FANUC Integration with Rockwell Automation

FANUC FANUC Robotics Integration - Fast/Easy Integration using CIP & EDA

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Rockwell Automation TechED 2016

@ROKTechED

#ROKTechED

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CNC | ROBOT | ROBODRILL

Source for Intelligent Automation Solutions

Core Technology > 350,000 robots installed worldwide

> 14.0 million servo motors installed worldwide

> 3 million CNCs installed worldwide

> Leading supplier of small machining centers, electric injection molding machines and wire EDMs

World Wide Support With Over 230 Offices in 45 Countries

We Support your FANUC product for its Entire Production Life

Diverse Markets

Aerospace

Energy

Agriculture Construction

Furniture

Cosmetics

Automotiv e

Glass Beverage Food

Jewelry Paper Textile

Metal

Die Casting

Fabric Electronics

Medical & Phamaceutical

Plastics

Wood

Voice of the Customer Increasing machine integration complexity … • More safety functions (area scanners, light curtains, gate switches …) • Auxiliary motion for Material Handling/Transfer, weld and dispense gun apps • Visual inspection systems (Cameras, surface scanning …) New safety & security requirements being added … • SIL3, PLd safety networks • Heightened security and access functionality Information Technology connection is more important . . . • Information is being driven throughout the organization • Traceability is now a standard requirement Seamless integration of multiple vendors products to meet • Ethernet being driven to many devices these requirements is a value to our customers! 6

Integrated Cell Architecture EtherNet/IP Integrated Machining Cell Architecture Provides:  Simplified Architecture  Improved Productivity  Manufacturing Intelligence

 Safety-Integrated Network

FANUC Robotics and Rockwell Automation Connectivity

FANUC / Rockwell Automation Integration FANUC has provided premier integration technologies for Rockwell Automation products for over 30 years based on common customer and market requirements.

FANUC’s partnership with Rockwell Automation includes an extensive collection of technologies and products from low level device I/O communication to advanced data and display integration that simplify and enhance the user experience.

FANUC / Rockwell Automation Integration History FANUC introduced an Allen-Bradley Remote I/O adapter interface back in the mid 1980s that integrated Allen Bradley hardware directly into the Robot backplane for tight I/O integration. FANUC has continued to expand the number of products that tightly integrate FANUC robots and Rockwell Automation PLCs / HMIs over the past 30 years.

Allen-Bradley Remote I/O Adapter

1980

DeviceNet Master DeviceNet Slave

1990

Ethernet/IP Safety Enhanced Data Access PC Remote iPendant Remote iPendant

Ethernet/IP Scanner Ethernet/IP Adapter DeviceNet Safety

2000

2010

FANUC / Rockwell Automation Integration Timeline

2020

FANUC / Rockwell Automation Integration FANUC is focused on providing integrated products in 3 major technology areas Tight HMI Integration • Provides the same Robot HMI screens on both the robot teach pendant and the system HMI Structured Data Collection/Access • Enables enriched custom HMI screens by providing most robot data types in a structured format

Open Standards I/O and Safety Integration • Provides quick and easy to setup device I/O connections for both standard and safety rated I/O between the PLC and Robot

FANUC / Rockwell Automation Integration HMI Integration PC Remote iPendant (RTL-R850) Remote iPendant (RTL-R843)

Structured Data Collection/Access Ethernet/IP Enhanced Data Access (RTL-R822)

Standard and Safety I/O Communication Ethernet/IP Adapter (RTL-R784)

Ethernet/IP Scanner (RTL-R785)

Ethernet/IP Safety (RTL-R713)

Premiere Integration Based on Customer Demands

EtherNet/IP Adapter EtherNet/IP Scanner CIP Safety Enhanced Data Access Internet Connectivity Remote iPendant Rockwell Automation AOP for FANUC Robot

PanelView Plus

Logix Controllers

Standard and Safety I/O Communication

EtherNet/IP Options • EtherNet/IP Adapter – Adapter functionality for communication to PLC or other robots

• EtherNet/IP Scanner – Scanner functionality for communications to robot controlled devices

• EtherNet/IP Safety (CIP Safety) – Safety adapter functionality for safety interlocks with PLC without need to hardwire cell safeties • Can be used to compliment, or in-lieu of hardwired interlocks

• EDA (Enhanced Data Access) – Provides an easy way to share variables, registers and other data between the PLC and robot with an easy setup that is done from the robot Teach Pendant Full Suite of EtherNet/IP options to fit the application

Ethernet/IP Adapter FANUC’s EtherNet/IP Adapter option allows the robot to communicate with an Ethernet/IP Scanner – typically a PLC or another FANUC robot quickly and easily

• Up to 32 connections are supported, allowing multiple scanners (PLC’s) to communicate simultaneously • Supports API’s as fast as 8ms • (2) Ethernet ports on the robot support EtherNet/IP, allowing independent and isolated networks

Control Logix with Ethernet/IP Scanner

Robot with E/IP Adapter

Robot with E/IP Adapter

Ethernet/IP IO Block

Robot with E/IP Adapter

Ethernet/IP Scanner FANUC’s EtherNet/IP Scanner option allows the robot to communicate with an Ethernet/IP adapters– typically I/O blocks, Valve Packs, Process Equipment or other FANUC robot quickly and easily • • • • •

Up to 32 connections are supported, allowing connection to up to 32 devices Supports API’s as fast as 8ms Supports Quick Connect for tool changes or other disconnectable devices Includes the EtherNet/IP Adapter option (2) Ethernet ports on the robot support EtherNet/IP, allowing independent and isolated networks

Robot with E/IP Scanner Robot with E/IP Adapter

Ethernet/IP IO Block

Ethernet/IP IO Block

Robot with E/IP Adapter

With 2 available Ethernet ports, It is possible to use one port for EtherNet/IP to the PLC, and the second port for robot controlled devices

Ethernet/IP Safety FANUC’s EtherNet/IP Safety option allows the robot to communicate with an Ethernet/IP Safety Scanner such as Rockwell Automation GuardLogix • • • • •

A single Safety Connection is supported Up to 8 bytes of Safety Rated Inputs and Outputs are available Supports Category 4 PLe Either Ethernet port in the robot can be used No additional hardware is required in the robot to support CIP Safety

PLC with Ethernet/IP Safety Robot with E/IP Safety

Robot with E/IP Safety

Robot with E/IP Safety

Robot with E/IP Safety

DCS (Dual Check Safety) Architecture FANUC’s Robots provide for Software Safety in much the same way GuardLogix from Rockwell Automation, through the use of multiple CPU’s to provide Cat 4, PLe SIL3 performance for CIP safety inputs as well as Hardwired signals • Provides for increased functionality over traditional Safety Interface Main board

CPU 1 CPU2

CPU 1

CPU 2

Hardwired Signals E-Stop

Fence Servo Off + SPI’s

E-Stop Unit I/O circuit #1

6 Axes Amplifier

I/O circuit #2

Robot Mainboard Servo Power

MCC #1

MCC #2

CIP Safety CIP Safety • Supported on DeviceNet and EtherNet/IP interfaces • Category 4, PL e, SIL 3 safety rating for I/O • Up to 4 words of safety I/O available, allowing up to 64in/64out of Safety I/O – Exceeds what is possible without network safety – Capable of complex safety logic and interlocking that is either not possible, or cost effective with hardwired solutions

Bypass mode is used to disable CIP Safety during initial setup

Safety I/O Size Safety PLC is configured to include a Configuration Signature check as part of connection establishment

Integrated CIP Safety

Non-Integrated Network Safety Interface Required a 3rd Party Safety I/O Block • Additional wiring to hardwire robot safety signals • Limited I/O Size (typically1 or 2 bytes) • Limited Signal Access • Could handle only basic safety requirements • Added Cost and complexity

Integrated Network Safety Interface No need for a 3rd Party I/O Block or Additional Wiring • Uses the same connection as Non-Safe I/O • Up to 8 bytes of available I/O • Extended signal access • Easily handle advanced safety requirements

Seamless Integration, Improved Flexibility, Enhanced Performance, Lower Cost

Safe I/O Connect The Safe I/O Connect feature provides a means to tie the CIP-Safety I/O to a particular safety signal in the controller

•

Category 4, PL e, SIL 3 Interconnection of CIP Safe I/O to specific Safety signals in the robot – i.e. CSO[1] = SSI[6] Robot E-Stop Push Button Pressed – CIP Safety Output (1) is associated to the robot EStop’s

• • •

Supports up to 64 I/O connect settings Supports logical operations such as AND, OR, NOT Up to 2 Inputs allowed per Output – To include 3 or more inputs, use safe internal relay (SIR)

• •

2ms Scan time for Safe I/O Connect Can be used in conjunction with hardwired safety circuits if desired –

Hardwired safety circuits on E-Stop boards Why the need for are so always muchactive available Safety

on a Robot?

I/O

DCS Position/Speed Check DCS Position and Speed Check allows for increased flexibility and function for both Application and Design •

• •

DCS monitors the position and/or speed of the robot and shut down motor power when the defined safety parameters are exceeded – Cartesian & Joint Position Monitoring – Cartesian & Joint Speed Monitoring

Meets Safety Category 3 PLd and the requirements of ANSI/RIA/ISO/EN 10218-1 for safety performance Dynamically enable/disable checking based on Safety Inputs

It is the ability to use CIP Safety Inputs to enable or disable these zones safely that has improved not only functionality, but also safety

DCS Speed Check

DCS Position Check

CIP Safety Muting DCS Cartesian Zone used to protect Operator loading to robot shared Space. CIP Safety I/O used to safely Mute zone • When CSI[11] = OFF • Robot DCS Zone active • When CSI[11] = ON • Robot DCS Zone Muted Easily handle even the most complex interfaces with ease by expanding Safety I/O to meet required functionality

Safety Signature Aggregation Many FANUC/Rockwell Automation Customers require that the individual safety signatures of ‘Safe’ devices be tracked and verified within the manufacturing system to ensure safety 1. EDA –

Using EDA, the robot can send the Safety signature(s) to the PLC, as either part of an Implicit or Explicit Connection

2. Traditional Explicit Message – Signature value can be passed based on a standard Explicit Message request

3. Standard I/O –

Group Output from the robot to represent the construct of the current signature

Structured Data Collection/Access EDA Enhanced Data Access

Ethernet/IP Enhanced Data Access FANUC’s Ethernet/IP Enhanced Data Access option allows users to quickly and easily communicate non-I/O data between a FANUC robot and a Rockwell Automation PLC/HMI The robot creates the necessary UDT data structures and ladder logic in the PLC to send and receive data based on a user defined data structure.

Supported data types include: • Data, Position and String Registers* • System variables (read access only) • KAREL Variables • Current Position PLC Logic and Data Structures Exported from Robot

Use Data from Robot in custom HMI display PLC Logic and Data Structures Imported into User Project

* Available with Explicit Messaging

Robot-PLC Interface - Overview FANUC R-30iB Controller

Studio 5000

2. Import data file into Studio 5000 Software

1. Setup & generate data file on the Robot

PC w/ Industrial Monitor or Panel View Plus

Standard setup w/ Factory Talk View

EtherNet/IP Logix Ladder function blocks created automatically Standard I/O, safe I/O & data are setup from same interface

Ethernet/IP Enhanced Data Access Data Configuration Process • Data setup is done either with the robot teach pendant, or a textbased XML file to communicate data to the PLC (.L5X file) • Both Implicit and Explicit Connections are available • Implicit Connection limited based on amount of traditional I/O Assigned • Explicit Messaging

• Data Structures (including Comments) are then imported directly into Studio 5000

Import into Studio 5000 Import file into Studio 5000 1. Import program generated on Rungs for Implicit Connection Robot (.L5X extension) 2. Upon import, data structures Data Structures Created and Rungs created automatically Rungs for Explicit Connection

Enhanced Data Access (Capabilities) Useful Information

– Requires RSLogix5000 V20 and higher – Implicit connection maximum data size: • 490 bytes of Robot Input data per connection • 490 bytes of Robot Output data per connection

– Explicit connection maximum data size: • 464 bytes of Robot Input data per connection • 496 bytes of Robot Output data per connection

– Number of simultaneous connections per Robot • 1 Implicit Connection from each PLC Scanner Module (General Profile) • 4 Implicit Connection from each PLC Scanner Module (FANUC Robot AOP) • Up to 6 Explicit connections including other manually created Explicit Message Blocks

EDA Settings to set correct .L5X file format • 8.30/P21 and older – .L5X works for generic profile, but needs to be manually updated support new AOP from Rockwell Automation

• 8.30/P22 – User Selects desired configuration so no editing of .L5X is necessary for Rockwell Automation Import • Ethernet Module = Generic Interface • FANUC Robot = New AOP

HMI Integration

Remote iPendant FANUC’s Remote iPendant option allows Remote read/write access to most iPendant screens from non-PC HMIs • PanelView Plus 6 Enhanced • PanelView Plus 7 Performance, Apple iPad, Android Tablet)*

iPendant for HMIs

Provides support to remotely jog the robot from the HMI

Some iPendant screens are excluded based on lack of ActiveX controls • 4D Graphics, Panel Wizard, iRVision setup

View on iPad / Android Tablet

Emulated iPendant Keypad

* Requires Brower support

PC Remote iPendant The PC Remote iPendant option allows you to connect a HMI / PC as the iPendant and jog the robot remotely. The connection is only allowed when the robot is in Auto Mode. The teach pendant, if disabled, is logically disconnected from the robot. Allows remote pendant operations with no limitations: • View all menus and change settings • Foreground editing a program • Change I/O status • Change register, position registers, string register • Jogging the Robot • Running a robot using the FWD/BWD keys • Changing COORD • Changing Speed Override • Clearing DCS alarm • Applying DCS parameter

* Requires Windows and IE Browser

Flexibility in Implementation

Scalable Architecture FANUC products are designed to work together at the machine level without the need of PLC • Many Customers for small installations prefer not to add the initial complexity of a PLC, and simply use the FANUC interfaces – As additional systems are added, and higher level monitoring is required, they then look to add a PLC

• With EtherNet/IP it is easy to add a PLC to the system without having to re-engineer the original system – Easily add Control – Easily add or enhance Safety – Easily add system monitoring

Automation Fair - 2015 For the Automation Fair 2015 FANUC highlighted not only our proprietary interfaces, but also how easy it was to tie everything together for additional control, enhanced safety, and enterprise level monitoring

Automation Fair - 2015 CR-35 EtherNet/IP

PMI

FL-NET

ETHERNET/IP CIP Safety

ETHERNET/IP CIP Safety EDA SYSTEM HMI

ETHERNET/IP CIP Safety EDA

FL-NET WITH SAFETY

Rockwell Automation PLC System

ETHERNET/IP CIP Safety EDA FL-NET WITH SAFETY

Integrated Multiple CNC’s & Robots IT Network

ENET Router To other Stations

PanelView Plus

RFID Model A I/O

IP67 I/O ArmorBlock IP67 I/O ArmorPoi nt

IP20 I/O Flex I/O Safety Component s

Dual Check Safety I/O

Model A I/O

IP67 I/O ArmorBlock

Dual Check Safety I/O

Model A I/O

IP67 I/O ArmorBlock

IP20 I/O Flex I/O Safety Component s

Dual Check Safety I/O

IP20 I/O Flex I/O Safety Component s

GuardLogix

Safety Guarding, Gantry Control, Conveyors, Coolant & Chip System, etc



One Network for IT, Interlocking, Distributed I/O, and Safety



Ethernet/IP Media is common industrial standard cabling and connectors

One EtherNet/IP Network Connects Everything … including Safety!

What’s New?

FANUC Robot Add-On Profile A FANUC Robot AOP is available that will make the Fanuc Robot available in the module selection dialog

Add on Profile Benefits The New AOP provides the following enhancements over the original generic module • Support for up to 4 Implicit connections • Support for both Safe and NonSafe I/O on the same device – No more requirement for 2 connections and the ramifications

• Up to 8 Logix controllers can be connected to a robot

Single Connection Benefits • Previous ‘Generic’ Profile required separate connections for Safe and non-Safe I/O – 2 Connections in RS Logix

• New AOP for FANUC Robots requires only 1 connection in Logix for both safe and non-Safe I/O

• Either (2) IP addresses (2 Cards) or one IP Address and one DNS

IP:205.55.45.13 IP:205.55.45.13 IP:205.55.45.14

IP:205.55.45.13 DNS: ROBOT

Recent Trends

Offline Validation • Users are looking to connect their Rockwell Automation PLC to their Virtual Robot in ROBOGUIDE to perform some controls debug before the system is built Logix • This is possible by enabling EtherNet/IP within the virtual, and EIP then connecting the PC to the PLC network – Support for • EIP Adapter • Enhanced Data Access

– Not Supported • CIP Safety

Power Users: TESLA Metalsa

EtherNet/IP in ROBOGUIDE Configuring your Virtual Robot to talk to an Rockwell Automation PLC will be easy and straight forward 1. 2. 3. 4.

Create your Workcell with EIP Setup PC IP Address Enable EIP in virtual robot (Virtual Robot will get IP address from PC) Connect PLC and connect using standard Rockwell Automation Tools

Supports EDA, not just I/O

The Future is NOW • Integrated Architecture • Interoperability • Future Proofed with Open Standards • Proven Performance from Industry Leaders

Value = Reduce Total Life Cycle Costs •

Highly scalable solution (I/O capacity, Logix capability, communications options, FANUC controller platforms…) – Purchase only what you need from our standard product offerings

•

Reduce Engineering, Start-up and IT integrations costs

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Reduce Maintenance Costs

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Access to control architecture from anywhere via seamless routing between networks

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High degree of familiarity, capabilities, quality, etc.

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Global Support & Local Supply

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Reutilization of legacy products – backwards compatible with current FANUC installed base controls

World Class Companies Working Together FANUC & Rockwell Automation

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Thank you! Rockwell Automation TechED 2016

@ROKTechED

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