‘Most advanced’ controller avoids need for separate components
10 July 2025 
Image: Mitsubishi Electric Europe
Mitsubishi Electric has announced its most advanced industrial controllers to date. The Melsec MX-F and MX-R controllers integrate sequence control, motion control and network communication in one module, eliminating the need for separate components typically found in conventional systems, thus reducing hardware requirements, simplifying system architectures, and streamlining engineering processes.
For system designers, this consolidated approach is said to result in smaller control cabinets, less complex wiring, and easier maintenance.
The controllers combine four key requirements: precision, intelligent integration, cybersecurity, and reliability. They are suitable for applications from 8-256 axes.
The MX-F model is aimed at packaging lines, labelling machines, and pick-and-place applications, where space efficiency and cost-effectiveness are priorities. The MX-R model excels in more complex environments such as battery production, semiconductor manufacturing, and precision cutting systems, where multi-axis synchronisation is critical.
“Manufacturing processes increasingly demand faster control and integrated capabilities that exceed conventional PLC functionality,” points out Daniel Sperlich, strategic product manager for controllers for Mitsubishi in the EMEA region. “The MX Controller addresses these advanced requirements through the combination of high-speed PLC functions, precise motion control, IO/OT, cybersecurity, and other embedded functions in a single platform that reduces system complexity, while enhancing manufacturing performance.”
The controllers have been designed for applications where precision and ultra-fast, accurate synchronisation are critical. Their capabilities include:
- synchronisation cycles as short as 0.125ms, providing rapid machine coordination;
- microsecond-level timing accuracy with TSN, allowing precise operation across connected devices and networks;
- mark detection and cutter control with 1μs precision, for applications such as high-speed packaging and semiconductor handling; and
- mixed calculation cycles per axis – for example, 125μs, 500μs or 2ms – allowing each part of the system to run at its optimal speed for tighter production tolerances.
Sperlich explains that even the most advanced and precisely synchronised production lines can encounter unexpected disruptions. In such cases, fast and accurate diagnostics are essential to reduce downtime and protect productivity.
“Sometimes unpredicted events happen that can’t be foreseen, caused by mechanical issues or external factors,” he says. “Like in a dashcam, video and production data can be saved automatically, with cycle-accurate precision. Together with our software and AI support, it lets you recover the machine with minimum time loss.”
This combination of high-precision control and rapid diagnostics is said to guarantee consistently accurate manufacturing.
The expandable MX controllers adapt to changing manufacturing needs. They supporting protocols such as OPC UA, MQTT, and CC-Link IE TSN, and can link to devices such as robots, sensors, and Scada platforms. High-performance multi-core CPUs and large memories ensure efficient analytics and real-time control, simplifying data-driven strategies. They are compatible with Mitsubishi’s iQ-R and iQ-F modules, protecting earlier investments and allowing step-by-step upgrades.
The MX controller has received TÜV Rheinland certification to IEC 62443-4-1 and IEC 62443-4-2 security standards, verifying protection against unauthorised access and cyberattacks.
Security functions include encrypted communications, user authentication and access control mechanisms, and secure data storage.
In connected manufacturing environments, the controllers protect intellectual property and sensitive data using robust protocols. The safeguards enable safe exchange of data between production floor and enterprise systems.
The controllers support high system availability through built-in diagnostics and automatic fault data recording – helping manufacturers to respond swiftly to unexpected events.
Consegic Business Intelligence has predicted that the global market for advanced controllers will grow from $6.38bn in 2024 to more than $10.86bn by 2032 – a CAGR of 7.5%.
