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MAN_Kap12_01_ROB_Common_General_160218_en.docx
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Page 1 of 78
Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
Page 2 of 78
Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
MAN_Kap12_01_ROB_Common_General_160218_en.docx
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Page 3 of 78
Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
Change history:
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
12.1.1 General
The guidelines for erection, handling and programming of the robot specification
"SPEZ_Kap_04_robot _xxxxxx.pdf" are to be adhered to.
12.1.1.1 Purpose
The rules, regulations and concepts described in this document are to be observed and ap-
plied to ensure the overall standards and concepts are adhered to.
Not included in the scope of this document are all application-specific requirements, which
are described within the specific "application standard documents".
The System Suppliers and subsequent robot programmers have the responsibility to comply
with all the requirements stated within the BMW standards and forward any questions for
clarification with the responsible BMW robot project “GEL”.
The standard documentation is intended to provide users with instructions, guidelines, ex-
amples, explanations and solutions to all BMW standard robot related issues.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
The robot must always (also in the Home positions) be operated with this real-world measured data.
The system supplier must ensure that the robot is never overloaded.
If the load data determination reveals that the robot is overloaded then the BMW technical depart-
ment responsible must be notified immediately.
Note: If incorrect weight data is used at the start of programming the robot the "Absolute accuracy"
function can cause point offsets.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
Note: It must be ensured that each axis has enough room to move when in the adjustment position
on order to be able to perform a complete adjustment (incl. various different tools). In individual cas-
es it is permissible for axes 1+7 to be adjusted at a different position. Axes 2 to 6 must always be
adjusted at the same position!
12.1.1.7 Language
All text entries (descriptions/comments etc.) must be provided in the native language of the relevant
factory. (China in English)
Every user program must contain a program header with the following information, which must be
kept up to date until handover.
Program description
Company name
Author name
Creation date
Change history
For better comprehension, Comments are to be inserted at important places in the program.
Caution: When external editors are used, ANSI format must be set!
No umlauts may be used!
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
12.1.1.8 Documentation
All data is to be documented in the RobotWorkbook (robot documentation).
Attention:
In addition to the user data, an archive also contains Standard data and System data. The robot pro-
grammer is responsible for ensuring that this data cannot be deleted or modified.
Especially after a Standard update, care must be taken to ensure that a complete archive is restored.
The system supplier / Programmer / SE Partner may not either add or remove any BMW standard
application system files unless permitted to do so by the standard documentation or agreed by the
appropriate BMW robot project “GEL”.
12.1.1.12 Passwords
The currently valid passwords can be requested from the Robot System technical department if re-
quired. Passwords may not be changed by the user!
12.1.1.13 Acceptance
Conformance to the standard is a partial prerequisite for acceptance. The standard settings for pa-
rameters and machine data, e.g. for speed, acceleration etc. must not be changed without prior con-
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
sultation. Test routines that systematically search the memory image for irregularities are used by
BMW during the acceptance process. If irregularities occur that influence the correct operation of
the robot then the acceptance is retracted and the system supplier must correct all defects.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
Provision of the commissioning data is a basic prerequisite and this System builder
must be provided to the robot supplier before commissioning.
The commissioning files are generated using the "XML Generator"
(project.xml). The basis for this is Derived from the E-Plan.
The commissioning files contain the following location-specific infor-
mation:
Required applications (IBN.xml)
Profinet configuration of the robot
I/O connections and start addresses of the individual partici-
pants
Long texts
Current GSDML files
IP address and computer name for message output
The system builder must check the functionality and plausibility of the
data.
Installation of the BMW standard application software with the com- KUKA
missioning files provided by the system builder.
Mounting of the tools as specified, incl. (manual axes A4, A5, A6 in System builder
zero position)
All participants that are not operated via a tool changer must be set to Programmers
"always available".
Device christening of the individual Profinet participants is to be per-
formed.
Calibrate the robot into the vehicle coordinates network and en- Programmers
ter/check the specified data.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
The correct load data, incl. additional load data must be determined Programmers
for every tool (Tool) See section 12.1.1.3
Creation, installation and optimization of the user program, incl. ad- Programmers
herence to the programming standards.
Perform a risk analysis and define any measures necessary System builder
Programming and testing of the safety measures required by the risk Programmers
analysis. See section 12.1.3
Setting and optimization of the media package. Have the media pack- Programmers
age accepted by the robot supplier. See section 12.1.1.6
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
The connection to the PLC consists of a standardized region of 255 bytes. The assignment of the
individual application signals is not defined in advance and is generated according to the E-plan data
on commissioning.
User and System signals (Bytes: 0-63 / Bit 1 -512) > Fixed assignment
Application signals (Bytes: 64-253 / Bit 513-2032) >Assigned
according to E-Plan
System-internal occupied (Bytes: 254-255 / Bit 2033-2048) > Fixed as-
signment
Connection of the applications to the lower level "Master area" consists of a standardized area of
max. 718 Bytes. The assignment of the individual application signals is not defined in advance and
is generated according to the E-plan data on commissioning.
The dynamically assigned signals for the visualization are available under the menu
"Display" -> "BMW" application-specific status window.
Concept: During commissioning, the "XML-Generator" tool is used via "WorkVisual" to load the
required application packets and implement the dynamic I/O assignment, based on the planning
information from the E-Plan.
Note: The E-Plan must correspond to the real system configuration at the time of commissioning,
otherwise the robot commissioner (KUKA) cannot install the correct application package.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
A fundamental requirement is that all robots must be made safe in accordance with the currently
applicable versions of SPEZ_xxxxxx_SafetyConcept_ChassisConstruction, the EN ISO 10218 stand-
ard and all other relevant standards and documents.
A risk assessment must be performed for every robot.
If protective measures are necessary as a result of the risk assessment then the required safety
parameters (e.g. coordinates of the protected area, geometry of the tool, permissible speed, etc.)
must be entered into the robot controller.
The data, e.g. for protected spaces, can be generated on the real robot or created with an offline
system. The operation and entry of the configuration data for "KUKA SafeOperation" is performed
using the WorkVisual software or directly at the robot system.
In the chassis construction sector, the cyclic brake test must be activated for all axes on all robots.
The protective measures must be checked in the real cell and the correct function ensured. The
protection target according to the risk assessment must be achieved.
Note:
The protective measures must be checked again if robot sequence programs are changed where
the robot moves into a protected area (e.g. employee workspace).
Among other examples, a program change is: removal of motion points, modified movement to the
protected area. modification of speed etc.. Such program changes cam change the braking path
angles of the robot and possibly result in the safety target no longer being achieved.
12.1.3.2 Functions
KUKA SafeOperation provides the following functions:
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
Note:
Configuration, programming and function tests are to be performed based on the KUKA
KUKA.SafeOperation documentation, the risk assessment and the
SPEZ_xxxxxx_SafetyConcept_ChassisConstruction.
The following configuration options can be set for the monitoring spaces:
Workspace and protected space
Space-specific Cartesian velocity inside or outside
Activation and deactivation via safe inputs
Violation signals via safe outputs
Stop on violation of the space borders
Reference stop in the case of missing adjustment referencing
Note:
Configuration, programming and function tests are to be performed based on the KUKA
KUKA.SafeOperation documentation, the risk assessment and the
SPEZ_xxxxxx_SafetyConcept_ChassisConstruction.
Stopping paths are to be taken into consideration if indicated by the risk assessment and/or the
SPEZ_xxxxxx_SafetyConcept_ChassisConstruction / MAN_xxxxxxx_8_2_Leitfaden_Standardsituationen.
Meaningful names are to be defined for the spaces.
A safe tool is basically modeled using the Safe TCP and up to 6 freely configurable spheres When
modeling, care must be taken to ensure that no parts / tool elements protrude outside the sphere
(tool incl. part must be completely enclosed by the spheres).
The safe tools are activated using safe inputs. The actuation and activation of tools is performed
exclusively by the safety PLC.
The "Normal TCP" is to be used as the Safe TCP (e.g. spot gun with fixed sleeve, auxiliary TCP for
the gripper). With a tool combination (e.g. spot gun/ handling) the TCP furthest away from the center
of the flange is to be used as the Safe TCP. When using a tool with only one safe tool model (no
switching of the safe tool) the "Normal TCP" furthest away from the flange is to be used as the Safe
TCP.
With changer tools, in some situations it may be necessary to define multiple safe tools that are
switched over by the safety PLC (according to the optional safety switches at the stations).
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
As far as possible, as many tools as possible should be combined into a safe tool. This means that
only one tool is to be used if the tool geometries are almost identical.
The tool with the largest geometry, including parts, must be configured as a safe tool.
Note:
The parts in the tool cannot be switched in and out, i.e. the Safe Tool always has parts!!
Multiple tools may only defined in the case of different geometries that cannot be combined for rea-
sons of accessibility (see also following concept diagrams)
If necessary, Safe Tool 15 is to be used for the tool changer without a docked tool.
If accessibility problems occur with the Safe Tool "gripper with docked mobile tool changer/milling
tool" then an additional Safe Tool can be configured by mounting an additional optional safety
switch on the mobile milling tool resting area.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
A Safe TCP, which is monitored for the configured speed, is defined for every safe tool. The Safe
TCP is not automatically identical to the active TCP of the base system.
12.1.3.2.4 Axis, Spatial and Cartesian speeds and safe operational stop-
ping
If required (as a result of the risk assessment) it can be used according to the KUKA SafeOperation
documentation.
If persons can be present in the vicinity of a robot that presents a hazard due to its mass and/or tool
load, then a cyclic brake test must be provided.
The brake test must be implemented for every robot used in the chassis construction sector!
Note:
The KUKA Standard Brake Test program must not be used!
The BMW brake test program "Prog251_braketest.src" and the BMW parking position program
"BMWBrakeTestPark.src" are to be created (positions, paths, tool change etc. teaching) or the
equivalent OLP program generated offline must be adjusted.
The brake test is started by the PLC every 24 hours. The call in the automatic sequence is
"Prog251_BrakeTest".
Note:
The brake test is started from Home1. If possible, Home1 should be used as the test position. The
parking position is ideally the transport position and must be chosen so that the robot can collapse
without danger.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
The mastering test is used to check that the actual position of the robot corresponds with a refer-
ence position. The robot can only be safely monitored with SafeOperation if the mastering test was
successful.
Attention:
This program is only required if the risk assessment resulted in the requirement for SafeOperation
functions.
The reference switch provided in the KUKA scope of delivery must be used.
The reference switch should not be used in conjunction with the KUKA actuating plate (tuning fork)
but rather with the gripper or the gun!
No movable parts such as pins, clamps etc. are to be used, also rounded parts such as electric
shafts are not permitted!
The alternative variant of moving safety switches to and fro above the PLC is not permitted!
Notes:
The KUKA Standard mastering test programs must not be used!
The program starts and ends at Home 1. The robot position must be chosen so that all axes of the
robot (incl. linear axis if present) can be measured.
The call in the automatic sequence is "Prog250_MasterReference".
When using tool changers, referencing is only to be implemented for one tool. The tool used in the
"Home1" position should preferably be used.
The decision as to whether the stopping distance must be taken into consideration depends on the
results of the risk assessment. The diagrams from the robot manufacturer's specifications are to be
used for determining the stopping distance in the planning phase.
The "Nachlauf Logging tool" from KUKA can also be used for the actual situation in the fully pro-
grammed cell. In the case of a violation of the protected space this tool records the axis angles at the
time of violation and the time of standstill. This is then used to calculate and output the braking dis-
tance.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
On commissioning the cyclic brake test is automatically switched active. The settings remain at the de-
fault values. The PLC starts the brake test cyclically (every 24 hours).
The settings according to the figure below must be made in the Hardware Options.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
The rotatory axis monitoring is set to 100 °/s at the maximum speed T1 (KUKA default 30 °/s)
The reference probe provided in the KUKA must be used for adjustment referencing. The reference
probe must not be damped with the KUKA damping plate (tuning fork) but rather damped with the grip-
per or the gun wherever possible!
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
No movable parts such as pins, clamps etc. are to be used, also rounded parts such as electric shafts are
not permitted
Meaningful names must be used for the monitoring spaces and safe tools (e.g. station or tool numbers).
Safe Tool 15 must be used for the tool changer without tool!
The "Normal TCP" is to be used as the Safe TCP (e.g. spot gun with fixed sleeve, auxiliary TCP for the
gripper). With a tool combination (e.g. spot gun/ handling) the TCP furthest away from the center of the
flange is to be used as the Safe TCP. When using a tool with only one safe tool model (no switching of
the safe tool) the "Normal TCP" furthest away from the flange is to be used as the Safe TCP.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
The different program numbers are to be used primarily for restarting the robot in the case of "Start
after fault" The organization program e.g. "Prog001_xxxxx" contains a complete robot sequence
robot. Further program numbers each represent a reduced scope of the organization program, as
illustrated in the following figure.
In exceptional cases and after consultation with/ approval from the respective BMW technical de-
partment it is possible to allow a program to run in an endless loop. In this case the program must
still be started from CELL.
Due to the possibility of being able to implement program aborts with return movement to a home
position, the following program structure is favored.
The robot program starts from Home 1 moves through all sequences directly one after another and
the ends back at Home 1. All other Home positions are only moved to in the case of an error, after
an abort.
The gripper must always be empty at the Home 1 position.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
Prog001_xxx: Job 1 – 2 – 3
Prog002_xxx: Job 2 – 3
Prog003_xxx: Job 3
Prog062_TipDress: Job 62 (for multiple clamps, call incl. UserNum)
Prog063_TipChange: Job 63 (for multiple clamps, call incl. UserNum)
Prog064_Maintenance: Job 64 (for multiple tools, call incl. UserNum)
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
The programmer must ensure that all programs are tested for function and freedom from collisions.
When using "conditional" program sequences (e.g. IF or SWITCH /CASE commands) all branching
possibilities must be tested and erroneous combinations ruled out. (e.g. by using a default - CASE)
A default error program is available to the user! "Plc_DefaultError()"
More information is provided in Section 0
Example:
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
A "CASE" condition for every program number is to be entered into CELL.SRC. Only the call to the
organization program is to be entered into the respective CASE statement.
Cell.SRC
......
......
SWITCH
CASE 1
Prog001_xxxxx() Prog001_xxxxx.SRC
CASE 2
Prog002_xxxxx () ; complete sequence
CASE 3 Pick_part
Prog003_xxxxx () Welding
..... Place_part
ENDSWITCH Prog002_xxxxx.SRC
END
; reduced sequence
Welding
Place_part
END Prog003_xxxxx.SRC
; reduced sequence
Place_part
END
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
{Task}_{ToolArea}_{Type}
Example: Spot_ST20FX1_G11
Description: Subtask
The subtask describes the main activity in each respective program. This can be (e.g.) placing, weld-
ing, machining, gluing etc.
Description: Type
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
3 characters are reserve for the type description. (e.g. G11 or G30). If a program is to be used simul-
taneously for multiple types (e.g. for G11 and G12) the designation of G1x is also permitted. The
type can be omitted if only one type is programmed in the robot and no additional type is integrated
later.
After consultation with, and approval from the respective BMW technical department, it is also pos-
sible to choose a different program structure.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
A maintenance program incl. a maintenance position must always be implemented for every tool.
When using a tool changer a maintenance position without a docked tool is also to be provided.
Cleaning position:
A cleaning program must be created for every robot. This is called by calling the maintenance pro-
gram and passing "User-Nr. 100".
The cleaning position must be chosen to ensure free and non-hazardous access to the system for
the cleaning personnel. This is usually a position above Home1.
The positions must be selected under consideration of various ergonomic factors and these must
be defined in agreement with the respective BMW technical department.
A collision-free execution must be ensured and a collision protection concept must be taken into
consideration if necessary.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
Whether or not the Abort concept should be implemented, and the scope of any implementation,
must be clarified with the BMW technical department responsible!
Aborts can be programmed using the "Job Request" and "Area Request" commands.
Note: Abort programs must always end in a Home position and must be created to have an appro-
priately safe speed.
A collision-free execution must be ensured and a collision protection concept must be taken into
consideration if necessary. When using or changing the program, care must be taken to ensure that
all possible program sequences have been properly tested.
Note: With subsequent software updates, the standard programs can be changed or completely
replaced.
The customer must always be consulted if changes are required.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
Attention: Changing a Home position can result in collisions in other programs! All affected pro-
grams must be checked after every change.
Linking of the home position with part checks or other similar functionality is not implemented in the
robot program but rather in the PLC.
Note: The "Home Output" is only set by the system when the configuration is performed via this
menu.
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Section 12.1 Robotics - General Component
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However, it must be assumed that an operator will eventually abort execution if a fault occurs and
then restart the robot via "CELL". This situation must be trapped and explicitly handled!
The following initialization programs (Start after fault)are available to the user in the directory
"BMW_Init".
Init_BeforeHome: (InitBeforeHome.src)
Initialization of user scopes, before the robot moves
Init_InHome: (InitInHome.src)
Initialization of user scopes, after the robot has reached the home position
Init_Produktion: (InitProduction.src)
Initialization of user scopes user query, every time before a new PLC program no. is requested!
Note:
The system program "A01_plc_init.src", which is called from within the program "InitProduc-
tion.src", initializes all system outputs to the PLC. This call must not be removed.
If individual functions (e.g. Areas, Jobs, CollZone, user outputs) are still required in the program se-
quence, then the user must always explicitly set these functions again after calling
"A01_plc_init.src"!
Attention:
"InitProduction.src" is immediately executed at the end of a program sequence. If a function (e.g.
Job Done) is set too late at the end of program execution, then the PLC might not receive the corre-
sponding signal (cycle time) because "InitProduction.src" immediately resets the function. The only
solution: Set the function earlier in the program sequence or program a small waiting time if neces-
sary!
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Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
Overview image:
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
12.1.9 Jobs
A program usually defines a number of different subtasks to be performed by the robot, i.e. a num-
ber of different jobs to be completed The Job concept synchronizes these subtasks with the PLC
via standardized inputs and outputs. The PLC evaluates these signals for visualization, for preparing
a Start after Fault and for time monitoring.
The following concept diagram illustrates the use of Job Started, Job Done and JobClearAll.
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Standard documentation for chassis construction systems
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The Inline Form for the Job command is designed so that it dynamically changes according to the
settings. The individual data entry possibilities are described on the following pages.
The "Job" standard command (with and without movement) for 64 Jobs is available for program-
ming.
Please also observe the notes on the initialization concept in Section12.1.8
JobStarted:
This function is used to notify the PLC that a Job has been started. The "JobStarted" is not auto-
matically executed on release of the "JobRequest" but is rather programmed at the position in the
user program where the subtask actually begins.
Example: The "Welding" is released in advance and the robot moves to the turntable. The
robot cannot move into the area until the area until the turntable signals "ready". The "Weld-
ing" only starts after the release.
JobDone:
This function is used to notify the PLC that a job has been completed. "JobDone" is usually set after
execution of the last process point. The status of "JobStarted" remains unchanged.
Example: After the last welding point has been completed on the part, the PLC calls "Job-
Done" to signal that this part has been fully processed. If this is followed by a manual inter-
vention and the robot is manually moved to the home position, the PLC can perform further
program preparation.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
JobRequest:
The PLC is queried to see if the release for a particular job is present. This function is usually only
used in the organization program. It is also possible to request a type number and/or a user number
for the corresponding job request
A JobRequest command can be canceled via the PLC.
The PLC asks whether approval for a certain job has been given. In exceptional cases it is also pos-
sible for the PLC to specify a job No. This is the "AnyJob" function, but it may only be used with the
consent of the relevant control technology.
The JobRequest function is usually only used in the organization program.
It is also possible to request a type number and/or user number for the job request. If "AnyJob" is
used, you should also remember that in certain circumstances there is not a user or type number
available in the PLC for all possible jobs.
JobClearAll:
This function is used to inform the PLC that all jobs have been completed. The "Job-interface" is
completely reset. Single jobs cannot be reset. All "JobStarted" and "JobDone" signals retain their
status until everything is deleted by "JobClearAll".
This function has been developed primarily for use in the initialization programs and for last program
step.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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BP V2.0
After selection of "PTP or LIN" all fields necessary for the respective motion settings are shown.
The position is moved to according to the selection. The "Started-output" is always set in advance,
execution of "Done-output" and "ClearAll" is triggered at the programmed position.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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BP V2.0
A maximum of 64 jobs are available. Inputs and outputs are mapped to the I/O interface analogous
to the Job numbers.
If the "CONT" switch is set the robot performs "approximate positioning", otherwise a stop in ad-
vance of execution is performed and the robot remains in this position.
The "Done" and "ClearAll" functions are always executed exactly at the specified position, regard-
less of this setting.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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BP V2.0
The entry should be comprehensible and provide additional information for the user.
An entry such as "Job 1 finished" provides no additional information!!!
In addition to a Job number request (Job_Request) a Type number and/or a User number can also
be requested from the PLC. This only requires a "tick" to be set in the corresponding field. The pro-
gram execution is stopped until the valid numbers are sent by the PLC. The function is processed in
advance.
A range of 1-255 is defined for both numbers. "0" cannot be selected.
The passed Type number and/or User number are temporarily stored in variables by the system and
can later be read once using the "GetTypNum" and "GetUserNum" functions.
Note: For safety reasons the "GetTypNum" and "GetUserNum" functions only return the valid values
once after these have been requested! Querying again returns a value of "0"!
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Section 12.1 Robotics - General Component
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BP V2.0
Implementation of an abort function is not compulsory for every job. This function carries a signifi-
cant risk of collision if used incorrectly. Agreement must be reached with the customer on the ap-
propriate method and scope for implementing the abort concept.
Abort= "NoAbort"
The program abort function is not activated.
Abort= "AbortProgXX"
The program abort function is activated and an "Abort" can be initiated by the PLC. The PLC does
not initiate an abort the setting has no effect and execution of the program continues as pro-
grammed!
If an abort is initiated the running program is exited and the selected "Abortprogram" is started. Af-
ter this, a new program no. is requested from the PLC.
Attention: The programming must ensure that the robot can execute the abort program without a
collision.
Note: An abort program is generally executed at reduced speed for system-technical reasons.
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Program sequence
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
12.1.10 Areas
Robots usually operate in different areas. Management of these areas is implemented using the
Area concept. Unlike the collision protection concept, areas do not apply across the entire plant but
rather only between specific respective robots. Basically the PLC is the manager of the area and the
robot can only "ask" if an area is free or "notify" when an area can be entered or is free.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
AreaRequest:
This function is used by the PLC to query if an area is free for moving into. The query always occurs
in advance, which means that under certain circumstances the query is processed by the PLC sev-
eral motion steps before reaching the area border. If the area is locked out then the robot stops at
the programmed position and waits until the release is enabled. If the release is already enabled
before reaching the programmed position the robot does not stop but rather only "approximately
positions" the movement.
AreaRelease:
This function is used to inform the PLC that the robot has exited an area of the system. This com-
mand is not processed in advance but is triggered exactly at the programmed position.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
On selection of "PTP or LIN" all fields necessary for the respective motion settings are shown. The
position is moved to according to the selection.
The "Request" is always executed in advance and the Release is always executed when triggered at
the programmed position.
A maximum of 32 areas are available. Outputs and inputs are assigned to the I/O interface, analo-
gous to the Area numbers.
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If the "CONT" switch is set the robot performs approximate positioning, otherwise a stop in advance
of execution is performed and the robot remains in this position. The "Release" function is always
executed exactly at the specified position, regardless of this setting.
The entry should be comprehensible and provide additional information for the user.
An entry such as "Query area 1" provides no additional information!!!
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BP V2.0
Implementation of an abort function is not compulsory for every area. This function carries a signifi-
cant risk of collision if used incorrectly. Agreement must be reached with the customer on the ap-
propriate method and scope for implementing the abort concept.
Abort= “NoAbort"
The program abort function is not activated.
Abort= “AbortProgXX"
The program abort function is activated and an "Abort" can be initiated by the PLC. The PLC does
not initiate an abort the setting has no effect and execution of the program continues as pro-
grammed!
If an abort is initiated the running program is exited and the selected "Abort Program" is started.
After this, a new program no. is requested from the PLC.
Attention: The programming must ensure that the robot can execute the abort program without a
collision.
Note: An abort program is generally executed at reduced speed for system-technical reasons
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The ClearAll function deletes all requests and releases all areas at the same time. This function has
been developed primarily for use in the initialization programs. Basically, the area releases should be
programmed individually at the places where the robot leaves the area.
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Section 12.1 Robotics - General Component
Standard
Electrics
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Note: The motion sequence must still be secured via collision protection even if the robots do not
come into contact because they work at different times. For example, a robot might be operated at
reduced speed for testing!
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
The Inline Form for the Collision protection: command is designed so that it dynamically changes
according to the settings. The individual data entry possibilities are described on the following pag-
es.
The "CollZone" standard command (with and without movement)) for 1-254 collision zones is
available for programming.
CollZone Request:
This function asks the PLC if the robot is allowed to move into an area of the system (collision zone).
The query always occurs in advance. This means that under certain circumstances the query is re-
ceived by the PLC several motion steps before reaching the collision border. If the zone is locked
out then the robot stops at the programmed position and waits until the release is enabled. If the
release is already enabled before reaching the programmed position the robot does not stop but
rather only "approximately positions" the movement.
CollZone Release:
This function is used to inform the PLC that the robot has exited an area of the system (collision
zone). This command is not processed in advance but is triggered exactly at the programmed posi-
tion.
Note: Only the robot occupying a given zone can later release this zone. Releases for non-occupied
zones have no effect!
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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On selection of "PTP or LIN" all fields necessary for the respective motion settings are shown.
The command should usually takes effect in the own PLC area. The PLC can also be optionally noti-
fied that the communication is provided for the PLC neighbor area.
PLC= “ExtPlc"
In rare situations it is possible that a robot must perform tasks across the plant in 2 different PLC
controller areas. (E.g. a part is picked up in the area of the associated PLC and must be placed in the
area of another PLC). In this case the selection "ExtPlc" can be used to notify the PLC that this
command is to take effect in the other PLC area.
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A maximum of 1-254 zones are available. No individual inputs and outputs of the I/O interface are
available to the user. The communication is implemented using an 8 bit number and control bits.
The values "0" and "255" are not valid zone numbers and cannot be selected.
If the "CONT" switch is set the robot performs approximate positioning, otherwise a stop in advance
of execution is performed and the robot remains in this position. The "Release" function is always
executed exactly at the specified position, regardless of this setting.
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Standard documentation for chassis construction systems
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The ClearAll function releases all collision areas occupied by this robot. This function has been de-
veloped primarily for use in the initialization programs. The collision releases should always be pro-
grammed individually at the places where the robot leaves the area.
The entry should be comprehensible and provide additional information for the user.
An entry such as "Coll zone 1" provides no additional information!!!
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
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BP V2.0
Example 1:
The robot has reached the maintenance position and signals this to the PLC.
Example 2:
The robot is to remove different parts from a magazine. The PLC knows the content of the magazine
and specifies the removal sequence.
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BP V2.0
The Inline Form for the User Communication command is designed so that it dynamically changes
according to the settings. The individual data entry possibilities are described on the following pag-
es.
The "Plc_Com" standard command (with and without movement)
The User communication command can be programmed with and without motion positions be . On
selection of "PTP or LIN" all fields necessary for the respective motion settings are shown. The
position is moved to according to the selection.
Data entry field: Selection of the function for the 1st command
The "Set user output" and "Reset user output" actions can be selected.
No selection ("_") means that no function is executed.
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Data entry field: Select a user output for the 1st command
Only the 512 PLC outputs of the standard interface be selected. Other inputs are not supported by
this command.
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Data entry field: Selection of the function for the 2nd command
Wait_Input=1
The program pointer waits until the specified input reaches the "high" state.
Wait_Input=0
The program pointer waits until the specified input reaches the "low" state.
Request_UserNum
A user number is requested from the PLC via the standardized interface. The program stops at this
selection until the PLC sends a valid User-Num (1-255). The number "0" cannot be used. This user
number can then be used later in the program. (See Section 12.1.13.3)
Send_UserNum
PLC can be sent a user number via the standardized interface. A numeric range of 0-255 is permit-
ted. (see Section 12.1.13.1)
Request_TypNum
A type number is requested from the PLC via the standardized interface. The program stops at this
selection until the PLC sends a valid Type-Num (1-255). The number "0" cannot be used. This type
number can then be used later in the program. (See Section 12.1.13.3)
Send_TypNum
The PLC can be sent a type number via the standardized interface. A numeric range of 0-255 is
permitted. (see Section 12.1.13.1)
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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Only the 512 PLC inputs of the standard interface can be selected. Other inputs are not supported
by this command.
Selection of "Send_UserNum" and "Typ_UserNum" allows a numerical value from 0-255 to be en-
tered into the data entry field.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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BP V2.0
The "Reset_Output" and "Set_Output" actions can be selected. No selection ("_") means that no
function is executed.
Only the 512 PLC outputs of the standard interface be selected. Other inputs are not supported by
this command.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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If the "CONT" switch is set the robot performs the movement with approximate positioning. The
configured actions are performed in advance. If "CONT" is not set the robot remains at the pro-
grammed position. The configured actions are only performed after this.
The entry should be comprehensible and provide additional information for the user.
An entry such as "Set Output 1 and wait for Input1" provides no additional information!!!
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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Attention: Type numbers and User numbers must always be requested / sent using the specific
commands and functions provided for this purpose. Evaluation of the direct I/O signals is not per-
mitted because they only have the correct status briefly during communication!
The function has been developed to allow the PLC to check if the robot has actually jumped into the
specified sequence! This can occur when the organization program contains logical errors or (e.g.) if
sequence programs have been incorrectly copied.
When a Type number / User number is requested via the JobRequest command, the PLC expects
the same number to be "mirrored back" in the first response after the command! If a different
number is returned the program startup is stopped and corresponding messages are displayed on
the robot control panel and the system PC.
The return mirroring is performed using the "Plc-Com-Command" in the sequence program!
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Standard documentation for chassis construction systems
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The checking function in the PLC only works for the first return mirroring of a number after a
"JobRequest-Command incl. TypNum/UserNum-Request" has been programmed!
Type numbers and User numbers must be requested using the “JobRequest" or "PlcCom" robot
commands. If no valid numbers are present in the PLC at the time of the request then the moved
pointer stops at the robot command and generates a message after the expiry of "MaxTime". This
message cannot be acknowledged, the robot program waits until a valid number has been exchanged
and verified.
After a successful request the number is temporarily stored in an internal system variable. This can be
processed further in the user program via the "GetTypNum" or "GetUserNum" functions. If the number
is only required once then it can be used directly via the function, otherwise it can be copied into a
user variable.
Attention: For safety reasons, the functions return the valid values only once these have been re-
quested!! Querying again returns a value of "0"!
Further information:
JobRequest: Section 12.1.9.2
PlcCom: Section12.1.12.2
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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If the number is also passed, as shown in the sample program: 12.1.13.5 then it is shown on the dis-
play.
The "Start CELL" manual intervention and checking or possible modification of the user program
would then be necessary.
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In general, the abort must be implemented at suitable positions in the program (e.g. before starting a
job). Aborting a job that has been started is not permitted!
Note: The abort function carries a significant risk of collision if used incorrectly. Care must be taken
to ensure that all possible program sequences have been properly tested. Agreement must be
reached with the customer on the appropriate method and scope for implementing the abort con-
cept.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
If the PLC triggers an abort then a check is made to see if the robot is in a Home position. If yes, the
robot program is aborted at this position and the program pointer in the "CELL" program is set to
the "Request new program number" line. In this case the initialization programs are not not execut-
ed!
Attention: In this application case it must be ensured that the robot is in the specified Home posi-
tion, otherwise the robot would move to the selected Home position using a direct path.
Further information:
Job command in Section 12.1.9.2, Data entry field abort
If the PLC triggers an abort then the selected "Abort Program" is started or the robot moves directly
to the specified "Home position". This occurs at a reduced speed. It must be ensure that the abort
program ends at a Home position, otherwise the abort is denied with an error message. The "Start
CELL" manual intervention and checking or possible modification of the user program would then
be necessary.
After a successful abort the program pointer in the "CELL" program is set to the "Request new pro-
gram number" line. In this case the initialization programs are not executed!
Further information:
Job command in Section 12.1.9.2, Data entry field abort
Area command in Section 12.1.10.2, Data entry field abort
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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Electrics
BP V2.0
All abort programs must always be designed and tested to exclude the possibility of collisions in all
cases.
Abort programs can only be used in the "Job" and "Area" commands when they have first been
created via the "ModAbortPrograms" menu. Conformance to the naming convention is compulsory!
Since abort programs are not included in the regular sequences and are only used in exceptional
cases, these must be programmed with an appropriate speed.
For an abort, it must be noted that the collision protection and area concept may need to be updat-
ed. The last position must be a home position, otherwise automatic execution of the program can-
not continue.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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Electrics
BP V2.0
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
Standard
Electrics
BP V2.0
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Standard documentation for chassis construction systems
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Note:
This functionality is only available in version V1.4.0 of A01 and later.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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Electrics
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The “ModHomePrograms” GUI is used for creating “Home to Home” programs similar in concept to the
“Abort Programs”. The “HomeX_to_HomeX” programs are stored inside the “Home Programs” Folder
and MUST be programmed to enable a safe robot path between homes.
It is the responsibility of the line builder to ensure all programs are fully tested prior to handover.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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Electrics
BP V2.0
The operator must enter the Process ID and the associated Application Number. A maximum check-
ing time, specifying the maximum time allowed for finding the process point, must also be set. The
check is automatically ended if not robot has recognized this ID within this time. The check is start-
ed via the Start button.
Note: Poorer cycle times are to be expected while a check is active. This is because every robot
queries the SPS signal ProcessRel before each process point. If process point monitoring is activat-
ed, this signal is not set to "one" until the PLC has confirmed that the next process number output
by the robot is not the number to be checked.
The inline form for the Controlled Stop command is provided for special cases only, where a con-
trolled stop is required, which cannot be covered via the standard commands.
Note: The ILF must be programmed with a Repeat Until loop with waiting time.
An application case is e.g. the ILF at a visual inspection position for adhesive application verification.
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Standard documentation for chassis construction systems
Section 12.1 Robotics - General Component
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Implementation example:
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Standard documentation for chassis construction systems
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12.1.16.2 Locking in the case of multiple querying of the same areas and colli-
sion zones
The "Area" and "CollZone" commands can be position-triggered and programmed with approxi-
mate positioning for advance execution. If the same areas are multiply queried and released in suc-
cession then this presents a danger of the corresponding signals overlapping in time and creating
an undefined state in the PLC.
Example:
Multiple querying and intermediate releases are pointless and the user program must be corrected.
In Automatic operation the following message is generated:
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Standard documentation for chassis construction systems
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In T1 or T2 operation, moving the cursor or aborting a program can cause an area to be requested
again. In this case there is no program error but the lock still engages. The following message dia-
log is displayed.
If the dialog is answered with "Yes" then the "previous request query" is canceled and "new request
query" is sent to the PLC!
If acknowledged with "No" the program sequence remains unchanged and the controller continues
to wait for a release from the PLC.
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