Boosting Machine Speed and Precision with Omron Sysmac PLCs

For applications where machine speed and precision are non-negotiable, Omron's Sysmac platform provides a decisive advantage. This guide explores how the integrated nature of Sysmac controllers, powered by the high-speed EtherCAT motion network, enables engineers to build faster and more accurate machines. Discover how Sysmac Studio simplifies the development of complex, synchronized motion profiles and how built-in IIoT connectivity transforms high-performance machines into smart, data-rich assets.

By ZhuoMingyu

October 9, 2025 5 min read

Boosting Machine Speed and Precision with Omron Sysmac PLCs

Omron's Sysmac platform integrates logic, motion, safety, and vision into a single, cohesive system.

Introduction: The Fusion of Logic, Motion, and Data

In industries where speed, precision, and data are paramount—such as electronics, packaging, and life sciences—the automation platform must do more than just execute logic. It must perfectly synchronize complex motion, ensure machine safety, and seamlessly share data with higher-level systems. This is the domain where Omron's Sysmac automation platform excels. Centered around the powerful NJ and NX-series controllers, Omron has engineered an ecosystem that unifies machine control and IT connectivity, enabling manufacturers to build faster, smarter, and more flexible machines for the modern era.

Key Takeaways

Omron's Sysmac platform integrates PLC logic, multi-axis motion, safety, and vision into a single controller and one software environment.
EtherCAT is the core of Sysmac's high-speed motion control, enabling precise synchronization for demanding applications like robotics and packaging.
The Sysmac NJ/NX series controllers are built for the IIoT, with native support for MQTT, OPC UA, and direct SQL database connectivity.
Sysmac Studio software provides an all-in-one Integrated Development Environment (IDE) that accelerates machine design and reduces complexity.

The Sysmac Platform: One Controller, One Software, One Connection

At the heart of Omron's modern automation strategy is the Sysmac (System for Machine Automation Control) platform. Its philosophy is built on complete integration, eliminating the traditional barriers between different control disciplines.

Sysmac Studio: The Integrated Development Environment

Instead of using separate software tools for PLC programming, motion configuration, HMI design, and safety, Omron provides Sysmac Studio. This all-in-one IDE delivers a unified engineering experience with significant benefits:

Reduced Engineering Time: A shared set of variables and a common interface for all devices mean engineers don't have to waste time mapping tags between different software packages. Configuring a complex machine with synchronized motion profiles, vision inspection, and safety interlocks is done in one project.
Powerful Simulation: Sysmac Studio includes advanced 3D simulation tools that allow developers to visualize and debug machine motion and logic sequences offline. This helps identify potential mechanical clashes and optimize cycle times before a single piece of hardware is assembled, dramatically reducing commissioning time.
Simplified Diagnostics: With a single point of connection to the entire machine network, troubleshooting becomes faster and more intuitive. Engineers can monitor the status of the PLC, servo drives, safety devices, and vision sensors from one screen.

High-Speed Motion and IIoT Connectivity

The Sysmac platform is built on a foundation of two key technologies: a high-speed motion network and comprehensive data connectivity.

EtherCAT: The Motion Powerhouse

For real-time control, Omron has standardized on EtherCAT. This high-performance fieldbus is the backbone of the Sysmac platform, providing the microsecond-level speed and synchronization required for the most demanding motion control applications. The NJ and NX controllers leverage EtherCAT to control dozens of servo axes, enabling features like linear and circular interpolation, electronic gearing, and complex electronic cam profiles. This allows machines to operate faster and more precisely while simplifying the control cabinet and reducing wiring.

Built for the IIoT: OPC UA, MQTT, and SQL

Omron controllers are designed to be data-rich citizens in a connected factory. They support multiple protocols for seamless vertical integration:

MQTT and OPC UA: The NX/NJ controllers support both of the leading IIoT protocols. A dedicated MQTT communication library allows the PLC to securely publish machine data directly to a cloud or on-premise broker with minimal configuration. Built-in OPC UA server functionality provides a standardized, secure way to share data with SCADA and MES systems.
Direct Database Connectivity: A standout feature is the ability for the PLC to connect directly to SQL databases (like Microsoft SQL Server and Oracle). This allows the controller to log production data, retrieve recipes, or perform quality control checks without needing an intermediate PC or gateway, creating a more robust and streamlined architecture.

Choosing Your Platform: NJ-Series vs. NX-Series

Within the Sysmac family, Omron offers two main controller series to fit different application scales and requirements.

Sysmac NJ-Series: For Large-Scale, High-Axis Applications

The NJ-Series is the original Sysmac machine automation controller, designed for complex, high-performance machines. It is the ideal choice for applications requiring a large number of synchronized motion axes (up to 64) and extensive I/O capabilities. Its powerful processing capabilities make it perfect for controlling entire production lines, complex robotic cells, and high-speed packaging systems.

Sysmac NX-Series: Modular and Versatile

The NX-Series offers the power of the Sysmac platform in a more flexible, modular format. The flagship NX7 is one of the world's fastest controllers, while the compact NX1 and NX1P2 provide an all-in-one solution for smaller machines. The NX-Series allows standard and safety CPU units to be combined in the same rack, and its modular design makes it easy to tailor the system with the exact I/O, motion, and communication capabilities needed. This makes it a highly versatile choice for mid-size machines and distributed control systems.

Advanced PLC Applications

Omron controllers are particularly popular in industries that demand a combination of high speed, precision, and flexibility.

Electronics & Semiconductor: Sysmac PLCs are used to coordinate rapid pick-and-place robots and high-resolution machine vision inspections. The tight motion synchronization provided by EtherCAT is essential for achieving the required throughput and accuracy.
Food, Beverage & Packaging: In high-speed packaging lines, Omron PLCs manage the entire process, from conveyors and fillers to labelers and case packers. Built-in features like IO-Link support allow them to gather detailed diagnostic data from sensors for predictive maintenance and quality control.
Automotive Assembly: The platform is used to control synchronized robots, gantries, and transfer lines where precision and reliability are critical. Integrated safety allows for the creation of collaborative work cells where operators and robots can work safely in close proximity.

Conclusion: Integrating Speed and Intelligence

Omron's Sysmac platform is a powerful testament to the benefits of integration. By combining logic, motion, safety, and vision on a single controller and providing a unified software environment, Omron empowers engineers to build more sophisticated machines in less time. With its foundation in high-speed EtherCAT motion and its native support for IIoT protocols, the Sysmac NJ/NX series is engineered not just to automate machines, but to transform them into intelligent, data-rich assets that drive continuous improvement on the factory floor.

Looking to build a faster, smarter machine? Explore our complete inventory of Omron products or speak with a ChipsGate automation specialist to find the right controller for your application.