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IRC5 vs.

S4Cplus I/O System


© Robotics - 1 -
2019-03-18
Topics

 IRC5 I/O design considerations


 New panel board
 SW-structure of the IRC5 I/O system
 I/O system configuration
 Error handling in the I/O system
 Simulation of I/O
 Fieldbus commands and FCI.
© Robotics - 2
IRC5 I/O design considerations

 Fieldbus type shall be completely optional

 Use ‘COTS’ solutions for the HW

 Simplify the I/O configuration

 Make the base for a “Plug and Produce” I/O system

 Ease the implementation of future fieldbuses

 Simplify the internal design to improve SW quality


© Robotics - 3
New Panel Board

 Not a unit on DeviceNet anymore

 Located on a separate serial link to the RCC

 Contain 8DI/8DO signals for custom use

 Configured on bus “Local”


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IRC5 supported master fieldbuses
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Basically the same I/O system structure

Bus

Unit type

Unit

Group
= Signal

Cross-Connection &
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I/O System Configuration

RobotStudio Online
Used at Warm start

CFG File

RAPID
WriteCfgData “/EIO/EIO_SIGNAL/process_error”,”Unit”,io_unit;
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What to configure in the I/O system?

 In IRC5  NOT in IRC5


 Buses  Mapping of physical signals
 Unit types  Parameters (DeviceNet)
 Units  Parameter values
 Signals (dig/ana/grp) (DeviceNet)

 Cross connections
 System inputs and outputs
 Command types
 Commands
© Robotics - 8
I/O bus configuration

Parameter Example
-Name “DeviceNet1”
-BusType “DNET”
-BoardNumber “1”
-ConnectorLabel “X3”
-RecoveryTime “15”

(+ BusType specific parameters)


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I/O unit type configuration

Parameter Example
-Name “d328”
-BusType “DNET”
-VendorName “ABB Robotics”
-ProductName “24v digital I/O”

(+ BusType specific parameters)


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I/O unit configuration

Parameter Example
-Name “GripUnit”
-UnitType “d328”
-Bus “BASE”
-UnitLabel “On arm, U137”
-TrustLevel “1”
-Disabled
-StoreLogicalState

(+ BusType specific parameters)


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Unit trustlevels

 TrustLevel 0 (Unit required)


 Loss of unit causes error and stop
 Reconnection and warmstart required

 TrustLevel 1 (Default)
 Loss of unit causes an error message
 Program execution stop when the lost module is accessed
 Reconnection of unit and restart of program is required

 TrustLevel 2 (Allow loss)


 No error when the unit is lost
 Error and stop when a signal is accessed (from RAPID)

 TrustLevel 3 (Quickstop)
 As trustlevel1 but stop on path when the unit is lost
© Robotics - 12
I/O Signal Configuration

Parameter Example Parameter Example


-Name “CloseGrip” -UnitMap “0”
-SignalType “DO” -EncType “ ”
-Unit “GripUnit” -MaxLog “ ”
-Blocked -MinLog “ ”
-Invert -MaxPhysLimit “ ”
-Store -MinPhysLimit “ ”
-Default “0” -MaxPhys “ ”
-FiltPas “ ” -MinPhys “ ”
-FiltAct “ ” -MaxBitVal “ ”
-Category “Handling” -MinBitVal “ ”
© Robotics - 13
The UnitMap parameter

 Replaces the S4Cplus parameters “PhSig” and “Length”


 Describe the mapping of a signal onto a unit
 Makes the cumbersome signal mapping of S4Cplus
obsolete

Examples:
-UnitMap 0 // A one bit mapping (digital signal)
-UnitMap 0-15 // A 16 bit signal (analog or group)
-UnitMap 8-15, 0-7 // A “byte-swapped” signal
-UnitMap 8-15,0,1,2-6,7 // … a complicated example…
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The internals of an I/O unit

DI DI DI DI DI DI DI DI
1 2 3 4 5 6 7 8

Memory

00010001
Fieldbus
AI
CPU
1 A/D 10011011 Fieldbus
Connection

AI
A/D 10100000
2

Data in fieldbus message


10011011 10100000 00010001
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The Unit mapping and “Bit-values”

 A way to describe the “A/D-converter” and the “Fieldbus CPU”

Data in fieldbus message


10011011 10100000 00010001

Configuration of “MyAI_2”
-Name “MyAI_2”
-SignalType “AI”
-Unit “MyAIDIUnit”
-UnitMap “8-15” Configuration of “MyDI_5”
-EncType “UNSIGNED” -Name “MyDI_5”
-MaxPhys 10 -SignalType “DI”
-MinPhys 0 -Unit “MyAIDIUnit”
-MaxBitVal 255 -UnitMap 20
-MinBitVal 0
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Configuration of analog signals
Physical value (V, mA etc.)

MaxPhys x

MaxPhysLimit

Logical value
Used in RAPID
MinLog MaxLog (mm/s etc.)
MinBitVal MaxBitVal
“Bitvalue”…
Transmitted on
MinPhysLimit
the fieldbus.

x MinPhys
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Simple cross connections

EIO_CROSS:
-Lact di0 -Lres do0

di0 do0
=
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Cross connection with logical expressions

Require the option “Logical Cross Connections”

EIO_CROSS:
-Lact di1 & di2 -Lres do1 + do2
-Lact do1 ! *di3 -Lres do3

di1 do2
di2 & do1

do3
di3 !
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Error Handling

 Error recovery from RAPID when accessing signal on a


lost unit

 Error behavior according to unit trustlevel


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Simulated I/O

 Simulated bustype – SIM


 Controlled by the bus setting -Bustype SIM
 All accesses to units on the bus is redirected to a SW-bus
 Predefined bus Virtual1

 Virtual signals
 Signals that are not configured to a unit

 Simulated I/O
 Enabled/disabled from the GTPU or RSI
 A way to run programs but to avoid real I/O interaction
© Robotics - 21
Fieldbus commands and FCI

 FCI – Fieldbus Command Interface


 A SW-option
 DeviceNet explicit messaging from RAPID using open/close and
read/write.
 Fieldbus commands
 Configuration of DeviceNet parameters for I/O units
 Downloaded to I/O unit at system startup

EIO_COMMAND_TYPE: EIO_COMMAND:
-Name “StationAddress” -Unit “Myd352”
-UnitType “d352” -CommandType “StationAddress”
-DefValue 126 -Value “20”
-OrderNr 3
-DN_Path “6,20 67 24 01 30 04,C6,1”
© Robotics - 22

-DN_Service 0x10
Summary

 IRC5 I/O design considerations


 New panel board
 SW-structure of the IRC5 I/O system
 I/O system configuration
 Error handling in the I/O system
 Simulation of I/O
 Fieldbus commands and FCI.
© Robotics - 23