Easy Connect connection between SINUMERIK and a robot

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1 Application description 10/2015 connection between SINUMERIK and a robot SINUMERIK 828D, SW 4.5 SP3

2 Warranty and liability Warranty and liability Note The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Application Examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are used correctly. These application examples do not relieve you of the responsibility to use safe practices in application, installation, operation and maintenance. When using these Application Examples, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Application Examples at any time without prior notice. If there are any deviations between the recommendations provided in these application examples and other Siemens publications e.g. Catalogs the contents of the other documents have priority. We do not accept any liability for the information contained in this document. Any claims against us based on whatever legal reason resulting from the use of the examples, information, programs, engineering and performance data etc., described in this Application Example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act ( Produkthaftungsgesetz ), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract ( wesentliche Vertragspflichten ). The damages for a breach of a substantial contractual obligation are, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. The above provisions do not imply a change of the burden of proof to your detriment. Any form of duplication or distribution of these Application Examples or excerpts hereof is prohibited without the expressed consent of the Siemens AG. Security informati on Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens products and solutions undergo continuous development. Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party products that may be in use should also be considered. For more information about industrial security, visit To stay informed about product updates as they occur, sign up for a productspecific newsletter. For more information, visit Entry-ID: , V1.0, 10/2015 2

3 Table of contents Table of contents Warranty and liability Task Solution Solution overview Detailed sequence of operation Requirements of the robot program The robot programs: Prepare single or double gripper The robot programs: Unload/Load single or double gripper Timing diagram Timing diagram for the Prepare command Timing diagram for the Unload sequence Timing diagram for the Load sequence and NC program restart HMI components Diagnosis screen Used Components Installation and Startup Installing the HMI components Adapting the sample production program for the robot link Realizing the physical link to the robot Signals from SINUMERIK to robot Signals from robot to Sinumerik Implementing the link to robot via discrete input/outputs Implementing the link to robot via PN/PN coupler Modifying the machine PLC to include the robot link SBR s and DB_ROB_1_CYCLE Additions to the existing PLC program for the two Robot SBR s Additions to the existing PLC program for the fixture Testing the application - using another 828D in place of the robot Contact History Entry-ID: , V1.0, 10/2015 3

1 Task 1 Task The increasing interest in integrating a robot into a CNC controlled machine tool installation has lead to the requirement to provide an application example of how this could be done.

4 1 Task 1 Task The increasing interest in integrating a robot into a CNC controlled machine tool installation has lead to the requirement to provide an application example of how this could be done. The typical application case is where a robot is used to load and unload machined parts of a CNC machine. The application example needs to take several characteristics of a robot/cnc machine installation into account. Some of these characteristics are: The application must work for as many types of robot, from as many manufacturers as possible. The application must be as easy as possible to implement The robot may be servicing several machines The robot may have a single or double gripper Figure 1-1 Manufacturing cell with one robot and several machines Entry-ID: , V1.0, 10/2015 4

5 1 Task Figure 1-2 typical double gripper Figure 1-3 Robot with single gripper Entry-ID: , V1.0, 10/2015 5

6 2 Solution 2 Solution 2.1 Solution overview The solution described in this application note has these characteristics: The interface between the SINUMERIK control and the robot is a digital signal interface. The physical connection between the robot and the SINUMERIK can be either via PROFINET using the PN/PN coupler (see section for ordering data) or via discrete individually wired signals using the PP72/48 on the SINUMERIK side. These two characteristics make the solution widely applicable, with most type of robot or automation. Further characteristics are: The robot programs are writing in the manufacturer s robot language and are stored on the robot, not in the SINUMERIK. The robot can service several machines. The solution is applicable to robots with either double or with single grippers. Is compliant with the VDMA Draft Standard 34180, level 1. The basic operation sequence is that the NC machining program will run to the end and the NC channel will go into reset. The robot will unload the finished part, load the next part. When the robot has left the machine, the machining program will be automatically reselected and started. 2.2 Detailed sequence of operation 1. Machine start up. Here the machine is powered up and the fixture or machining area does not have any workpieces, is empty. 2. The operator selects Auto mode, and presses a user defined button to start Robot mode. 3. Since the fixture is empty, the PLC will issue a Prepare command to the robot to bring the first part. The robot brings the first part to the machine door and acknowledges the Prepare. 4. The machine PLC opens the loading door and then issues a Load Request to the robot. 5. The robot makes sure the fixture is open, loads the part, and issues a Request for clamp to the machine. When the machine PLC confirms Status clamped, the robot leaves the machine. 6. The machine PLC closes the machine door. 7. The machine PLC for security reselects the correct machining program and issues NC Start. 8. Sometime before the end of the machining program, the M-function for Prepare will go to the robot. The robot will prepare to unload/load, position just outside the machine and acknowledge the Prepare. 9. The program finishes. The machine PLC opens the loading door and then issues an Unload Request to the robot. Entry-ID: , V1.0, 10/2015 6

7 2 Solution 10. The robot unloads the part, coordinating the fixture control with the machine. When it is finished, the robot issues the Unload complete message. 11. The machine issues a Load request. 12. The robot loads the part, coordinating the fixture control with the machine. When it is finished, the robot issues the Load complete message and leaves the machine. 13. The process reverts to step 6 above. 14. Finish production. When Finish production is selected the application will not issue a Prepare command to the robot. At the end of the cycle the finished part will be unloaded but no new part will be loaded. Depending on when in the cycle the Finish production is selected, the application will finish a load/unload cycle before starting the Finish production cycle. 2.3 Requirements of the robot program For this application to work the robot needs to have just two or three routines (depending on whether the robot has a double or single gripper) for its interaction with the SINUMERIK controlled machine tool. These are: 1. The Prepare routine for when the SINUMERIK issues a Prepare command. 2. The Unload/Load routine for when the SINUMERIK issues a Unload or Load command The robot programs: Prepare single or double gripper In the case of a robot with single gripper, the prepare program must have this structure. Entry-ID: , V1.0, 10/2015 7

8 2 Solution Figure 2-1 Robot program for prepare with single gripper Single gripper reaction to Prepare for part swap Prepare for swap First load cycle when - not yet a part in the machine No Is there a part in the spindle? Yes Is Finish production selected? Yes No Fetch next part Move to waiting position in front of machine End In the case of a robot with double gripper, the prepare program must have this structure Entry-ID: , V1.0, 10/2015 8

9 2 Solution Figure 2-2 Robot program for prepare with double gripper Double gripper reaction to Prepare for part swap Prepare for swap Yes Is Finish production selected? No Fetch next part Move to waiting position in front of machine End Entry-ID: , V1.0, 10/2015 9

10 2 Solution The robot programs: Unload/Load single or double gripper In the case of a robot with single gripper, the unload/load program must have this structure. Figure 2-3 Robot program for unload/load with single gripper Single gripper reaction to Unload/load command Unload/load No Is there a part in the spindle? Yes Unload the part and deposit outside the machine Is Finish production selected? No Yes Load the next part Return to home position End Entry-ID: , V1.0, 10/

11 2 Solution In the case of a robot with double gripper, the unload/load program must have this structure. Figure 2-4 Robot program for unload/load with double gripper Double gripper reaction to Unload/load command Unload/load Unload the finished part/load the next part (Do the motions even if no finished part or no new part) No Is there a finished part? Yes Deposit the finished part End Entry-ID: , V1.0, 10/

12 2 Solution 2.4 Timing diagram The example PLC and NC programs provided with this application note work according to these timing diagrams Timing diagram for the Prepare command Figure 2-5 Timing diagram for the Prepare command Entry-ID: , V1.0, 10/

13 2 Solution Timing diagram for the Unload sequence Figure 2-6 Timing diagram for the Unload sequence Timing diagram for the Load sequence and NC program restart Figure 2-7 Timing diagram for the Load sequence Entry-ID: , V1.0, 10/

2 Solution 2.5 HMI components 2.5.1 Diagnosis screen The Robot interface screen which can be selected from the Diagnosis area shows status information for the interface to the robot.

14 2 Solution 2.5 HMI components Diagnosis screen The Robot interface screen which can be selected from the Diagnosis area shows status information for the interface to the robot. Figure 2-8 the robot interface screen Used Components Hardware components The application was generated with the following components: Table 2-1 Component No. Article number Note Sinumerik 828D PPU.3 1 6S7... PN/PN Coupler 1 6ES AD01-0XA0 Standard software components Table 2-2 Component No. Article number Note Software in der Sinumerik 828D 1 Software 4.7 SP1 preliminary was used. The solution has not been tested on Sinumerik 828D with SW <4.7, however no components have been used which should prevent the solution running on. earlier software versions, eg Entry-ID: , V1.0, 10/

15 2 Solution Sample files and projects Component No. Article number Note SW4.5 with PPU.2 The following list includes all files and projects that are used in this example. Table 2-3 Component Note xyz_code_v10.zip <This zip file includes the STEP 7 project.> xyz_doku_v10_e.pdf This document. Entry-ID: , V1.0, 10/

3 Installation and Startup 3 Installation and Startup 3.1 Installing the HMI components This entry is added to the file: System CF card/oem/sinumerik/hmi/cfg/systemconfiguration.

16 3 Installation and Startup 3 Installation and Startup 3.1 Installing the HMI components This entry is added to the file: System CF card/oem/sinumerik/hmi/cfg/systemconfiguration.ini [oem_dirs] OEM_1=ROBLINK_SC The directory ROBLINK_SC is copied to the directory: System CF card/oem/sinumerik/hmi/ The screens are effective after the HMI is restarted. Figure 3-1 Location of the ROBLINK_SC directory 3.2 Adapting the sample production program for the robot link The production program used to write this application note is included as an attachment and can be used as a template. The program is called PROD_PROG_ROBOT_CYCLE.MPF. The only addition which it is necessary to make to the production is to add the M-function to trigger the Prepare command to the robot. This M-function should be far enough from the end of the program that the robot has enough time to position in front of the machine door, if double gripper is used, with the next part, before the machining program has finished. Entry-ID: , V1.0, 10/

17 3 Installation and Startup 3.3 Realizing the physical link to the robot The interface between the SINUMERIK and the robot is relatively compact and can be contained within 1 or at the most 2 bytes. The following table shows the signals needed to realize the solution described here Signals from SINUMERIK to robot Table 3-1 Outputs from Sinumerik 828D to robot Address in this application note (using PN/PN coupler) Signal name Signal description Q96.0 Prepare Prepare command Q96.1 Not used Q96.2 Finish Finish production Q96.3 Door open Machine loading door is open Q96.4 Fixture open Fixture (chuck etc) in unclamped position Q96.5 Fixture closed Fixture (chuck etc) in clamped position Q96.6 Not used Q96.7 Live signal Heartbeat 1 Hz (alarm after 1.5Hz) Q97.0 ProdRdy Machine is ready for robot load/unload Q97.1 ENA_Rob_in_Mach Motion enable for robot when in the machining area Name in the VDMA Draft Standard 34180, if applicable MA_REQ_PrepareUnldPart01 MA_REQ_RunEmpty MA_STA_LdgDoorOpnd MA_STA_UnClpd01 MA_STA_Clpd01 MA_STA_Alive MA_STA_ProductionRdy MA_ENA_InIntfrArea Q97.2 Station_empty Station_empty MA_STA_Empty Q97.3 Request_unload_to_robot Unload request to robot Q97.4 Request_load_to_robot Load request to robot MA_REQ_UnldPart01 MA_REQ_LodPart01 Entry-ID: , V1.0, 10/

18 3 Installation and Startup Signals from robot to Sinumerik Table 3-2 Address in this application note (using PN/PN coupler) Signal name Inputs to Sinumerik 828D from robot Signal description I96.0 Robot is outside Robot is outside the machine I96.1 Prepare acknowledge The robot is ready to service the machine I96.2 Unload_complete_fr_robo Unload complete from robot I96.3 Load_complete_fr_robot Load complete from robot part, the machine should clamp it I96.4 Robot alive Heartbeat from robot ( 1Hz). Alarm if no signal after 1.5 sec., I96.5 The robot is ready for production I96.6 Not used Robot ready for production I96.7 Robot disabled The robot cannot do the part swap. This signal is not processed in this application. The user should process this signal as required. Î97.0 Request_unclamp_fr_rob Request unclamp from robot I87.1 Request_clamp_fr_rob Request clamp from robot Name in the VDMA Draft Standard 34180, if applicable AM_STA_OutIntfrArea AM_ACK_UnldPartCmpl01 AM_ACK_LodPartCmpl01 AM:STA_Alive AM_STA_ProductionRdy AM_ACK_REQLodUnlodNeg AM_REQ_UnClp01 AM_REQ_Clp01 The physical connection can be realized in one of these two ways. Entry-ID: , V1.0, 10/

19 3 Installation and Startup Implementing the link to robot via discrete input/outputs Since only about 7 or 8 individual signals, the wiring work is reasonable. The inputs and outputs of the PP72/48 would be used to communicate with the robot. It may be necessary to add a wire connecting the grounds of the two systems Implementing the link to robot via PN/PN coupler The interface can also be realized using a PN/PN (Profinet/Profinet) coupler. In this case the wiring work in minimal. On the Sinumerik 828D side the inputs and outputs start at byte 96, and this is fixed. An example of how to set up the communication between the SINUMERIK 828D and a) a S7 300 PLC or b) a KUKA robot with PROFINET interface using the PN/PN coupler can be found under and ID Modifying the machine PLC to include the robot link NOTE It is assumed that the PLC program for the machine without robot is completed and tested. The PLC components used to write this application note are included PLC program Easyconnect to Robot PLC Machine side.ptp, which is delivered with the note SBR s and DB_ROB_1_CYCLE Transfer the: SBR_Rob_SW47_Single_Cyc (SBR4), SBR_RobDiag_Screen_1Cy SBR5) and the DB_ROB_1_CYCLE DB9036) from the Easyconnect to Robot PLC Machine side.ptp to the machine PLC program. Can they be renumbered? The SBR s can be renum bered but the DB_should preferably not be renumbered, otherwise the calls in SBR s and references in the easyscreen files must be altered. Entry-ID: , V1.0, 10/

3 Installation and Startup Figure 3-2 The SBR s an DB should be taken from the sample program The SBR_Rob_SW47_Single_Cyc (SBR4) and SBR_RobDiag_Screen_1Cy (SBR5) must be called from MAIN, so it is

20 3 Installation and Startup Figure 3-2 The SBR s an DB should be taken from the sample program The SBR_Rob_SW47_Single_Cyc (SBR4) and SBR_RobDiag_Screen_1Cy (SBR5) must be called from MAIN, so it is convenient simply to copy the networks with the calls out of MAIN in the sample program, and then modify the parameters as needed. The two tables following explains the parameters of SBR_Rob_SW47_Single_Cyc (SBR4) and SBR_RobDiag_Screen_1Cy (SBR5) Table 3-3 Parameter description for SBR_Rob_SW47_Single_Cyc (SBR4) Input or Name of paremeter Data type Description output In Representation Byte This parameter is only to optimise the view of the call in the programming tool. It has no role in the robot interface. Enter any number In Prepare_M_func Bool Address in DB2500 of the number of the M function for prepare command. This M function will be in the machining program In Prepare_acknowledge Bool Input from the robot to indicated that the prepare has been completed In Robot_is_outside_machin Bool Input from robot that the robot is outside the machine In Prep_after_startup Bool Input from machine PLC, to get the load/unload process started the first time.this input will trigger a Prepare to the robot to fetch the first part In Door_is_open Bool Inputs from the machine PLC indicating Entry-ID: , V1.0, 10/

21 3 Installation and Startup Input or output Name of paremeter Data type Description In Door_is_closed Bool the corresponding door status. In Station_empty Bool Input from the machine PLC indicating that fixture is empty. The OEM must program this bit This bit will be 1 only on the first machine cycle when the machine is starting up with no part in the fixture. In Unload_complete_fr_rob Bool In Load_complete_fr_rob Bool Unload/load complete from robot In Abort Bool Abort the robot interaction Out Open_door_to_plc Bool These command to open/close the Out Close_door_to_plc Bool loading door must be added to the existing machine,logic Out NC_Start_request_to_mac Bool This is the command to start the NC program. The command must be added to the existing machine,logic. Out Prepsre_to_robot Bool Prepare command to the robot Out UnloadReq_to_robot Bool Out LoadReq_to_robot Bool Unload /load request to the robot SBR_RobDiag_Screen_1Cy (SBR5) is used to generate auxillary signals and to update the bits indb_rob_1_cycle DB9036). Table 3-4 Parameter description for SBR_RobDiag_Screen_1Cy Input or output Name of paremeter Data type Description In Representation Byte This parameter is only to optimise the view of the call in the programming tool. It has no role in the robot interface. Enter any number In fixture_open Bool Inputs from the machine logic for the In fixture_closed Bool status of the fixture only used for the diagnostic screen In in_mach_rdy Bool Inputs from the machine logic for machine ready used for the diagnostic screen and passed to the robot at out_mach_rdy In in_enable_robot_in_mach Bool Input from PLC: move enable for robot when the robot is in the machine doing the load or unload eg. This signal could be 1 when all axes and spindles in the machine are disabled In istation_empty Bool Station empty status only used for the diagnostic screen In door_is_open Bool Inputs from the machine logic for the In door_is_closed Bool status of the door only used for the diagnostic screen Entry-ID: , V1.0, 10/

22 3 Installation and Startup Input or Name of paremeter Data type Description output In from_rob_rob_outside_mc Bool From robot : robot is outside the machine only needed for diagnosis screen In from_rob_prepare_ackn Bool From robot : robot has brought the next part only needed for diagnosis screen In from_rob_robot_alive Bool Heartbeat from robot In from_robot_ready_to_run Bool From robot : robot ready to run only needed for diagnosis screen In from_robot_disabled Bool From robot : robot cannot perform the unload/load operation only needed for diagnosis screen In Request_unclamp_f_robot Bool From robot unclamp /clamp request only In Request_clamp_f_robot bool needed for diagnosis screen Out live_signal Bool Heartbeat signal from the machine to the robot Out out_mach_rdy Bool Output to the robot : the machine is ready. This signal comes from the input in_mach_rdy Out out_enable_robi_in_mach Bool This signal is passed through from the input in_enable_robot_in_mach Additions to the existing PLC program for the two Robot SBR s The user must add these additions listed below for this application to work. 1. Outputs from SBR_Rob_SW47_Single_Cyc (SBR4) close door to PLC and open door to PLC The operands on these outputs must be added to the existing door control logic. 2. Outputs from SBR_Rob_SW47_Single_Cyc (SBR4) NC Start. The operand on this output must be added to the existing NC Start logic 3. Input to SBR_Rob_SW47_Single_Cyc (SBR4) Prepare after startup The user must provide a 1 pulse on this input to get the robot unload/load sequence running. 4. Inputs to SBR_Rob_SW47_Single_Cyc (SBR4) and SBR_RobDiag_Screen_1Cy door is opened/ door is closed. The user must provide these signals from the door logic. The door is opened goes out to the robot. 5. Input to SBR_Rob_SW47_Single_Cyc (SBR4) and SBR_RobDiag_Screen_1Cy Station empty The user must provide a 1 on this input when the machine is started up with no part in the fixture. The signal must go to 0 after the first cycle. Entry-ID: , V1.0, 10/

23 3 Installation and Startup Additions to the existing PLC program for the fixture Regarding the signals from robot Request for clamp and Request for Unclamp : the user must add these inputs to the existing fixture control logic to close/open the fixture. The user must provide feedback to the robot for the status of the fixture, these are the signals Status Clamped and Status Unclamped. These status signals are also provided to SBR_RobDiag_Screen_1Cy for display on the diagnosis screen 3.5 Testing the application - using another 828D in place of the robot When this application was developed a second Sinumerik 828D was used as a robot, since no real robot was available. The robot Sinumerik 828D had separate programs for Prepare, Load, Unload and serviced the robot side of the interface. The two Sinumerik 828D s ( one as the machine, one as the robot) were linked by Profinet with a PN/PN coupler. This application notes comes with the archive and PLC of this second 828D, this may be a help in becoming familiar with the application. The archive and PLC program are in the directory:.:\files\828d which simulated the robot Entry-ID: , V1.0, 10/

24 4 Contact 4 Contact Siemens AG Digital Factory DF MC MTS APC Frauenauracher Strasse Erlangen Germany mailto: MC-MTS-APC-Tech-Team.i-dt@siemens.com Entry-ID: , V1.0, 10/

25 5 History 5 History Table 5-1 Version Date Modifications V1.0 10/2015 First version Entry-ID: , V1.0, 10/

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