MELSOFT Gemini 3D Simulator

Solution Software

Gemini is a 3D simulation software to virtually model machines and manufacturing processes. It is a perfect software solution for: • Layout planning • Production/operation flow simulation • Robot programming and cell design • Virtual commissioning • Enabling digital twins

Manufacturing with Visible "Results" Before Launch

Amidst the digital transformation trend, a demand has emerged to speed up the process from product planning to commercialization, however there are hurdles to this, such as an increase in the labor time required for rework and on-site adjustment due to problems during equipment development and upon launch of lines, and delays in decision-making as it is difficult to visualize the effects of investment.

Line Simulation

Line simulation capabilities for people, robots, and Automated Guided Vehicles (AGVs). Our innovative technology enables dynamic simulations of complex flow lines and operational scenarios with unparalleled accuracy and efficiency.

Equipment Simulation

Perfect solution for equipment simulations of mechanical interference in 3D space, seamless integration with control devices for advanced logic validation, and real-time reproduction of error occurrences in immersive 3D environments based on log data

MELSOFT Gemini 3D Simulator Introduction

Utilization of MELSOFT Gemini 3D Simulator

1. Line layout verification - Productive line set up and verification

Build & verify layouts from the eCatalog

Layouts can be built and verified by simply dragging and dropping the necessary parts for line verification from the library and performing easy settings.

Visualize & analyze using a chart/statistics function

Simulation results can be visualized and analyzed to identify bottlenecks and changes in operating ratio.

2. Machine Specification Verification - Significant reduction of labor time for rework

Operations can be set up by importing 3D CAD data, setting up the mechanism, then using the script in MELSOFT Gemini. This makes it possible to create and simulate machine operations even if ladders and other programming are incomplete. This streamlines the task of alignment conventionally using 2D drawings and timing charts.

3. Control program verification - Reduced on-site adjustment time

Direct connection to various simulators and FA equipment made by Mitsubishi Electric improves the accuracy of mechanical collision checks. Through connection to other companies’ equipment and simulators via an OPC Server, control logic verification is possible regardless of the equipment or machine

4. Problem verification - Efficient troubleshooting is possible by reproducing machine operations in Gemini based on log data, thus making it possible to reproduce the error without going to the shop floor.

Status at time of error is reproduced as a 3D model based on log data.Swifter troubleshooting is possible by combining ladder monitor display, waveform display, and image data display. Efficient troubleshooting is possible by reproducing machine operations in Gemini based on log data, thus making it possible to reproduce the error without going to the shop floor.

5. Communication Support - Facilitating Seamless Understanding and Efficient Business discussions

When proposing in-house developed machines and systems to customers, utilizing a 3D Simulator to demonstrate product functionalities ensures clear and precise information exchange. By showcasing products through diverse mediums such as 3D models, Virtual Reality (VR), and animations, we foster smooth mutual understanding and expedite business discussions.

6. Support for Trial Calculation of Investment Cost for Equipment/Workers

When installing new production equipment or expanding existing lines, verification via simulation of multiple patterns makes it possible to grasp the necessary number of robots, processing machines and AGVs, as well as the necessary number of workers, thus enabling the trial calculation of optimal investment cost.

Optimal investment is possible! by trial calculating investment cost required forequipment and workers based on simulation results

Line Simulation Introduction Example

Users can take 3D models of equipment, etc. from the abundant library to build any line they wish to verify. Upon purchase of this product, the 3D model of the equipment line is pre-set with conveyor systems, AGVs, and worker movements. Users can identify areas requiring improvements during the concept design phase and compare results by individual improvement measure. Operating conditions can be simulated with ease.

Utilizing the line simulation function to easily perform pre-verification

1. Planning

Formulate improvement plans related to equipment, operator movement, etc.

2. Preparation

Reproduce current line based on line/work specifications

3. Verification

Verify effects of reproduced improvement proposal

4. Operation

Apply to actual factory lines for operation

Issue

The current production line could not keep up with the increase in demand, so there was an urgent need to increase production capacity. The customer urgently needed to increase its production capacity therefore considered adding a manual work station however wants to verify the line change in advance and build a system to increase production without any need for rework.

Example: Assembly line of Nagoya Works, Mitsubishi Electric

Work station/5 locations (5 operators)
Overhead crane/3 units　
Welding robot/2 units

Current:	Unit production: 69 units/months	Cycle time: 128 min/unit
Target:	Unit production: 80 units/months	Cycle time: 103 min/unit

Utilization flow

1. Planning

We wanted to increase the number of work stations from the current five to six and achieve a cycle time of 103 minutes/unit. However, it was difficult to conduct preliminary verification, including detailed loss analysis, and using conventional Excel®-based calculations.

2. Preparation

MELSOFT Gemini was used to reproduce the current line based on line specifications (station layout, individual work time, etc.) Current model construction was completed in around two days due to the abundance of 3D models already set up in the eCatalog.

3. Verification

Cycle time was reduced to 99 min/unit with one additional work station and one additional operator. A graph function detected idling losses that were previously unnoticeable, and the installation of an intermediate work station eliminated these losses. In actual operation, cycle time was reduced to 92 min/unit, thus increasing production capacity.

4. Operation

Based on the simulation results of MELSOFT Gemini, the target production volume of 80 unites/month was achieved. In addition, idling loss was eliminated by installing an intermediate work-in-process stand which saved approx. JPY600,000 annually. Due to the high accuracy of the preliminary verification, rework was reduced by redesign and additional work.

Benefits of introduction

Ability to verify improvement using multiple patterns
Simulations can easily be adjusted, therefore multiple improvement patterns can be swiftly verified.
Easy to review due to visualization of improvements
Observe process waste in 3D, utilize screen recording, operating ratio chart, etc. during simulations.
Prevent time loss due to rework
If the production line is actually modified based on Excel® trial calculation values, there is a possibility that a study into the improvement method will need to be repeated.

Verifies worker flow lines and line layouts of the assembly line in advance. As a result, we were able to establish a system to increase production without rework!

Equipment Simulation Introduction Example

By connecting with programmable controllers and other control devices, it is possible to confirm control logic via 3D motions. Users can identify problematic locations upon control execution, such as mechanical inter-reference or robot motions. Significantly reduces on-site engineering labor time. Smooth linkage between Mitsubishi Electric’s devices and engineering tools.

Direct connection to FA equipment and various tools for smooth collaboration

Verification items

Control program debugging

Verification items

Teaching + collision check

Verification items

Program verification for cycle time reduction

Issue

Delays in upstream mechanical design put pressure on the overall process schedule and did not allow enough time for debugging using actual equipment for downstream control design, which required a lot of on-site adjustment time. We want to perform equipment simulation in advance to achieve front loading!

Utilization flow

1. Control program debugging

Operations of the control program can be visually confirmed with a 3D model, and defects that were difficult to notice only in the program can be identified. Debugging of control programs without the use of actual equipment is now possible.

2. Teaching + collision check

MELSOFT Gemini is used to perform teaching work and faithfully simulate actual robot operations such as paths and range of motion.This means that teaching and collision check can be completed in advance without actual machine.

3. Program verification for cycle time reduction

Carrier transfer is performed in parallel with robot operation, preventing operation loss. Because wasteful movements were identified and improved at the design stage, the cycle time was reduced by 30 seconds, from 1 minute and 20 seconds to 50 seconds.

Benefits of introduction

Reduced on-site engineering labor time
Because verification is possible with a 3D model, less time is required for debugging and on-site engineering.
Enables accurate and rapid collision check
Linkage with RT ToolBox3 prevents equipment damage due to collision and reduces on-site adjustment and start-up time.
Reduces cycle time before going to the production shop floor
Because wasteful movements were identified and improved at the design stage, cycle time was reduced before going to the production shop floor.

Cost-effectiveness (e.g.):

Introduction cost

MELSOFT Gemini: - License cost - Training cost - Labor cost for development upon utilization

Build period

Reduced by approx. 6 weeks

Introduction benefit

6-weeks worth of production profit by reducing start-up time

Payback period

Approx. 5 days

Product Lineup

Product Line Design

Enables high-level production line planning and layout validation, supporting early-stage concept comparison, resource optimization, and investment decision-making.

Machine Design

Focused on detailed equipment simulation and control validation, allowing engineers to verify machine behavior, takt time, and PLC logic before physical deployment.

Machine Design Robotics

Extends machine design capabilities to robotic systems, enabling simulation of robot motion, reach, and collaboration with surrounding equipment for optimized cell design.

Digital Twin Factory Design

Provides full factory-level simulation, integrating processes, equipment, robots, and human operations to support holistic optimization and digital twin initiatives.

Runtime

Designed for operational use, this license allows stakeholders to visualize and leverage simulation results on the shop floor, supporting real-time decision-making and collaboration.

License Types

Standalone

Node-locked; One license per PC. Perpetual buy-out and limited period licenses are available.

Network

License exists on the server. Users can use MELSOFT Gemini simultaneously on as many client PCs* as the number of licenses on the server.*MELSOFT Gemini must be installed.

Annual Maintenance

Our dedicated support team responds to your inquiries remotely.

Software Licenses

To find your best-matching Gemini version for your requirements or for any topic please use the inquiry button on the right side.

System Requirements

Item	Recommended configuration
CPU	Equivalent to/greater than Intel® Core™ i7 12th generation
Memory	16GB or more
Hard Disk	15GB available space
Graphics Card	NVIDIA® GPU with at least 4GB dedicated memory (Equivalent to/greater than GeForce® GTX 1080)
Graphics Display	1920×1080 (Full HD) or more
Operating System	64-bit Microsoft® Windows®11, version 21H2 or later

30-day trial of MELSOFT Gemini

Register now to access our software and experience its benefits with a 30-day trial! Our local experts will swiftly reach out to you with an email containing all the details.

How to get 30-day trial:

1. Fill out the contact form below.
2. Wait for contact from our local expert, who will send an email with the license code and download link.
3. Install software on your device.
4. Use received license key during installation.
5. Enjoy benefits of MELSOFT Gemini .

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Solution Software
MELSOFT Gemini 3D Simulator