SECTION 10
ROBOT INTEGRATION
TABLE OF CONTENTS
ROBOT INTEGRATION
10.1 GENERAL
10.1.1 PURPOSE
The purpose of this section is to provide a standardized guide for the selection and application
of industrial robots and robot controllers. An Industrial robot as defined by ISO 8373:
An automatically controlled, reprogrammable, multipurpose manipulator programmable in
three or more axes, which may be either fixed in place or mobile for use in industrial
automation applications.
Reprogrammable: whose programmed motions or auxiliary functions may be changed
without physical alterations;
Multipurpose: capable of being adapted to a different application with physical
alterations;
Physical alterations: alteration of the mechanical structure or control system except for
changes of programming cassettes, ROMs, etc.
Axis: direction used to specify the robot motion in a linear or rotary mode
10.1.2 ROBOT SELECTION
The Supplier shall select a robot based on the environment and application. AAM approval of
robot manufacturer and model is required. AAM reserves the right to provide the selected
robot to the Supplier for integration.
10.1.3 SCOPE
This section includes specifications for robots and robot systems. Robot systems include the;
robot, end-effectors (or end of arm tooling, EOAT), and all other machinery, equipment,
devices, external auxiliary axes or sensors supporting the robot performing its task. Specific
applications, EOAT, and safety requirements shall be considered during the selection process.
Application areas that this section may be applied to include:
Materials handling or assembly process robots
Welding robots
Paint, adhesive or sealant application robots
10.1.4 SUPPLIER SUPPORT REQUIREMENTS
10.1.4.1 Systems Integration Capability. The Supplier shall have in house or subcontract staff that is
familiar and experienced with industrial robot systems integration and robot end-effector
design.
10.1.4.2 Robot Programmers. The Supplier robot programmers shall be certified as trained by the
robot manufacturer or other certification organization, and be familiar with the selected
robots.
10.1.4.3 Robot Simulation. Simulation of major motions, reach studies, time studies shall be included
as part of the AAM design approval process. Full program simulations may be required if
identified in the AAM RFQ, or if recommended by the Supplier. The extent of proposed
simulation shall be included in the Supplier’s proposal.
10.1.4.4 Documentation. The documentation requirements of Section 6 and Section 11 apply to the
robot system. The documentation for robot systems shall include a space study and
documentation as described in 10.2.3 Work Space, 10.2.4 Mechanical Space Requirements,
and 10.6 Safeguarded Space Requirements. Software unique to the application shall be
confirmed and approved by the AAM Controls Engineer.
10.1.4.5 Training. The training requirements of Section 4 apply to the robot system. The training
documentation shall include specific considerations of the integrated robot system.
Be maintenance-free.
Be self-cooled.
Be brushless AC.
Have integrally mounted pulse encoder.
Have integrally mounted brake.
Be as short in length as possible to minimize movement restrictions or to increase robot
density.
Not exhibit cogging at slow speeds.
10.2.2.2 Feedback Devices. Each robot shall retain position in the event of unanticipated loss of power.
Positional data shall be retained if a robot axis is manually repositioned with power off.
Robots shall not require calibration at power-up, pulse encoders shall be absolute optical type.
Battery-backed positioning memory shall last at least one (1) year without line power.
10.2.2.3 The robot selection should consider the application and the requirements for transmission of
motion at maximum payload that includes;
Position accuracy appropriate for the application
Minimal backlash
Minimal payload vibration
High duty cycle
Rigid mechanisms
High endurance against shock loads
10.2.2.4 Brakes. All axes (vertical, horizontal, rotational, etc.) shall include fail safe (apply with loss of
power) electrically actuated mechanical brakes, the brakes shall engage automatically with any
loss of power. All brakes shall be capable of manual release or manual movement if main
power is lost. Brakes shall be capable of stopping motion at full speed at full payload at full
extension to comply with the safety requirements of the application.
10.2.3 WORK SPACE
10.2.3.1 Maximum Reach. The reach capability of the robot should exceed the operating requirements
of the application with adequate margin to accommodate changes during development.
10.2.3.2 Axis Limits. All major axes shall have mechanical axis limiting devices that include both
hardwired limit switches and hard-stops. The mechanical axis limit devices define the three
dimensional Restricted Space. Mechanical axis limiting devices shall be provided by the robot
manufacturer and mounted per manufacturer recommendations. The restricted space should
be minimized and consider all safety requirements and robot damage.
10.2.3.3 Axis limit devices shall be provided by the robot manufacturer, collision detection, guarding, or
other devices shall not be used as motion limiting devices that define the restricted space.
10.2.3.4 The use of non-mechanical safety rated motion limiting devices requires AAM approval.
10.2.3.5 All axes (major and minor) shall have user-settable software limits.
10.3.5.2 Controllers shall be able to upload and download files during program execution. The
controllers shall have software capability to create backup image of whole controller.
10.3.6 NETWORKING COMMUNICATIONS
10.3.6.1 Ethernet. All controllers shall have at least one (1) Ethernet port standard, with additional
ports available optionally.
10.3.6.2 RS-232. All controllers shall have at least one (1) RS-232 port available.
10.3.6.3 Third-Party Product Networking. All controllers shall be able to support EtherNet/IP.
EtherNet/IP is ODVA conformance approved and AAM performance approved. All other
field buses shall be approved by the assigned AAM Controls Engineer.
10.3.6.4 Input/Output - User Configurable: All controllers shall offer a user-configurable I/O
system that permits:
Analog I/O to provide access to data with input/output voltages within a certain range.
Digital I/O to provide access to data on a single input or output line.
Group I/O to provide access to data on multiple input or output signal lines concurrently.
Robot end-effector I/O to provide access to data on the end-effector specific connector.
Standard operator panel I/O.
User operator panel I/O to provide data access by a remote device, for example, a remote
operator panel for control of the robot - eighteen (18) inputs minimum, twenty-four (24)
outputs minimum.
PLC I/O to permit the transfer of I/O signal status information to and from PLCs.
Remote mounting up to 100 m (328 ft.).
10.3.6.5 Input/Output - Process-Specific. For certain non-I/O intensive applications, process-specific
I/O may be used.
10.3.7 SERVO AMPLIFIER
Servo amplifiers shall:
Be digitally controlled (not analog)
Have a user-adjustable time-out feature
10.3.8 MOUNTING FLEXIBILITY
Robot connection cables shall:
Be at least 7 m (23 ft.) long standard
Be labeled at both ends
Be water and corrosion resistant
Use quick disconnects at the robot end
most material handling, material removal, and assembly applications. Counterpart packages
include arc welding, dispensing, painting, spot welding, etc. Each package shall be designed
for ease of use by employing menu-driven prompts in terminology and techniques specific to
the respective application area. Each package shall have a common, underlying environment,
have a similar look and feel to minimize operator training between packages, and assist the
user to:
Set up the information required for the application.
Program the application.
Test the program.
Run production.
Display and monitor process information.
10.4.1.2 Program Environment. When application-specific packages are not appropriate or powerful
enough, a programming environment capable of handling virtually any robotic application is
permitted with AAM Controls Engineer approval. This form of high-level programming
language uses symbols and descriptive command statements an operator can read. Other
distinguishing characteristics from the application-specific packages should include the
capability for:
At least sixteen (16) axes of control
Multi-user operating system to allow execution of at least four (4) concurrent users
User-defined associated data for path motions
File data types with built-in utility routines
User-defined data structures
Controls structures for loops and branch selections
Procedure and function routines
Real-time input or output monitoring via local or global condition handlers
Calculated positioning
Read and write to the teach pendant
Relative position operations
Discrete point-to-point and continuous-path motion types
Interference check and space check options for multiple robots in one (1) cell operation
Built-in dictionary and associated utility routines (help application to define robot function
etc.)
Automatic error logging and retrieving
Written AAM Controls Engineer approval is required for use of internal robot PLC
functionality
10.4.1.3 Capability. Either the application-specific packages or the high-level programming
environment capable of performing a series of instructions, constructs for conditional
statement execution, positional motion, arithmetic, comparative logic, looping, nested or
recursive routines, and multi-tasking operations, etc.
10.4.1.4 Program Editing.
On-line. All controllers shall allow on-line editing via the teach pendant. All controllers
shall allow programs to be edited and positional data modified during program execution.
Write Protection. All controllers shall have a software lockout that prevents unauthorized
editing of on-line application programs.
Off-line. Software packages for programming and point teaching off-line shall exist.
These packages shall consist of program code creation and editing on a Windows®
compatible PC and three (3)-dimensional interactive graphics simulation on a Windows®
compatible PC.
10.4.2 EASE OF TEACHING
10.4.2.1 Position. All controllers shall automatically create templates that have default parameters for
each motion position taught. These parameters include:
Motion type (joint, linear, circular).
Position type (position or position register).
Automatic position number.
Speed (expressed in percentages, in./min, deg/sec, mm/sec, cm/min, sec)
Termination type (graduated from a full deceleration / stop / reacceleration to no
deceleration).
Acceleration control.
Each parameter shall be settable independently.
10.4.2.2 Frames. All controllers shall support four frame types: world, tool, user, and jog.
Requirements are as follows:
World Frame: Default frame of robot which is unique and cannot be changed.
Tool Frame: A user defined frame that has the tool center point at its origin; up to five (5)
different tool frames may be created and stored in memory; shall be creatable by simply
teaching three (3) approach points to define location, simply teaching three (3) location
and three (3) orientation points to define direction vector, or by direct numerical entry
when data are available.
User Frame: A user defined frame that is the reference frame for all recorded positional
data in a program; up to five (5) different user frames may be created and stored in
memory; shall be creatable by simply teaching three (3) approach points to define
location, simply teaching three (3) location and one origin points to define the reference
of the frame, or by direct numerical entry when data are available.
Jog Frame: A user-defined frame for use in non-orthogonal jogging; multiple jog frames
may be created and stored in memory; up to five (5) different jog frames may be created
and stored in memory; shall be creatable by simply teaching three (3) points to denote the
origin and plane of the frame, or by direct numerical entry when data are available.
10.4.3 PROGRAM AND POSITION TESTING AND DEBUGGING
Testing and debugging are essential during the programming and position teaching phase in
order to validate logic and motion. Production should commence only after thorough testing,
debugging, and validation. All controllers shall have the following testing and debugging
capabilities:
10.4.3.1 Single Step. This technique permits running individual program instructions one (1) at a time.
Single step testing can be done two (2) ways:
Forward executes one (1) instruction or subprogram one (1) step at a time in the forward
flow of the program.
Backward executes the preceding motion instruction one (1) step at a time.
10.4.3.2 Routine. This technique permits running individual program instructions one (1) at a time, but
each routine is executed as one (1) step.
10.4.3.3 Continuous. This technique permits running a program from beginning to end without
stopping.
10.4.3.4 Simulating I/O. This technique permits the forcing of inputs or outputs without signals actually
entering or leaving the controller. This is essential to test and debug program logic and motion
when I/O devices and signals are not set up.
10.4.3.5 Machine Lock. This technique allows the program to run without any robot motion.
10.4.3.6 Tool Disable (Dry Run). This technique allows the program to run without activating the end-
effector.
10.4.3.7 Step Path Node. This technique permits the program to pause after each path node in a path
statement.
10.4.4 POWER FAILURE RECOVERY
In the event of a black-out or brown-out, follow the recovery procedure mentioned in the code
development guidelines section.
The part present sensors shall be integrated inside the grippers, and not exposed to the
environment.
10.5.2 WELDING ROBOT SPECIFICATIONS
See Section 14 – Welding Equipment.
guarding shall consider all hazards including other machinery, falling or ejected objects,
operating environment, and the stop time of motions.
10.6.3.2 Perimeter guarding shall be securely installed and comply with the reach over, under, around,
and through requirements of Section 2. Perimeter guarding shall suit the environment, be of
rigid construction, and be a minimum of 1.4 m (4.6 ft.) from adjacent walking surfaces.
10.6.3.3 Access doors, gates, etc. open-close “swing path” shall not cross into the restricted space.
10.6.3.4 Light Curtains, safety mats, or other Electro-sensitive protective equipment (ESPE) shall not be
used as perimeter guarding..
10.6.3.5 Axis limiting switches shall be included on all major axis (see 10.2.3.2). AAM Controls
Engineering approval is required if switches are not mounted on the axes.
10.6.3.6 A request to enter function shall be installed to allow an operator access inside the cell when
needed. If the HMI panel is not within reach, an enclosure with an indicator light and a
selector switch shall be mounted by the safeguarded space main entry for a request to enter.
10.6.3.7 The robot disconnect shall be mounted close to the entry of the robot cell.
10.6.4.8 A proper bracket and mount for the teach pendant and cable shall be installed next to the
entry of the cell.
10.6.3.9 The guarding safety gate interlock switch shall include a mechanical override facing inside the
guarding to permit override for egress from within the safeguarded space.
centers, lathes, grinders, welders, gauges and other testing equipment, conveyors,
washers, etc.
10.7.3 GENERAL ROBOT INTEGRATION COMMUNICATION
Integration of any equipment shall use both hardwired safety circuits and process interlock
signals.
10.7.3.1 All equipment integrations shall include a touch safe twenty-four (24) pin bulk head style
connector for each integrated piece of equipment hardware safety circuits and 24VDC source
for both pieces of connecting equipment.
10.7.3.2 All hardwired safety circuits shall be a minimum of category three (3) and comply with local,
state, and federal regulations (e.g. OSHA, NFPA 79).
10.7.3.3 Process interlock signals between the robot and an external piece of equipment shall be
exchanged between the robot controlling PLC and the external equipment PLC. Direct
communication from the robot controller to the external equipment requires AAM written
approval.
10.7.4 HARDWIRED SAFETY CIRCUITS – EMERGENCY STOP INTEGRATION
10.7.4.1 The hardwired emergency stop circuit wiring shall meet specific requirements of the
application or components that are being integrated.
10.7.4.2 A risk assessment for the equipment integration shall determine if the emergency stop of
either the robot or an integrated piece of equipment requires the other integrated piece to go
into an emergency stop state. Some equipment integrations will require that all integrated
equipment stop either controlled or immediately for safety purposes. Contact the AAM
Controls Engineer for assistance in determining which type of integration should be
implemented.
10.7.4.3 For integrations that require all integrated pieces of equipment to stop with an emergency
stop condition;
Safety circuits shall be category three (3) or better hardwired circuits implemented to
comply with local, state, and federal regulations (e.g., OSHA, NFPA 79).
Two (2) channels of the emergency stop safety relay are monitored by both the robot and
the integrated piece of equipment. An emergency stop on either the robot or the
integrated piece of equipment will cause both the robot and equipment to enter an
emergency stop state
10.7.4.4 For integrations that do not require all integrated equipment to stop with an emergency stop
condition, the hardwired emergency stop channels shall be wired to the PLC as inputs to be
used to supersede other process interlock signals. With this type of installation, either piece of
equipment shall use the emergency stop status to disregard other process interlock signals
from a piece of equipment that is in an emergency stop state.
• The first twenty-four (24) wires of the multi conductor cable shall be terminated to the
associated pin on the bulk head connector.
• The 25th wire of the cable shall be used for ground. This ground shall connect to the bulk
head ground connector.
10.7.8 PROGRAMMING SAFETY PRECAUTIONS
The programming safety measures are included to prevent damage to machine tools and
external devices.
10.7.8.1 The system should be programmed to back-check limit switches in the work cell to verify they
have not failed and are properly functioning.
10.7.8.2 Implement “failure routines” in programs that will provide appropriate robot actions if an
external device or another robot fails.
10.7.8.3 Use handshaking to synchronize robot and external device operations. Handshaking refers to
a request and acknowledge signal to and from the robot. For example, the robot requests to
enter a hazard area. The PLC acknowledges the request and grants permission; the robot then
signals the PLC it has entered the hazard area.
10.7.8.4 Program the robot to check the condition of all external devices or limit switches during an
operating cycle.
5. Initialization Routines
● Initialization Input and Output Routines
6. Recovery (See Recovery Section 10.9.10)
● Mov_Home
● Mov_Maintenance
● Move_Pounce
● Home_IO
● Reset ALL
7. Background Routines
10.8.2 MOTION
The robot shall have instructions for linear, joint, and circular motion including position
information, velocity, acceleration parameters, and comment field.
o Pick Positions
L PR[] 500mm/s Fine
o Linear Approach Position
L PR[] 1200mm/s Cnt10
o Joint Motion
J PR[] 2000mm/s Cnt100
Offset programming in the main routines shall be approved by the AAM Controls Engineer.
Vision offsets are the exception since the vision application requires VR registers to perform
the calculated offsets.
10.8.3 START METHOD
AAM preferred: (MAIN Program)
The PLC can call program to run using a bit strobe sequence. (Program Number Select)
Inside the Robot Main Program the data moves from a group input to a register (e.g. R[8]
= GI[2]), which is Group word, input Two. (PLC will use: Group word output Two for
program calls. Using this value, program will start with jump commands to the required
line number in the program.)
The Main Program will be setup as follows:
Main (program)
Program Select
Style Select
10.8.4 I/O
Input/Outputs (Local I/O, Remote I/O, or Ethernet IP I/O)
10.8.4.1 UOP signals are user operated signals normally used to remotely control the robot.
10.8.4.2 Digital I/O are used for EOAT control, interlocks, status, fault codes (GO for faults that require
8 or more bits)
10.8.4.3 Robot I/O are used for EOAT control and device specific only to the robot (only used with the
permission of an AAM Controls Engineer).
10.8.4.4 Group I/O are used for decision control to monitor or advance into the next sequence or
anything that requires a numerical feedback that requires eight (8) or more bits (positional
feedback, etc.).
10.8.5 ROBOT INPUT/OUTPUT SIGNALS TO/FROM PLC
Refer to the standard drawing package for designated I/O points.
Register/Position Register ( R[ ]/PR[ ])
PR[1…5] Common Points
● PR[1:Home]
● PR[2:Maintenance]
Reserve PR[5- 19] Used for recovery program and check position program
Vision Position, Positions/Offsets
● PR[20…39] Application 1: Pick Place
● PR[30…49] Application 2: Pick Place
● PR[40…59] Application 3: Pick Place
● RR[50…69] Application 4: Pick Place
● PR[60…79] Application 5: Pick Place
● PR[70…89] Application 6: Pick Place
● …
● PR[199] Master Position
Registers
● R[5] Speed Override
● R[10] Used for recovery program and check position program
● R[#...#] Segments/Group Exchange
● R[#...#] Flags
● R[#...#] Vision
● R[#...#] Zones
● R[#...#] Collision Guard Sensitivity
● Frames
User Frames and UTOOL Frames
Set U Tool and U Frame at beginning of Subroutine
Example:
!Set the tool and frame ;
UFRAME_NUM=1 ;
UTOOL_NUM=1 ;
o Collision Guard ON or OFF will depend on application, parts and end of arm
tooling. Clarification shall be given by the AAM Controls Engineer.
Subprogram: Override
Request to Continue:
Send data or value (running robot program number) to PLC and compare
this value in the PLC to match program number called; if it does not match
then send immediate stop command to robot and generate fault for the
operator. Reset group output word value in the robot after PLC
acknowledgement and set complete bit to PLC.
! OPXXX MAIN
LBL[10] ‘Jump instruction’
! MACHINE 1 UNLOAD
GO[1] = 0 ‘Program Decision Echo‘ IF G[1] = 22, CALL UNLD_M1
GO[2] = 0 ‘Part Style Echo‘ ! RECOVERY
IF G[1] = 3, CALL RECOVERY
!OPERATOR POUNCE ! HOME
IF G[1] = 50, CALL PNC_OP IF G[1] = 1, CALL HOME
!OPERATOR PICK ! MAINTENANCE
IF G[1] = 51, CALL PICK_OP IF G[1] = 2, CALL MAINT
!MACHINE 1 POUNCE
IF G[1] = 20, CALL PNC_M1 WAIT 0.1(sec)
!MACHINE 1 LOAD
IF G[1] = 21, CALL LD_M1 JMP[10]
One push button for Homing/Recovery from the HMI; the operator should not touch the
Teach Pendent for recovery operation.*
10.8.10.10 Use dedicated position registers and data registers for Home/Recovery program.
10.8.10.11 On top of the sub-program give the description for the registers and position register.
10.8.10.12 The omission of the remote one button recovery will require written approval from the
AAM Electrical Engineer. Omissions would include situations which could result in
equipment damage, such as stud weld faults.
Recovery/Home Example:
!RECOVERY LBL[200]
GO[1:PROGRAM ECHO]=4 UTOOL_NUM=1
GO[3]=0
IF R[10:POS NUM]=1,JMP LBL[900] J PR[20:M1 POUNCE] 15% FINE
IF R[10:POS NUM]=2,JMP LBL[900] R[10:POS NUM]=20
GO[3]=R[10:POS NUM]
IF R[10:POS NUM]=50,JMP LBL[100] JMP LBL[999]
IF R[10:POS NUM]=51,JMP LBL[100]
IF R[10:POS NUM]=52,JMP LBL[100] LBL[250]
UTOOL_NUM=1
IF R[10:POS NUM]=20,JMP LBL[200] GO[3]=0
IF R[10:POS NUM]=21,JMP LBL[200] J PR[20:M1 POUNCE] 15% FINE
IF R[10:POS NUM]=23,JMP LBL[200] R[10:POS NUM]=20
IF R[10:POS NUM]=22,JMP LBL[250] GO[3]=R[10:POS NUM]
IF R[10:POS NUM]=24,JMP LBL[250] JMP LBL[999]
LBL[300]
IF R[10:POS NUM]=30,JMP LBL[300] UTOOL_NUM=1
IF R[10:POS NUM]=31,JMP LBL[300] GO[3]=0
IF R[10:POS NUM]=33,JMP LBL[300] J PR[30:M2 POUNCE] 15% FINE
IF R[10:POS NUM]=32,JMP LBL[350] R[10:POS NUM]=30
IF R[10:POS NUM]=34,JMP LBL[350] GO[3]=R[10:POS NUM]
JMP LBL[999]
!ERROR NO POS NUM FOUND
JMP LBL[999] LBL[350]
UTOOL_NUM=1
LBL[100] GO[3]=0
UTOOL_NUM=2 J PR[30:M2 POUNCE] 15% FINE
GO[3]=0 R[10:POS NUM]=30
J PR[50:OP POUNCE] 15% FINE GO[3]=R[10:POS NUM]
R[10:POS NUM]=50 JMP LBL[999]
GO[3]=R[10:POS NUM]
JMP LBL[999] LBL[900]
UTOOL_NUM=1 GO[3]=0
GO[3]=0 J PR[20:M1 POUNCE] 15% FINE
J PR[1:HOME] 100% CNT60 R[10:POS NUM]=20
R[10:POS NUM]=1 GO[3]=R[10:POS NUM]
GO[3]=R[10:POS NUM]
JMP LBL[300]
LBL[999]
LBL[300]
UTOOL_NUM=2
!HOME GO[3]=0
GO[1:PROGRAM ECHO]=1 J PR[50:OP POUNCE] 15% FINE
PR[6]=LPOS R[10:POS NUM]=50
GO[3]=R[10:POS NUM]
IF R[10:POS NUM]=1,JMP LBL[900] JMP LBL[900]
IF R[10:POS NUM]=2,JMP LBL[900]
LBL[900]
IF R[10:POS NUM]=30,JMP LBL[200]
UTOOL_NUM=1
IF R[10:POS NUM]=20,JMP LBL[300] GO[3]=0
IF R[10:POS NUM]=50,JMP LBL[900] J PR[1:HOME] 15% FINE
R[10:POS NUM]=1
!ERROR NO POS NUM FOUND GO[3]=R[10:POS NUM]
JMP LBL[999] JMP LBL[999]
LBL[200] LBL[999]
UTOOL_NUM=1
A minimum of sixteen (16) inputs and sixteen (16) outputs shall be used for process
interlock signals.
15 % of both inputs and outputs shall be spare for future additions.
10.10.3 PROCESS INTERLOCK SIGNALS - DISCRETE WIRING OVER DISTRIBUTED I/O
Discrete wiring with distributed I/O modules use communication devices attached to I/O
modules and communicate the I/O status to the PLC via communication cable. This
architecture reduces wiring and provides added flexibility future added I/O. This approach is
recommended when integrating multiple pieces of equipment.
The automation or robot PLC should be the controller of the distributed I/O
communication modules and not the integrated equipment.
The distributed I/O should be installed into the integrated piece of equipment as close to
the PLC as possible to limit wiring usage and provide easier diagnostics.
The equipment that is providing the distributed I/O communication module shall also
supply the 24VDC source and common to power the communication module.
24VDC power wiring shall be connected via the twenty-four (24) pin bulk head connector.
15 % of both inputs and outputs shall be spare for future additions.
A minimum of sixteen (16) inputs and sixteen (16) outputs shall be used for process
interlock signals.
10.10.4 PROCESS INTERLOCK SIGNALS – PRODUCED CONSUMED MODEL WIRING
This is the AAM preferred interlocking model that minimizes hardwiring and provides the most
flexibility of the three interlocking models.
Cat 5e or better cabling shall be used.
If a central switch is being currently being used to create a local area network then
Ethernet wiring shall run from both pieces of equipment to be interlocked to the central
switch. Depending on the criticalness of the process interlocks redundant Ethernet wiring
may be required.
If a central switch does not exist an Ethernet crossover cable shall be run between the
network switches of the integrated equipment.
The Ethernet cable shall not have any splices or disconnects.
Only manufactured cables to AAM requirements shall be used.
10.10.5 PROCESS INTERLOCKS AND DEFINITIONS
Process interlocks vary from integration to integration. Below is a list of example process
interlocks and their definitions. These interlock descriptors should be used when applicable.
Robot Clear: indication that the robot is clear of the interlocked piece of equipment.
Equipment Clear: indication to the robot automation that the equipment is safe to
interface with. This interlock may consider many equipment conditions before providing
this signal.
Machine Ready for Unload/Anticipate: indication that the equipment is ready for a part or
material to be removed or will be ready soon. The interfacing robot may use this signal to
prepare for unloading the equipment, however should not actually interface with the
equipment until the equipment clear indication is given.
Machine Ready for Load/Anticipate: indication that the equipment is ready to receive a
part or will be ready soon. The interfacing robot may use this signal to prepare for loading
the equipment, however should not actually load the equipment until the equipment
clear indication is also given.
Part Unload Complete: indication to the interlocked equipment that a part has been
unloaded.
Part Load Complete: indication to the interlocked equipment that a part has been loaded.
Part Type: indication given by either the robot or the interlocked equipment that
indicates which part is being loaded or unloaded. This is typically an integer value (1-n)
and should be set before the load or unload interlock is provided.
10.10.6 OTHER INTEGRATION CONSIDERATIONS
Where a robot interfaces with multiple pieces of equipment it is critical to maintain the robot
awareness of the equipment that is ready to process new material. Unload/load anticipate
signals can be used to reduce cycle time however a timeout shall exist in the event that a
machine faults, stops, etc. This timeout will allow the robot to abort the current operation and
service a piece of equipment that is ready to receive the material.
10.10.6.1 A light curtain is recommended on equipment when integrating a robot with multiple pieces of
equipment that have unsafe motion. This allows access to the integrated work cell without
stopping the equipment operations. It also allows for manual operation of the equipment and
provides a hardware measure to indicate that the robot is clear of the equipment before
performing equipment functions.
10.10.6.2 In the case that the integrated piece of equipment enters an emergency stop state while the
automation is interfacing with it, the robot shall halt and ignore all other process signals from
the integrated piece of equipment. Either the equipment needs to be pulled out of its
emergency stop condition to allow the robot to continue, providing all other process interlock
signals are ok, or the robot recovery procedure needs to be executed. Refer to paragraph
10.8.9 for more information on robot recovery.
10.10.6.3 Where a robot is interfacing with multiple pieces of equipment it may be important for some
of the hardwired safety circuits to be on the line side of the main disconnect to allow
maintenance to power down a piece of equipment for repairs while still monitoring key safety
components.
10.10.6.4 Additional logic, wiring, and hardware modifications will need to be made to all equipment
being interlocked. Responsibility for these modifications varies and needs to be discussed with
the AAM Controls Engineer.
10.10.6.5 For integrations that require a limited number of process interlock signals, the integrator may
use the remaining connections on the 24 pin hardwired connection with AAM Controls
Engineering approval.
10.10.6.6 When transferring data between equipment, (i.e., part type, serial number, etc.) use non-
volatile memory for recovery purposes in the event of a facility or equipment power failure.
Diagnostics
HMI interlocking screens shall be provided on both the HMI for the robot and the
integrated equipment.
Sequence screens shall be provided that indicate current active status.
Sequence faults shall be added where an integrated piece of equipment communicates
improperly or inaccurately.
10.10.7 INTEGRATED EQUIPMENT DOCUMENTATION
Each drawing set shall have a separate page that shows the interlocking connections between
the equipment being interlocked.
10.10.7.1 The interlocking connections sheet from each piece of equipment shall show that equipment
wire labeling, and the wire labeling and color codes for the interlocked equipment.
10.7.10.2 Sheets that are affected by the interlock wiring shall be updated to reflect the integration
additions.
10.7.10.3 Interlock definitions document shall be provided to the AAM Controls Engineer. These
definitions shall be agreed upon by all active parties responsible for the integration of the
equipment.