycle As fast as 31.25µs(with compatible servo amplifiers)

Supported Networks CC-Link IE TSN,SSCNET III/H,Ethernet(for engineering&data)

Programming Standards IEC 61131-3(ladder,ST,SFC,FBD),MELSEC-specific motion instructions

Built-in Safety Functions Compatible with CC-Link IE TSN Safety(SIL3/PL e per IEC 61508/ISO 13849)

Memory(User Program)60 MB standard(expandable via SD card)

Operating Temperature 0°C to+55°C

Mounting Method DIN rail(within iQ-R main base unit)

Dimensions(W×H×D)90 mm×90 mm×70 mm

Certifications CE,UL/cUL,KC,EAC,RoHS

Technical Principles and Innovative Values

Innovation Point 1:Sub-50µs Motion Cycle with Integrated Trajectory Planning

The BN624A960H03B leverages a dedicated motion co-processor that calculates complex paths(linear,circular,spline)independently of the main logic scan.This enables true parallelism—motion updates occur every 31.25µs while logic runs at 1–10 ms—eliminating jitter in high-dynamic applications like robotic pick-and-place or laser cutting.

Innovation Point 2:Time-Sensitive Networking(TSN)Native Architecture

Unlike retrofit solutions,the BN624A960H03B natively supports CC-Link IE TSN,converging motion,I/O,safety,and IT data over a single Ethernet cable.This reduces wiring by up to 70%and enables real-time analytics without impacting control performance—a key enabler for Industry 4.0.

Innovation Point 3:Seamless Migration from Q Series with Backward Compatibility

Existing users of MELSEC-Q motion systems can migrate to the BN624A960H03B with minimal re-engineering.The GX Works3 engineering environment auto-converts Q-series motion programs,preserving intellectual property while unlocking 3x faster axis response and built-in OPC UA server capability.

Application Cases and Industry Value

In a Japanese semiconductor wafer handling system,a manufacturer needed to synchronize 24 linear motor axes across three gantries with nanometer-level path coherence.Using the MITSUBISHI BN624A960H03B,they achieved±1µm positional deviation across all axes at 2 m/s—critical for preventing wafer breakage.The integrated safety functions also allowed safe human-robot collaboration during maintenance,reducing lockout/tagout time by 65%.

Another case involved a U.S.-based packaging OEM integrating the BN624A960H03B into a high-speed cartoner.By replacing mechanical cams with electronic gearing and flying shear logic,they increased line speed from 300 to 500 packs/minute while cutting mechanical maintenance costs by 40%.Customers praised the“single-point programming”experience—motion,logic,and HMI all developed in GX Works3.

Related Product Combination Solutions

MITSUBISHI MR-J5-G:Next-gen servo amplifier—paired with BN624A960H03B for 31.25µs cycle motion over CC-Link IE TSN

MITSUBISHI R120SFCPU:Safety CPU—combines with BN624A960H03B for integrated standard+safety control on one backplane

MITSUBISHI GOT2000 HMI:Touchscreen operator interface—shares project data directly from GX Works3 used for BN624A960H03B

MITSUBISHI RD77GF8:High-precision positioning module—extends BN624A960H03B for legacy pulse-train servo support

MITSUBISHI CC-Link IE TSN Switch(GT2508):Managed switch enabling deterministic multi-controller networks

MITSUBISHI FR-A800:Inverter series—controlled via BN624A960H03B for coordinated speed/motion in hybrid lines

MITSUBISHI MELSEC iQ-R Base Unit(RB05):Required mounting platform for BN624A960H03B with power and backplane

MITSUBISHI GX Works3:Unified engineering software—essential for programming,simulation,and diagnostics of BN624A960H03B

Installation,Maintenance,and Full-Cycle Support

Installing the MITSUBISHI BN624A960H03B requires mounting it onto an iQ-R base unit(e.g.,RB05)with proper airflow clearance(≥50 mm on all sides).Firmware must be updated via GX Works3 before first use,and network topology should follow Mitsubishi’s TSN design guidelines to ensure bounded latency.For motion tuning,the built-in oscilloscope function captures position,velocity,and torque waveforms without external tools—accelerating commissioning.

Maintenance is simplified by predictive diagnostics:the module logs thermal stress,network error rates,and axis following errors,which can be monitored via SNMP or MQTT to cloud platforms.In case of failure,hot-swap replacement is supported when used with redundant power supplies and backup configuration on SD card.Our company stocks genuine BN624A960H03B units,each verified for firmware integrity,network handshake,and motion loop stability.We offer 18-month warranty,full technical documentation,and remote support for GX Works3 configuration.

Whether you’re building a new high-speed assembly line or modernizing legacy machinery,the BN624A960H03B delivers the precision,speed,and intelligence to future-proof your automation investment.

Contact us for a customized solution—including system architecture review,compatibility validation,and rapid delivery of authentic MITSUBISHI BN624A960H03B modules with full lifecycle support.

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