PalletPack Integrator Reference Manual PDF

The information in this manual is subject to change without notice and should not be
construed as a commitment by Asea Brown Boveri, S.A. Asea Brown Boveri, S.A.
assumes no responsibility for any errors that may appear in this manual.
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© Copyright 2010 Asea Brown Boveri, S.A. All right reserved

Additional copies of this manual may be obtained from Asea Brown Boveri, S.A. at its
then current charge.
© Copyright 2010 Asea Brown Boveri, S.A. All right reserved.

Asea Brown Boveri, S.A.
BU Robotics
08192 Barcelona
Spain
Table of contents
Table of contents
Table of contents 5
Overview 8
1 PalletPack Application 10

1.1 Introduction ................................................................................................................................................. 10
1.2 Bill of materials ........................................................................................................................................... 11
1.3 PalletPack Concepts ................................................................................................................................... 12
1.4 Control Diagram .......................................................................................................................................... 13
2 PalletWare 14
2.1 Introduction ................................................................................................................................................. 14
3 PLC Program 15

3.1 Introduction ................................................................................................................................................. 15
3.2 Call Tree ....................................................................................................................................................... 16
3.3 Program Organization Units (POU) ........................................................................................................... 17
3.3.1 Clock_Pulses_Generation ................................................................................................................ 18
3.3.2 Flows ............................................................................................................................................... 19
3.3.3 Flows_Authors................................................................................................................................. 21
3.3.4 Flows_Format .................................................................................................................................. 24
3.3.5 Flows_Infeeder ................................................................................................................................ 27
3.3.6 Flows_Outfeeder.............................................................................................................................. 29
3.3.7 General............................................................................................................................................. 32
3.3.8 General_Access_Control ................................................................................................................. 35
3.3.9 General_Cell_Status ........................................................................................................................ 37
3.3.10 General_Changeover ..................................................................................................................... 38
3.3.11 General_Command_Summary ....................................................................................................... 41

3.3.12 General_Door_Control .................................................................................................................. 45
3.3.13 General_Light_Control .................................................................................................................. 46
3.3.14 IOMap_Read.................................................................................................................................. 48
3.3.15 IOMap_Write ................................................................................................................................. 50
3.3.16 Pallet_Magazine ............................................................................................................................ 51
3.3.17 PLC_PRG ...................................................................................................................................... 52
3.3.18 Robot ............................................................................................................................................. 53
3.3.19 Robot_HMI .................................................................................................................................... 55
3.3.20 Robot_IOGroups............................................................................................................................ 59
3.3.21 Robot_Start_Up ............................................................................................................................. 61
3.3.22 Robot_TP_Commands ................................................................................................................... 63
3.3.23 Slip_Sheet_Magazine .................................................................................................................... 66
3.3.24 Test_Mode ..................................................................................................................................... 67
3.3.25 Toggle_Function ............................................................................................................................ 68
3.4 Data Types ................................................................................................................................................... 69
3.4.1 CellDataMap .................................................................................................................................... 70
3.4.2 DataAccess ...................................................................................................................................... 71
3.4.3 DataDoor ......................................................................................................................................... 72
3AEJ04PalletPack Revision: 2.0 5

Table of contents
3.4.4 DataFlow .......................................................................................................................................... 73

3.4.5 DataGeneral ...................................................................................................................................... 74
3.4.6 DataInfeeder ..................................................................................................................................... 76
3.4.7 DataOutfeeder .................................................................................................................................. 77
3.4.8 DataPalletMagazine.......................................................................................................................... 78
3.4.9 DataRobot......................................................................................................................................... 79
3.4.10 DataSlipSheetMagazine ................................................................................................................. 83
3.4.11 InputsField ...................................................................................................................................... 84
3.4.12 InputsInfeeder................................................................................................................................. 86
3.4.13 InputsOutfeeder .............................................................................................................................. 87
3.4.14 InputsPalletMagazine ..................................................................................................................... 88
3.4.15 InputsSlipSheetMagazine ............................................................................................................... 89
3.4.16 IOMappingField ............................................................................................................................. 90
3.4.17 IOMappingInfeeder ........................................................................................................................ 91
3.4.18 IOMappingOutfeeder ..................................................................................................................... 92
3.4.19 IOMappingPalletMagazine............................................................................................................. 93
3.4.20 IOMappingSlipSheetMagazine ...................................................................................................... 94
3.4.21 OutputsField ................................................................................................................................... 95
3.4.22 OuputsInfeeder ............................................................................................................................... 96
3.4.23 OuputsOutfeeder ............................................................................................................................ 97
3.4.24 OuputsPalletMagazine.................................................................................................................... 98
3.4.25 OuputsSlipSheetMagazine ............................................................................................................. 99
3.4.26 SafetyInterface.............................................................................................................................. 100
3.4.27 SafetyStatusDevice ....................................................................................................................... 102
3.5 Memory Map ............................................................................................................................................... 103
3.5.1 Constants ........................................................................................................................................ 104
3.5.2 Addressable flag area (%M) ........................................................................................................... 105
3.5.3 Global variables.............................................................................................................................. 106
108

4 Safety PLC Program
4.1 Introduction ................................................................................................................................................ 108
4.2 Built-in program ......................................................................................................................................... 109
4.3 IO Map ......................................................................................................................................................... 110
5 Interfaces 112 © Copyright 2010 Asea Brown Boveri, S.A. All right reserved
5.1 Robot .......................................................................................................................................................... 112

5.1.1 Inputs .............................................................................................................................................. 113
5.1.2 Outputs ........................................................................................................................................... 117
5.1.3 Group Inputs Values ....................................................................................................................... 121
5.1.4 Group Ouputs Values ..................................................................................................................... 122
5.2 Human Machine Interface (HMI) ............................................................................................................... 126
5.3 Infeeders ..................................................................................................................................................... 127
5.3.1 Inputs .............................................................................................................................................. 128
5.3.2 Outputs ........................................................................................................................................... 129
5.4 Outfeeders .................................................................................................................................................. 130
5.4.1 Inputs .............................................................................................................................................. 131
5.4.2 Outputs ........................................................................................................................................... 132
5.5 Pallet Magazine .......................................................................................................................................... 133
6 3AEJ04PalletPack Revision: 2.0

Table of contents
5.5.1 Inputs ............................................................................................................................................. 134

5.5.2 Outputs........................................................................................................................................... 135
5.6 Slip Sheet Magazine .................................................................................................................................. 136
5.6.1 Inputs ............................................................................................................................................. 137
5.6.2 Outputs........................................................................................................................................... 138
5.7 Field Devices ............................................................................................................................................. 139
5.7.1 Inputs ............................................................................................................................................. 140
5.7.2 Outputs........................................................................................................................................... 141
5.8 Safety PLC ................................................................................................................................................. 142
5.8.1 Inputs ............................................................................................................................................. 143
5.8.2 Outputs........................................................................................................................................... 144

Overview
About this manual
This manual contains instructions for installing, configuring and running a system
with PalletPack function package.
Usage
This manual should be used during installation, commissioning, configuration of a

PalletPack function package. It describes PalletPack control system and includes
step-by-step instructions.
Who should read this manual?
This manual is intended for:

x System integrators
x ABB Service engineers
Prerequisites
The reader should be familiar with:

x Industrial robots and their terminology
x PLC programming
x Palletizing applications

Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
1. PalletPack Application Introduction to PalletPack., Bill of materials,

Description of important concepts.
2. PalletWare A reference to PalletWare.
3. PLC Program A description of PalletPack PLC program including:

x Call tree diagram
x Description of program organization units
x Description of data types
x Description of memory map
4. Safety PLC Program Description of PalletPack safety PLC program
5. Interfaces Description of the interfaces of PalletPack.
References
Reference Document ID
PalletWare Application Manual 3AEJ04 PalletWare
ABB Control Builder CD including both AC500 and 1SAP190100R0002

CodeSys documentation
Revisions
Revision Description
1.0 First issue.
2.0 Review safety interface


1 PalletPack Application
1.1 Introduction
Definition
A pre-engineered package of standard products that are brought together,

connected and tested in such a way that they deliver a plug and produce solution
for a End of line palletizing without need to resort to RAPID programming.
Components
PalletPack contains 4 components:

x A Control PLC with a built-in program ready to control an end-of-line
palletizing cell.
x A Safety PLC with a built-in program to handle cell safeties.
x A palletizing robot to palletize products.
x Palletizing robot software (PalletWare) designed to minimize learning and
setup time.
PalletWare Components
PalletPack Control PLC PalletPack Safety PLC
Palletizing robot PalletWare Software

1.2 Bill of materials
Structure of this chapter
This chapter lists the PalletPack bill of materials.
Bill of material
Product Type Quantity Description
AC500,CommunicationModulePROFIBUSDP
CM572-DP 1
Master
PM573-ETH 1 AC500,ProgrammableLogicController
TB541-ETH 1 AC500,TerminalBase,4slots,ETHERNET,24VDC
TA524 3 AC500,DummyCouplerModule
TA521 1 AC500,LithiumBatterySet
DC532 1 S500,DigitalInput/OutputModule16DI/16DC
S500,I/OTerminalUnit,24VDC,SpringforDCI/O
TU516 1
Modules
MC502 1 AC500,SDMemoryCard512MB
IRC5 1 IRC5Robotcontroller
IRB460 1 IRB460highspeedroboticpalletizer
Pluto S46 1 Jokab,SafetyPLC
BT51 2 Jokab,Expansionrelay
PalletWare 1 PalletWareIRC5roboticsoftware

1.3 PalletPack Concepts
The flow
The Flow concept defines the infeeder and the outfeeder where formats are picked
and placed.
PalletWare is limited to a maximum of 2 flows.
One outfeeder can only be used on 1 flow.
The picking formats
The “picking formats” refer to different ways of picking items from the infeeder for
a single job.
The device
In PalletPack every area which might be occupied for robots or machines is

identified as device, so signals, variables and any data are always referred to as
devices.
The below table shows the different devices:
Device Related to...

Device 1 Infeeder 1
Device 2 Infeeder 2
Device 3 Outfeeder 1
Device 4 Outfeeder 2
Device 5 Slip sheet stack station

Device 6 Pallet stack station

1.4 Control Diagram
Control diagram

2 PalletWare
2.1 Introduction
Overview
PalletWare is robot software running on the IRC5 controller for palletizing

applications.
It is designed to minimize the learning and setup time. The modular program
structure - program wizard and the graphical production window - together
decrease the time for training. As a result it is easy & efficient to use during
installation, production set-up and optimizing the robot cycle.
Related information
PalletWare Application Manual.

3 PLC Program
3.1 Introduction
This chapter describes the PLC program for the PalletPack and includes:
x The program organization tree.
x A description of the important program organization units (POU).
x The data types used on the program.
x The memory map.

3.2 Call Tree
Call tree diagram
IOMAP_READ
TEST_MODE
GENERAL
GENERAL_CELL_STATUS
GENERAL_COMMAND_SUMMARY
GENERAL_CHANGEOVER
GENERAL_LIGHT_CONTROL
GENERAL_ACCESS_CONTROL
GENERAL_DOOR_CONTROL
ROBOT
ROBOT_TP_COMMANDS
ROBOT_START_UP
ROBOT_IOGROUPS
ROBOT_HMI

FLOWS
FLOWS_FORMATS
FLOWS_INFEEDER
FLOWS_OUTFEEDER
FLOWS_AUTHORS
SLIPSHEET_MAGAZINE
PALLET_MAGAZINE
IOMAP_WRITE

3.3 Program Organization Units (POU)
This chapter describes the different program organization units (POU).


3.3.1 Clock_Pulses_Generation
Usage
It is used to generate timing pulse variables to be used on the program as time

base.
Type
Program
Input arguments
None
Input/Ouput arguments
None
Ouput arguments
None
Processing global variables
Type Name
Bool Pulse0
Bool Pulse1

Bool Pulse2
Bool Pulse3
Bool Pulse4
Bool Pulse5
Bool Pulse6
Bool Pulse7
Calling POU
None

3.3.2 Flows
Usage
This POU handles everything related to flows and current cycle.
Type
Program
Input arguments
None
None
Ouput arguments
None
Type Name
Bool CellData.Infeeder1.SelectedForProduction
Bool CellData.Infeeder2.SelectedForProduction
Bool CellData.Outfeeder1.SelectedForProduction
Bool CellData.Outfeeder2.SelectedForProduction
Bool CellData.Flow1.OutOfInfeeder
Bool CellData.Flow1.OutOfOutnfeeder
Bool CellData.Flow2.OutOfInfeeder
Bool CellData.Flow2.OutOfOutnfeeder
Bool CellData.Robot.ForceItem1LoadedInfeeder1
Bool doR1ChangeFlow
BYTE Infeeder1.Outputs.QtyItemsFormat1
BYTE Infeeder1.Outputs.CurrentFormatID

Type Name
BYTE Infeeder2.Outputs.CurrentFormatID
Calling POU
Flows_Infeeder_Instance1: Flows_Infeeder;
Flows_Infeeder_Instance2: Flows_Infeeder;
Flows_Outfeeder_Instance1: Flows_Outfeeder;
Flows_Outfeeder_Instance2: Flows_Outfeeder;
Flows_Formats_Instance1: Flows_Formats;
Flows_Formats_Instance2: Flows_Formats;
Flow_Authors_Instance1: Flow_Authors;
Flow_Authors_Instance2: Flow_Authors;

3.3.3 Flows_Authors
Usage
Flows_Authors is used to inform robot if the production flow (Infeeder, Outfeeder)

is ready for production and order the robot to pick and place items of that flow.
Type
Function block
Input arguments
Name Type A variable informing if...
diRobotOnFlow Bool Robotisexecutingtheflow.

diPauseRequest Bool Pausemodeisactive.
diFlowStarted Bool Flowisstarted.
diFlowBreak Breakisrequested.
Request Bool
diFlowBreakAfterLayer Bool Breakatendoflayerisrequested.
diFlowBreakAfterPallet Bool Breakatendofpalletisrequested.
diProgramCodeOK Bool Loadedjobsonrobotarecorrect.
diInfeeder1Ready Bool Infeeder1isready.
diInfeeder1Selected Bool Infeeder1isselectedonflow.
diInfeeder1 Bool Infeeder1isinproduction.

OnProduction
diInfeeder1 Bool Infeeder1isreadyforrobottopick
ReadyToUnload item.
diInfeeder2Ready Bool Infeeder2isready.
diInfeeder2Selected Bool Infeeder2isselectedonflow.
diInfeeder2 Bool Infeeder2isonproduction.
OnProduction
diInfeeder2 Bool Infeeder2isreadyforrobottopick
ReadyToUnload item.
diOutfeeder1Ready Bool Outfeeder1isready.
diOutfeeder1Selected Bool Outfeeder1isselectedonflow.
diOutfeeder1 Bool Outfeeder1isinproduction.
OnProduction
diOutfeeder1 Bool Outfeeder1isreadyforrobottoload

22
ReadyToLoad
item.
3AEJ04PalletPack Revision: 2.0

diOutfeeder2Ready Bool Outfeeder2isready.

diOutfeeder2Selected Bool Outfeeder2isselectedonflow.
diOutfeeder2 Bool Outfeeder2isinproduction.
OnProduction
diOutfeeder2 Bool Outfeeder2isreadyforrobottoload
ReadyToLoad item.
None
Ouput arguments
Name Type A variable to...
Informrobotthatflowisreadyfor
doFlowEnabled Bool production.
Allowrobottopickandplaceitemfor
doPickPlace Bool thatflow.
None
Calling POU
None

3.3.4 Flows_Format
Usage
Flows_Format is used to store picking formats information on memory.

Robot and CellHMI send information related to flows and Flows_Format transform
information in relation to infeeder.
Type
Function block
Input arguments
diInfeederSelectedOnFlow1 Bool Infeederispartofproductionflow1.

diInfeederSelectedOnFlow1 Bool Infeederispartofproductionflow2.
diFlow1Enabled Bool Flow1isenabled.
diFlow1Enabled Bool Flow2isenabled.
diTPPushButToggle PushbuttononCellHMIpicking
Format1Flow1 Bool format1offlow1ispushedbyuser.


Name Type A variable informing about...
Thequantityofitemsforpicking
diFlow1QtyItem format1toprepareoninfeederfor
Format1 Byte theflow1.
Thecurrentpickingformattoprepare
diFlow1CurrentItemID Byte onflow1.
Thecurrentpickingformattoprepare
diFlow2CurrentItemID Byte onflow2.
None
Ouput arguments
doInfeederTPToggle Holdthestatusofthepushbuttonfor
Format1 Bool thepickingformat1oninfeeder.

doInfeederQtyItem Holdthequantityofitemsforthe
Format1 Byte pickingformat1oninfeeder.
None
Calling POU
None

3.3.5 Flows_Infeeder
Usage
Flows_Infeeder is used to control infeeder. It handles:

x Unloading authorization of robot on infeeder.
x Picking format memories ready on infeeder.
x Requests to prepare new picking formats on infeeder.
Type
Function block
Input arguments
diInfeederSelected Infeederisselectedforproduction.
ForProduction Bool
diInfeederReady Bool Infeederisready
diInfeederSelectedFlow1 Bool Infeederisselectedonflow1
diInfeederSelectedFlow2 Bool Infeederisselectedonflow2
diItemDetectionOnInfeed Bool Anitemisdetectedoninfeed
diRobotOufOfInfeeder Bool Robotisoutofinfeederarea
diRobotFlow1 Robotrequestsanewitemforflow1.
NewItemReq Bool
diRobotFlow2 Robotrequestsanewitemforflow2.
NewItemReq Bool
diRobotItemOnGripper Bool Robotisholdinganitemongripper.
Robotrequesttomonitoritem
transferringfrominfeederto
diRobotMonitorGripper Bool outfeeder.
diRobotTPToggle PushbuttononCellHMIpicking
Format1OKInfeeder Bool format1ispushed.

Name Type A variable informing about...
diInfeederQtyItem Thequantityofitemsforthepicking
Format1 Byte format1oninfeeder.
diInfeeder Thecurrentpickingformattoprepare
CurrentItemID Byte oninfeeder.
None
Ouput arguments
doNewFormatRequest Bool Orderanewformatoninfeeder.

doInfeederReady Informinfeederisreadytobe
ToBeUnloaded Bool unloaded.
doFormat1Ready Holdstatusofpickingformat1ready
ToBeUnloaded Bool tobeunloadedoninfeeder

doRobotOnInfeed Bool Informrobotisinsideinfeederarea.
None
Calling POU
Toggle_Function_Instance1: Toggle_Function;

3.3.6 Flows_Outfeeder
Usage
Flows_Outfeeder is used to control outfeeder. It handles:

x Loading authorization of robot on outfeeder.
x Permission from user to work on outfeeder.
x Pallet empty and completed memories.
Type
Function block
Input arguments
Name Type A variable informing...
diOutfeederSelected Ifoutfeederisselectedforproduction.
ForProduction Bool
diOutfeederReady Bool Ifoutfeederisready.
diRobotOufOfOutfeeder Bool Robotisoutofoutfeederarea.
diOutfeederPresent Bool Ifpalletisonplace.
Aboutstatusofoutfeederenabling
diOutfeederValidation Bool pushbutton.
diConfirmation Robothasplacedanewpalleton
NewPallet Bool outfeeder.

diConfirmation Robothasplacedanewitemonpallet
ItemLoadedFlow1 Bool flow1.
diConfirmation Robothasplacedanewitemonpallet
ItemLoadedFlow2 Bool flow2.
diUserConf Userconfirmspalletisempty.
EmptyOutfeeder Bool

diOutfeeder Outfeederisselectedonflow1
SelectedOnFlow1 Bool
diOutfeeder Outfeederisselectedonflow2
SelectedOnFlow2 Bool
diConfirmation Robothasfinishedstackingpalletfor
PalletFinishFlow1 Bool flow1.
diConfirmation Robothasfinishedstackingpalletfor
PalletFinishFlow2 Bool flow2.
diNewPalletOnOutfeeder Anewpallethasbeenplacedon
Confimation Bool outfeeder.
None
Ouput arguments
doOutfeederEnabled Bool Holdoutfeederisenabledmemory.

doOutfeederCompleted Bool Holdpalletfullstatusmemory.
doOutfeederEmpty Bool Holdpalletemptystatusmemory.
doOutfeederReady Holdoutfeederreadytoloadanew

ToBeLoaded Bool itemstatusmemory.
doAllowPallet Informrobotthatitisallowedtoload
LoadingOutfeeder Bool anewpalletonoutfeeder.
Informtooutfeedersystemthatrobot
doOutputRobotOnArea Bool isinsideoutfeederarea.
Informtooutfeedersystemthatpallet
doOutputPalletFull Bool isfull.
Informtooutfeedersystemthatis
doOutputValidated Bool validated.
Informtooutfeedersystemanew
doOutputNewPalletLoaded Bool palletisloaded.
Informtooutfeedersystemapalletis
doOutputPalletPresent Bool present.
None

Calling POU

3.3.7 General
Usage
This POU is used to control general status of the cell and production changeover. It
handles:
x Automatic and manual mode.
x Cell Doors.
x Light stacks and lamps.
x Panel boxes push buttons.
x Access to cell.
x Changeover.
Type
Program
Input arguments
Program
None
Ouput arguments

None
Name Type
CellData.GENERAL.RequestStartCycleRobot Bool
CellData.GENERAL.RequestAccess Bool
CellData.GENERAL.PauseInCourse Bool
CellData.GENERAL.Flow1BreakReq Bool
CellData.GENERAL.Flow2BreakReq Bool
CellData.GENERAL.BreakFlow1InCourse Bool
CellData.GENERAL.BreakFlow1InCourse Bool
CellData.GENERAL.RequestPause Bool
CellData.General.ProductionChangeReq Bool

Name Type
CellData.General.Flow1Started Bool
CellData.General.Flow1EndBatchReq Bool
CellData.General.Flow2Started Bool
CellData.General.Flow2EndBatchReq Bool
doR1Flow1StopAfterItem Bool
doR1Flow1StopAfterLayer Bool
doR1Flow1StopAfterPallet Bool
doR1Flow2StopAfterItem Bool
doR1Flow2StopAfterLayer Bool
doR1Flow2StopAfterPallet Bool
Robotjobnumberflow1 Word
Robotjobnumberflow2 Word
Field.Outputs.doGreenStackLight1 Bool
Field.Outputs.doYellowStackLight1 Bool
Field.Outputs.doRedStackLight1 Bool
Field.Outputs.doGreenStackLight2 Bool
Field.Outputs.doYellowStackLight2 Bool
Field.Outputs.doRedStackLight2 Bool
Field.Outputs.doGreenPB_CMB1 Bool
Field.Outputs.doYellowPB_CMB1 Bool
Field.Outputs.doBluePB_CMB1 Bool
Field.Outputs.doGreenPB_CMB2 Bool
Field.Outputs.doYellowPB_CMB2 Bool
Field.Outputs.doBluePB_CMB2 Bool
Field.Outputs.doUnlockDoor1 Bool

Calling POU
General_Access_Control_Instance1: General_Access_Control;
General_Command_Summary_Instance1: General_Command_Summary;
General_Light_Control_Instance1: General_Light_Control;
General_Changeover_Instance1: General_Changeover;
General_Door_Control_Instance1: General_Door_Control;
General_Cell_Status_Instance1: General_Cell_Status;

3.3.8 General_Access_Control
Usage
General_Access_Control is used to check the conditions for the user access to cell
and also give command to robot to go the Access Positon
Type
Function block
Input arguments
diSummaryCellEStpOK Bool EmergenciesareOK.

diSummaryCellDoorsOK Bool DoorsareOK.
Aboutstatusoftaskexecutingsystem
diRobotTaskExecuting Bool outputfromrobot.
diDevice1InMovement Bool Device1ismovinginautomode.
diCellAccessRequest Bool Userhasrequestaccesstocell.
diCellStartOrder Startorder.
Bool
diTimeOut Time Commandtimeout.
dioAccessCellRunning Bool Accessrequestisinprocess.

dioAccessCellPermited Bool Accessisallowedoncell.
Toholdthestatusoftheaccess
dioModuleStatus WORD requestprocess.
dioCommnadRobot BYTE Robotcommand
Ouput arguments
None
None

36
Calling POU
None
3AEJ04PalletPack Revision: 2.0

3.3.9 General_Cell_Status
Usage
General_Cell_Status is used to inform the status of cell such:

x Auto and manual mode.
x Fault.
x Summary of emergencies.
x Summary of doors ok.
Type
Function block
Input arguments
None
None
Ouput arguments
None

Name Type
CellData.GENERAL.inAuto Bool
CellData.GENERAL.inManual Bool
CellData.GENERAL.inFault Bool
CellData.GENERAL.SummaryEStpOK Bool
CellData.GENERAL.SummaryDoorsOK Bool
CellData.Flow1.UnloadingFault Bool
CellData.Flow2.UnloadingFault Bool
CellData.GENERAL.UnloadingFault Bool
CellData.GENERAL.SummaryLampTest Bool
Calling POU
None

3.3.10 General_Changeover
Usage
General_Changeover handles the job changeover. The process is as follows:

x User requests end batch through CellHMI.
x PLC informs robot about the order and resets job number to robot.
x Robot finishes batch after an item is place, at end of layer or at end of
pallet as per the user request.
x Robot waits for new job number.
x User requests start new job from the CellHMI.
x PLC informs robot about the new job number to produce.
x Robot loads job and starts production.
Type
Function block
Input arguments
Name Type A variable...
diRobot Holdingthecommanddatavalue
TPCommandData WORD fromrobot.
diRobotStartBatch1 Bool Toorderstartofbatchonflow1.

diEndBatchConfFlow1 Bool Toorderendofbatchonflow1.
diRobotStartBatch2 Bool Toorderstartofbatchonflow2.
diEndBatchConfFlow2 Bool Toorderendofbatchonflow2.
diRobotStopBatch Toorderstopofbatchonflow1
Flow1AfterItem Bool afteranitemisplacedbyrobot.
Toorderstopofbatchonflow1
diRobotStopBatch afterrobothasfinishedstackinga
Flow1AfterLayer Bool layeronpallet.
Flow1AfterPallet Bool pallet.
diRobotStopBatch Toorderstopofbatchonflow2
Flow2AfterItem Bool afteranitemisplacedbyrobot.

Flow2AfterLayer Bool layeronpallet.
Flow2AfterPallet Bool pallet.
Input/Ouputs arguments
None
Ouput arguments
Informachangeofproductionhas
doProdChangeReq Bool beenrequested.
doFlow1Started Bool Informflow1isstarted.
Informendofbatchhasbeen
doFlow1StopBatchReq Bool requestedforflow1.
doFlow2Started Bool Informflow2isstarted.
Informendofbatchhasbeen
doFlow2StopBatchReq Bool requestedforflow2.
Orderrobottostopflow1afteran
doFlow1StopAfterItem Bool itemisplacedonpallet.
Orderrobottostopflow1when
finishingstackingcurrentlayer
doFlow1StopAfterLayer Bool pallet.
doFlow1StopAfterLayer Bool finishingstackingcurrentpallet.
Orderrobottostopflow2afteran
doFlow2StopAfterItem Bool itemisplacedonpallet.
finishingstackingcurrentlayer
doFlow2StopAfterLayer Bool pallet.

doFlow2StopAfterPallet Bool finishingstackingcurrentpallet.
HoldJobnumbertorunonrobotfor
doRobotJobFlow1 WORD flow1.
HoldJobnumbertorunonrobotfor
doRobotJobFlow2 WORD flow2.
None
Calling POU
None

3.3.11 General_Command_Summary
Usage
General_Command_Summary handles the cell commands. It summarizes all

command sent from panel boxes and CellHMI into single Boolean variables.
Type
Function block
Input arguments
diRobot Toorderrobotmotorsonandstart
MotorOnStart Bool
diRobotBreak Toorderbreakcycleafterrobotplaced
AfterItem Bool theitem.
diRobotBreak Toorderbreakcycleafterrobotfinishes
AfterLayer Bool stackingcurrentlayer.
diRobotBreak Toorderbreakcycleafterrobotfinishes
AfterPallet Bool stackingcurrentpallet.
diRobotFlow1 Toorderresumecycleforflow1.
ResumeCycle Bool
diRobotFlow1 Toorderbreakcycleonflow1after
BreakAfterItem Bool robotplacedtheitem.
BreakAfterLayer Bool robotfinishesstackingcurrentlayer.
BreakAfterPallet Bool robotfinishesstackingcurrentpallet.
diRobotFlow1 Informingrobothasplacedanewitem
ConfEnditem Bool forflow1.
diRobotFlow1 Informingrobothasfinishedstacking
ConfEndLayer Bool layerforflow1.
ConfEndPallet Bool palletforflow1.
diRobotFlow1 Informingifrobotisworkingonflow1.
WorkingOn Bool

diRobotFlow2 Toorderresumecycleforflow2.
ResumeCycle Bool
BreakAfterItem Bool robotplacedtheitem.
BreakAfterLayer Bool robotfinishesstackingcurrentlayer.
BreakAfterPallet Bool robotfinishesstackingcurrentpallet.
diRobotFlow2 Informingrobothasplacedanewitem
ConfEnditem Bool forflow2.
ConfEndLayer Bool layerforflow2.
ConfEndPallet Bool palletforflow2.
diRobotFlow2 Informingifrobotisworkingonflow2.
WorkingOn Bool
Informingaboutthestatusofstartcycle
diStartCycleCMB1 Bool pushbuttonfrompanelbox1.


Informingaboutthestatusofaccess
requestpushbuttonfrompanelbox1.
diAccessReqCMB1 Bool
diAccessReqCMB2 Bool requestpushbuttonfrompanelbox2.
Informingaboutthestatusofpause
diPauseCycleCMB1 Bool pushbuttonfrompanelbox1.
None
Ouput arguments
Name Type A variable to inform...
CellData.GENERAL. Startcyclehasbeenrequested.
RequestStartCycleRobot Bool
CellData.GENERAL. Accesstocellhasbeenrequested.
RequestAccess Bool
CellData.GENERAL. Bool Pauserequestisinprocess.
PauseInCourse
CellData.GENERAL. Bool Breakonflow1hasbeenrequested.
Flow1BreakReq
CellData.GENERAL. Bool Breakonflow2hasbeenrequested.
Flow2BreakReq
CellData.GENERAL. Bool Breakrequestonflow1isinprocess.
BreakFlow1InCourse
CellData.GENERAL. Bool Breakrequestonflow1isinprocess.
BreakFlow2InCourse
CellData.GENERAL. Bool Pausehasbeenrequested.

RequestPause
doRobotFlow1 Bool Robotbreakcycleonflow1afteran
BreakAfteritem itemisplaced.
doRobotFlow1 Bool Robotbreakcycleonflow1after
BreakAfterLayer finishingstackingcurrentlayer.
BreakAfterPallet finishingstackingcurrentpallet.
doRobotFlow2 Bool Robotbreakcycleonflow2afteran
BreakAfteritem itemisplaced.
BreakAfterLayer finishingstackingcurrentlayer.
BreakAfterPallet finishingstackingcurrentpallet.
None
Calling POU
None

3.3.12 General_Door_Control
Usage
General_Door_Control is used to control cell door.

Once conditions are safe to grant access to cell, General_Door_Control will unlock
cell door.
Type
Function block
Input arguments
diAccessPermited Bool Ifaccesstocellisallowed.

diAccessCell Bool Ifaccesstocellisrequested.
diStartCell Bool Ifstartisrequested.
diResetPB Bool Aboutstatusofresetbutton.
diTimeRstUnlock Time Timeouttounlockcelldoor.

dioModuleStatus Bool Holdingmodulestatus.
Ouput arguments
doUnlockDoor Bool Unlockcelldoor.
None
Calling POU
None

3.3.13 General_Light_Control
Usage
General_Light_Control is used to handle light stacks and push button lamps.

The below table describes the meaning of every light behaviour:
Color It means...
x Blinking.Cellisreadytostartinautomode.
Green x Fixlight.Cellisrunninginautomode.
x Blinking.Unloadingfaultonrobot.
Yellow x Fixlight.Cellisinpausemode.
x Blinking.Celldoorsopen.
Red x Fixlight.Emergencyoncell.
x Blinking.Accessrequestonprocess.
Blue x Fixlight.Accesstocellisallowed.
Type
Function block
Input arguments

diSummaryCellDoorsOK Bool CelldoorsareOK.
diSummaryCellEStpOK Bool CellEmergenciesareOK.
diCellInAuto Bool Cellisinautomode.
Aboutstatusoftaskexecutingsystem
diRobotTaskExecuting Bool outputfromrobot.
diCellPaused Bool Cellisinpausemode.
diUnloadingFault Bool Unloadingerrorisactive.
diAccessPermited Bool Accessisallowedincell.
diAccessInCourse Bool Accessrequestisinprocess.
diTestLamp Bool Testoflampsisrequired.
None

Ouput arguments
doGreenStackLight1 Bool Activategreenlamponstacklight1.

doYellowStackLight1 Bool Activateyellowlamponstacklight1.
doRedStackLight1 Bool Activateredlamponstacklight1.
doGreenStackLight2 Bool Activategreenlamponstacklight2.
doYellowStackLight2 Bool Activateyellowlamponstacklight2.
doRedStackLight2 Bool Activateredlamponstacklight2.
Activatelampofgreenbutton(start
doGreenPB_CMB1 Bool button)ofpanelbox1.
Activatelampofyellowbutton(pause
doYellowPB_CMB1 Bool button)ofpanelbox1.
Activatelampofyellowbutton(reset
doBluePB_CMB1 Bool button)ofpanelbox1.
Activatelampofgreenbutton(start
doGreenPB_CMB2 Bool button)ofpanelbox2.
Activatelampofyellowbutton(pause
doYellowPB_CMB2 Bool button)ofpanelbox2.
Activatelampofyellowbutton(reset
doBluePB_CMB2 Bool button)ofpanelbox2.
None
Calling POU
None

3.3.14 IOMap_Read
Usage
IOMap_Read is used for mapping physical input addresses to memories. Then the
memories are used on the program.
NOTE!
Replace “EditInputAddress” variables for the physical inputs you want to use.
Type
Program
Input arguments
None
None
Ouput arguments
None

Name Type
%MD0.0 Double
%MD0.1 Double
%MD0.2 Double
%MD0.3 Double
%MD0.4 Double
%MD0.5 Double
%MD0.6 Double
%MD0.7 Double

Name Type
Field.Inputs InputsField
Infeeder1.Inputs InputsInfeeder
Infeeder2.Inputs InputsInfeeder
Outfeeder1.Inputs InputsOutfeeder
Outfeeder2.Inputs InputsOutfeeder
SlipSheetMagazine.Inputs InputsSlipSheetMagazine
PalletMagazine.Inputs InputsPalletMagazine
CellData.GENERAL.LampTest1 Bool
CellData.GENERAL.LampTest2 Bool
Safety SafetyInterface
Calling POU
None

3.3.15 IOMap_Write
Usage
IOMap_Write is used for assigning memory outputs map to physical output

addresses.
NOTE!
Replace “EditOutputAddressBit” and “EditOutputAdressByte” variables for the
physical outputs you want to use.
Type
Program
Input arguments
None
None
Ouput arguments
None

None
Calling POU
None

3.3.16 Pallet_Magazine
Usage
Pallet_Magazine is used to control those things related to pallet magazine station.
Type
Program
Input arguments
None
None
Ouput arguments
None
Name Type
CellData.PalletMagazine.Enabled Bool
doR1RstHeightPalletMag Bool
Calling POU

3.3.17 PLC_PRG
Usage
The PLC_PRG is a special predefined POU. It is the main program and it contains
all the calls to program POU.
Type
Program
Input arguments
None
None
Ouput arguments
None
Name Type
Test_Mode_Instance1 Test_Mode
Test_Mode_Instance2 Test_Mode

Calling POU
Clock_Pulse_Generation;
IOMAP_Read;
Test_Mode_Instance1: Test_Mode;
Test_Mode_Instance2: Test_Mode;
General;
FlowData_Collect;
Robot;
Flows;
SlipSheet_Magazine;
Pallet_Magazine;
IOMAP_Write;

3.3.18 Robot
Usage
This POU is used to for everything related to robot. It handles:

x Robot commands.
x Robot start up.
x Robot inputs and outputs groups.
x Robot CellHMI.
Type
Program
Input arguments
None
None
Ouput arguments
None

Name Type
CellData.Robot.TPPushButFlow1Resume Bool
CellData.Robot.TPPushButFlow1BreakAfterItem Bool
CellData.Robot.TPPushButFlow1BreakAfterLayer Bool
CellData.Robot.TPPushButFlow1BreakAfterPallet Bool
CellData.Robot.TPPushButFlow1StartBatch Bool
CellData.Robot.TPPushButFlow1StopAfterItem Bool
CellData.Robot.TPPushButFlow1StopAfterLayer Bool
CellData.Robot.TPPushButFlow1StopAfterPallet Bool
CellData.Robot.TPPushButFlow1ToggleFormat1Loaded Bool
CellData.Robot.TPPushButFlow1StopAtPick Bool
CellData.Robot.TPPushButFlow1StopAtDrop Bool
CellData.Robot.TPPushButFlow2Resume Bool

Name Type
CellData.Robot.TPPushButFlow2BreakAfterItem Bool
CellData.Robot.TPPushButFlow2BreakAfterLayer Bool
CellData.Robot.TPPushButFlow2BreakAfterPallet Bool
CellData.Robot.TPPushButFlow2StartBatch Bool
CellData.Robot.TPPushButFlow2StopAfterItem Bool
CellData.Robot.TPPushButFlow2StopAfterLayer Bool
CellData.Robot.TPPushButFlow2StopAfterPallet Bool
CellData.Robot.TPPushButFlow2StopAtPick Bool
CellData.Robot.TPPushButFlow2StopAtDrop Bool
CellData.Robot.TPPushButAccess Bool
CellData.Robot.TPPushButReset Bool
CellData.Robot.TPPushButStopRobot Bool
CellData.Robot.TPPushButStartRobot Bool
CellData.Robot.TPPushButBreakAfterItem Bool
CellData.Robot.TPPushButBreakAfterLayer Bool
CellData.Robot.TPPushButBreakAfterPallet Bool

CellData.Robot.TPPushButRobotToHome Bool
CellData.Robot.TPPushButRobotOutOfLine Bool
CellData.Robot.TPPushButEnableOutfeeder1 Bool
CellData.Robot.TPPushButEnableOutfeeder2 Bool
CellData.Robot.TPPushButEnableSlipSheetMag Bool
CellData.Robot.TPPushButEnablePalletMag Bool
CellData.Robot.CommandToRobot Byte
Calling POU
Robot_Start_Up_Instance1: Robot_Start_Up;
Robot_IOGroups_Instance1: Robot_IOGroups;
Robot_HMI_Instance1: Robot_HMI;
Robot_TP_Commands_Instance1: Robot_TP_Commands;

3.3.19 Robot_HMI
Usage
The Robot_HMI handles the information displayed on the CellHMI.
Type
Function block
Input arguments
diCellInAutoInf Bool Cellisinautomaticmode.

diCellPausedInf Bool Cellisinpausemode.
diFlow1BreakInCourseInf Bool Breakrequestforflow1isinprocess.
diFlow2BreakInCourseInf Bool Breakrequestforflow2isinprocess.
diCellPauseInCourseInf Bool Pausemoderequestisinprocess.
diFlow1Selected Bool Flow1isselectedforproduction.
diFlow2Selected Bool Flow2osselectedforproduction.
diFlow1BreakReq Bool Breakhasbeenrequestedonflow1.
diFlow2BreakReq Bool Breakhasbeenrequestedonflow2.
diCellAccessInf Bool Accesstocellisallowed.
diCellAccessInCourseInf Bool Accessrequesttocellisinprocess.

diCellSafetiesInf Bool CellsafetiesareOK.
diCellFaultInf Bool Therearefaultsinthecell.
diRobotTaskExecutingInf Bool Robotisexecutingprogram.
diDev1ReadyInf Bool Device1isready.
diDev1FaultedInf Bool Thereisafaultondevice1.
None

Ouput arguments
None
Name Type A variable to ...
doR1Flow1RunningInf Bool InformFlow1isRunning

doR1Flow2RunningInf Bool InformFlow2isRunning
doR1CellRunningInf Bool InformCellisRunningInf
doR1CellAccessInf Bool InformCellinAccessInf
doR1CellSafetiesInf Bool InformCellSafetyOK
doR1CellFaultsInf Bool InformCellFaults
doR1Flow1PauseInf Bool InformFlow1isinPause
doR1Flow2PauseInf Bool InformFlow2isinPause
doR1CellPauseInf Bool InformCellisinPause
doR1CellDoor1Inf Bool InformCellDoor1Status

doR1CellEStop1Inf Bool InformCellEStop1Status

Name Type A variable informing ...
doR1OutOfInfeeder1 Bool RoboutoutofInfeeder1

doR1Infeeder1ReadyInf Bool Infeeder1isReady
doR1Infeeder1ASInf Bool Infeeder1AutoStopInfo
doR1Infeeder1ESInf Bool Infeeder1GeneralStopInfo
doR1Infeeder1FaultedInf Bool Infeeder1faulted
doR1Infeeder1ItemSensor1Inf Bool Infeeder1ItemSensor1status
doR1OutOfInfeeder2 Bool RoboutoutofInfeeder2
doR1Infeeder2ReadyInf Bool Infeeder2isReady
doR1Infeeder2ASInf Bool Infeeder2AutoStopInfo
doR1Infeeder2ESInf Bool Infeeder2GeneralStopInfo
doR1Infeeder2FaultedInf Bool Infeeder2faulted
doR1OutOfOutnfeeder1 Bool RoboutoutofOutfeeder1
doR1Outfeeder1ReadyInf Bool Outfeeder1isReady
doR1Outfeeder1EmptyInf Bool Outfeeder1isEmpty
doR1Outfeeder1FullInf Bool Outfeeder1isFull

doR1Outfeeder1PresentInf Bool Outfeeder1isPresent
doR1Outfeeder1EnabledInf Bool Outfeeder1Enabled
doR1OutOfOutnfeeder2 Bool RoboutoutofOutfeeder2
doR1Outfeeder2ReadyInf Bool Outfeeder2isReady
doR1Outfeeder2EmptyInf Bool Outfeeder2isEmpty
doR1Outfeeder2FullInf Bool Outfeeder2isFull
doR1Outfeeder2PresentInf Bool Outfeeder2isPresent
doR1Outfeeder2EnabledInf Bool Outfeeder2Enabled

Name Type A variable informing ...
doR1OutOfSlipSheetMag Bool RobotoutofSlipSheetMagazine

doR1SlipSheetMagReadyInf Bool SlipSheetMagazineReady
doR1SlipSheetMagPresentInf Bool SlipSheetMagazinePresent
doR1SlipSheetMagEnabledInf Bool SlipSheetMagazineEnabled
doR1OutOfPalletMag Bool RobotoutofPalletMagazine
doR1PalletMagReadyInf Bool PalletMagazineReady
doR1PalletMagPresentInf Bool PalletMagazineisPresent
doR1PalletMagEnabledInf Bool PalletMagazineisEnabled
Calling POU
None

3.3.20 Robot_IOGroups
Usage
The Robot_IOGroups is used to handle group of outputs to robot.
Type
Program
Input arguments
diReset Bool Holdingthestatusofresetbuttons.

Holdingthecommanddatatosendto
diRobotOrderToSend Byte robot.
diRobotEchoOrder Byte Holdingthefeedbackorderfromrobot.
diRobotEchoPositionCode Byte Holdingthepositionvaluefromrobot.
Holdingthejobnumberloadedonrobot
diRobotEchoJobFlow1 Word forflow1.
Holdingthejobnumberloadedonrobot
diRobotEchoJobFlow2 Word forflow2.
None
Ouput arguments
doRobotFlow1Job Informloadedjobonrobotforflow1is
CodeOk Bool correct.
doRobotFlow2Job Informloadedjobonrobotforflow2is
CodeOk Bool correct.
doOrderReceived Bool Informrobothasreceivedtheorder.
doOrderSent Bool Informtheorderhasbeensenttorobot.
doOrderExecuted Bool Informrobothasexecutedorder.
doOrderTimeOut Bool Informtheorderhasexpired.
Holdthevalueofcommandtosendto
doOrderSentToRobot Byte robot.
doRobotEchoInfoPosition Byte Holdthevalueofrobotposition.

Holdthevalueoftheloadedjobonrobot
doRobotEchoJobFlow1 Word forflow1.
Holdthevalueoftheloadedjobonrobot
doRobotEchoJobFlow2 Word forflow2.
Holdthevalueofcommandtosendto
doOrderToRobot Byte robot.
None
Calling POU
None

3.3.21 Robot_Start_Up
Usage
Robot_Start_Up is used to start and stop robot when requested like motors On and
Quick Stop to the Robot
Type
Function block
Input arguments
diStartCycleOrder Bool Toorderrobotstartcycle.

diResetEmergencyReq Bool Toresetemergencystateonrobot.
Containingstatusofrobot
diRobotEmergency Bool emergencystate.
Containingstatusofrobotrunchain
diRunchOk Bool state.
Containingstatusofrobotmotorson
diRobotMotorOn Bool state.
Containingstatusofrobotauto
diRobotInAuto Bool mode.
Containingstatusoftaskexecuting
diRobotTaskExecuting Bool systemoutputfromrobot.
Toinformifitisnecessarytostart
diStartfromMainNeeded Bool robotatmainroutine.
diStopRobot Bool Toorderrobottostop.
diImmediateStopSelected Bool Toselectimmediatestoptype.
Toselectstopafterinstructionstop
diStopAfterInstructionSelected Bool type.
Containingthecommandtobesent
diCommandToRobot Byte torobot.
None

Ouput arguments
doResetEmStop Bool Resetemergenciesonrobot

Requestrobottochangetomotorsonand
doMotOnStart Bool startprogramexecution.
doPPToMain Bool Orderrobotstartprogramatmainroutine.
doProductionMode Bool Informrobotproductionmodeisactive.
doPLCLifeBit Bool InformrobotcommunicationwithPLCisOK.
doQuickStop Bool Orderrobottoanimmediatestop.
doStopInstr Bool Orderrobotstopatendofinstruction.
None
Calling POU
None

3.3.22 Robot_TP_Commands
Usage
Robot_TP_Commands reads the commands send from the CellHMI and store
them on memory.
These memories are use later during the program.
Type
Function block
Input arguments
Containingthecommandvalueof
diRobotTPCommand Byte FlexpendantCellHMI.
Informingifanewcommandis
diTPCommandReq Bool availableondiRobotTPCommand
Informingifthenewjobcodeforthe
diFlow1JobCodeOK Bool flow1loadedinrobotiscorrect.
Informingifthenewjobcodeforthe
diFlow2JobCodeOK Bool flow2loadedinrobotiscorrect.
None
Ouput arguments
doFlow1Resume Bool Ordertoresumeflow1.

Ordertobreakflow1afterrobot
doFlow1BreakAfterItem Bool placeanitem.
Bool Ordertobreakflow1afterrobot
doFlow1BreakAfterLayer finishstackingcurrentlayeronpallet.
doFlow1BreakAfterPallet finishstackingcurrentpallet.

doFlow1StartBatch Bool Ordertostartbatchonflow1.

Bool Ordertostopbatchonflow1after
doFlow1StopBatchAfterItem robotplaceanitem.
robotfinishstackingcurrentlayeron
doFlow1StopBatchAfterLayer pallet.
doFlow1StopBatchAfterPallet robotfinishstackingcurrentpallet.
Bool Holdthetogglestatusofpicking
doFlow1ForceTogleFormat1 format1fortheflow1.
Bool Orderrobottostopatpickpositionon
doFlow1StopAtPick flow1.
Bool Orderrobottostopatdropposition
doFlow1StopAtDrop onflow1.
doFlow2Resume Bool Ordertoresumeflow2.
Ordertobreakflow2afterrobot

doFlow2BreakAfterItem Bool placeanitem.
doFlow2BreakAfterLayer finishstackingcurrentlayeronpallet.
doFlow2BreakAfterPallet finishstackingcurrentpallet.
doFlow2StartBatch Bool Ordertostartbatchonflow2.
doFlow2StopBatchAfterItem robotplaceanitem.
robotfinishstackingcurrentlayeron
doFlow2StopBatchAfterLayer pallet.
doFlow2StopBatchAfterPallet robotfinishstackingcurrentpallet.

doAccess Bool Requestrobotgotoaccessposition.

doResetFault Bool Requestrobotresetfaults.
doRobotStop Bool Requestrobotstop.
Bool Requestrobotmotorsonandstart
doRobotMotorOnStart program.
Bool Requestrobotbreakcycleafteran
doRobotBreakAfterItem itemisplacedbyrobot.
Bool Requestrobotbreakcycleafterrobot
finishesstackingcurrentlayeron
doRobotBreakAfterLayer pallet.
Bool Requestrobotbreakcycleafterrobot
doRobotBreakAfterPallet finishesstackingcurrentpallet.
doRobotToHome Bool Requestrobottogohomeposition.
Bool Requestrobottogooutofline
doRobotToOutOfLine position.
doRobotEnableOutfeeder1 Bool Informrobotoutfeeder1isenabled.
doRobotEnableOutfeeder2 Bool Informrobotoutfeeder2isenabled.
Bool Informrobotslipsheetstackstationis
doRobotEnableSlipSheetMag enabled.
Bool Informrobotpalletstackstationis
doRobotEnablePalletMag enabled.
doCommandToRobot Byte Holdcommandvaluetosendtorobot.
None
Calling POU
None

3.3.23 Slip_Sheet_Magazine
Usage
SlipSheet_Magazine is used to control everything related to pallet magazine

station.
Type
Program
Input arguments
None
None
Ouput arguments
None
Type Name
Bool CellData.SlipSheetMagazine.Enabled
Bool doR1RstHeightSlipSheetMag

Calling POU

3.3.24 Test_Mode
Usage
This POU is used during test to make possible running robot on dry cycle.
It emulates the behaviour of infeeder item sensor.
Type
Function block
Input arguments
None
diNewFormatReq Informingthereisarequesttoprepareanew
OnInfeed Bool formatinfeeder.
diInfeedSelected Informinginfeederisselectedforproduction.
OnProduction Bool
Informingaboutthetypeofpickingformatto
diFormatReqID Bool prepareoninfeeder.
Informingaboutthenumberofitemsto
diQtyItemsFormat1 Bool prepareforpickingformat1.

Ouput arguments
doSensorSimulation Bool Simulateinfeedersensor
None
Calling POU
None

3.3.25 Toggle_Function
Usage
It is used to handle toggle buttons of CellHMI and latch memories.
Type
Function block
Input arguments
diToggleSignal Bool Tochangeorswapoutputvalue.

diInputSetToggle Bool Tosetoutput.
diInputResetToggle Bool Toresetoutput.
None
Ouput arguments
doToggleSignal Bool Holdthetogglevalue.

None
Calling POU
None

3.4 Data Types
This chapter describes the different data types used in the PLC program.

3.4.1 CellDataMap
Usage
CellDataMap is used for mapping the cell data.
Structure
Name Type Component to hold data related to...
General DataGeneral Generalofcell.

Access DataAccess Accesstocell.
Doors DataDoor Celldoors.
Robot DataRobot Robot.
Infeeder1 DataInfeeder Infeeder1.
Infeeder2 DataInfeeder Infeeder2.
Outfeeder1 DataOutfeeder Outfeeder1.
Outfeeder2 DataOutfeeder Outfeeder2.
DataPallet Palletmagazine.
PalletMagazine Magazine
DataSlipSheet Slipsheetmagazine.
SlipSheetMagazine Magazine
Flow1 DataFlow Productionflow1.

Flow2 DataFlow Productionflow2.

3.4.2 DataAccess
Usage
DataAccess is used for mapping the access to cell data.
Structure
Name Type Component to hold...
PermittedToZone BOOL Accesstocellallowed.

InCourse BOOL Accesstocellisinprocess.
InCourseBypassed BOOL Accesstocellprocessskipped.
ModuleStatus WORD Accessprocessstatus.

3.4.3 DataDoor
Usage
DataDoor is used for mapping the door status data.
Structure
Name Type Component to map status of...
ModuleStatusDoor1 BYTE Door1


3.4.4 DataFlow
Usage
DataFlow is used for mapping the production flow data.
Structure
Name Type Component to map...
OutOfInfeeder BOOL Robotoutofinfeeder.

OutOfOutfeeder BOOL Robotoutofoutfeeder.
UnloadingFault BOOL Unloadingfault.

3.4.5 DataGeneral
Usage
DataGeneral is used for mapping general data.
Structure
InManual BOOL Cellinmanualmode.

InAuto BOOL Cellinautomode.
InFault BOOL Cellinfault.
Flow1Started BOOL Flow1started.
Flow1BreakReq BOOL Breakrequestonflow1.
Flow2Started BOOL Flow2started.
Flow2BreakReq BOOL Breakrequestonflow2.
Flow1EndBatchReq BOOL Endbatchrequestflow1.
Flow2EndBatchReq BOOL Endbatchrequestflow2.
ProductionChangeReq BOOL Productionchangerequest.
RequestStartCycleRobot BOOL Requestrobotstartcycle.
RequestPause BOOL Requestpausemode/breakmode.
RequestEndCycle BOOL Requestendcycle.

RequestAccess BOOL Requestaccess.
AccessPermittedCell BOOL Accesstocellallowed.
AccessInCourse BOOL Accessincourse.
PauseInCourse BOOL Pauseincourse.
BreakFlow1InCourse BOOL Breakflow1oncourse.
BreakFlow2InCourse BOOL Breakflow2oncourse.
LampTest1 BOOL Lamptest1.
LampTest2 BOOL Lamptest2.

SummaryLampTest BOOL Summarylamptest

SummaryDoorsOK BOOL Summarycelldoorsok.
SummaryEStpOK BOOL Summarycellemergenciesok.
SummarySafetiesOk BOOL Summarycellsafetiesok.
SummaryPauseFromCellRob BOOL Summarypausemode.
SummaryAccessFromCellRob BOOL Summaryaccess.
UnloadingFault BOOL Unloadingfault.
AnyCommandRequested BOOL Commandrequest.

3.4.6 DataInfeeder
Usage
DataInfeeder is used for mapping the infeeder data.
Structure
Name Type Component to map infeeder...
SelectedForProduction BOOL Selectedforproduction.

ReadyToUnload BOOL Readyforrobottopickitems.
Format1Loaded BOOL Pickingformat1readyoninfeeder.

3.4.7 DataOutfeeder
Usage
DataOutfeeder is used for mapping the outfeeder data.
Structure
Name Type Component to map outfeeder...
SelectedForProduction BOOL Selectedforproduction.

ReadyToLoad BOOL Readyforrobottoplaceitems.
Empty BOOL Empty.
Completed BOOL Completed.(Palletfinished)
Enabled BOOL Enabledforproduction.

3.4.8 DataPalletMagazine
Usage
DataPalletMagazine is used for mapping the pallet magazine data.
Structure
Name Type Component to map pallet magazine...

3.4.9 DataRobot
Usage
DataRobot is used for mapping the robot data.
Structure
Name Type Component to map robot...
CommandTimeOut BOOL Commandtimeout.

CommandSent BOOL Commandsent.
CommandReceived BOOL Commandreceived.
CommandExecuted BOOL Commandexecuted.
UnloadingFault BOOL Unloadingfaultstatus.
Fault BOOL Faultstatus.
Ready BOOL Readystatus.
TPPushButFlow1Resume BOOL Resumepushbutton.Flow1.
TPPushButFlow1Break BOOL Breakafteritemisplacedpush
AfterItem button.Flow1.
TPPushButFlow1Break BOOL Breakwhenfinishstackingcurrent
AfterLayer layerpushbutton.Flow1.
AfterPallet palletpushbutton.Flow1.
TPPushButFlow1StartBatch BOOL Startbatchpushbutton.Flow1.
TPPushButFlow1Stop BOOL Endbatchafteritemisplacedpush
BOOL Endbatchwhenfinishstacking
TPPushButFlow1Stop currentlayerpushbutton.
AfterLayer Flow1.

TPPushButFlow1Stop currentpalletpushbutton.
AfterPallet Flow1.
TPPushButFlow1StopAtPick BOOL Stopatpickpushbutton.Flow1.
TPPushButFlow1StopAtDrop BOOL Stopatdroppushbutton.Flow1.
TPPushButFlow1 BOOL Togglebuttonpickingformat1.
ToggleFormat1Loaded Flow1.
TPPushButFlow2Resume BOOL Resumepushbutton.Flow2.
TPPushButFlow2Break BOOL Breakafteritemisplacedpush
AfterLayer layerpushbutton.Flow2.
AfterPallet palletpushbutton.Flow2.
TPPushButFlow2StartBatch BOOL Startbatchpushbutton.Flow2.
TPPushButFlow2Stop BOOL Endbatchafteritemisplacedpush

TPPushButFlow2Stop currentlayerpushbutton.
AfterLayer Flow2.
TPPushButFlow2Stop currentpalletpushbutton.
AfterPallet Flow2.
TPPushButFlow2StopAtPick BOOL Stopatpickpushbutton.Flow1.
TPPushButFlow2StopAtDrop BOOL Stopatdroppushbutton.Flow1.

BOOL Breakafteritemisplacedpush
TPPushButBreakAfterItem button.
BOOL Breakwhenfinishstackingcurrent
layerpushbutton.
TPPushButBreakAfterLayer Flow2.
BOOL Breakwhenfinishstackingcurrent
palletpushbutton.
TPPushButBreakAfterPallet Flow2.
TPPushButStartRobot BOOL Startpushbutton.
TPPushButStopRobot BOOL Stoppushbutton.
TPPushButAccess BOOL Accessrequestpushbutton.
TPPushButReset BOOL Resetpushbutton.
TPPushButRobotToHome BOOL Tohomepushbutton.
TPPushButRobotToAccess BOOL Toaccesspushbutton.
TPPushButRobotOutOfLine BOOL Tooutoflinepushbutton.
TPPushButEnableOutfeeder1 BOOL Enableoutfeeder1pushbutton.
TPPushButEnableOutfeeder2 BOOL Enableoutfeeder2pushbutton.
BOOL Enableslipsheetmagazinepush
TPPushButEnableSlipSheetMag button.
BOOL Enablepalletmagazinepush
TPPushButEnablePalletMag button.
BOOL Pickingformat1pushbutton.
ForceItem1LoadedInfeeder1 Infeeder1.

RobotJobCodeFlow1OK BOOL Jobcodeok.Flow1.

RobotJobCodeFlow2OK BOOL Jobcodeok.Flow2.
EchoRobotJobCodeFlow1 WORD Jobcode.Flow1.
EchoRobotJobCodeFlow2 WORD Jobcode.Flow2.
TPCommandData WORD Commanddata.
EchoRobotPosition BYTE Position.
CommandToRobot BYTE Commandtosend.
CommandNumberSent BYTE Commandsent.

3.4.10 DataSlipSheetMagazine
Usage
DataSlipSheetMagazine is used for mapping the slip sheet magazine data.
Structure
Name Type Component to map slip sheet

magazine...


3.4.11 InputsField
Usage
InputsField is used for mapping field devices inputs.
Structure
BOOL Resetpushbuttonof
diResetPB_CMB1 panelbox1.
BOOL Startpushbuttonof
diStartPB_CMB1 panelbox1.

BOOL Accesspushbuttonof
diAccessPB_CMB1 panelbox1.

BOOL Pausepushbuttonof
diPausePB_CMB1 panelbox1.
BOOL Automodeselectorof
diAutoSelector_CMB1 panelbox1.

3.4.12 InputsInfeeder
Usage
InputsInfeeder is used for mapping infeeder device inputs.
Structure
diReady BOOL Readyinput.

diFault BOOL Faultinput.
diAutoOn BOOL Inautomodeswitch.
diSensorItemOnInfeed BOOL Itempresentsensor.

3.4.13 InputsOutfeeder
Usage
InputsOutfeeder is used for mapping outfeeder device inputs.
Structure

diPresent BOOL Palletpresentsensor

3.4.14 InputsPalletMagazine
Usage
InputsPallettMagazine is used for mapping pallet magazine inputs.
Structure

diPresent BOOL Stackpresentsensor.
diValidation BOOL Validateforproductionpushbutton.

3.4.15 InputsSlipSheetMagazine
Usage
InputsSlipSheetMagazine is used for mapping slip sheet magazine inputs.
Structure

diPresent BOOL Sensorstackpresent.
diValidation BOOL Validateforproductionpushbutton.

3.4.16 IOMappingField
Usage
IOMappingField is used for mapping the cell field devices.
Structure
Inputs InputsField Cellfielddevicesinputs.

Outputs OutputsField Cellfielddevicesoutputs.

3.4.17 IOMappingInfeeder
Usage
IOMappingInfeeder is used for mapping the infeeder device.
Structure
Inputs InputsInfeeder Infeederinputs.

Outputs OutputsInfeeder Infeederoutputs.

3.4.18 IOMappingOutfeeder
Usage
IOMappingOutfeeder is used for mapping the outfeeder device.
Structure
Inputs InputsOutfeeder Outfeederinputs.

Outputs OutputsOutfeeder Outfeederoutputs.

3.4.19 IOMappingPalletMagazine
Usage
IOMappingPalletMagazine is used for mapping the pallet magazine station.
Structure
Inputs Palletmagazineinputs.
Inputs PalletMagazine
Outputs Palletmagazineoutputs.
Outputs PalletMagazine

3.4.20 IOMappingSlipSheetMagazine
Usage
IOMappingSlipSheetMagazine is used for mapping the slip sheet magazine station.
Structure
Inputs Slipsheetmagazineinputs.
Inputs SlipSheetMagazine
Outputs Slipsheetmagazineoutputs.
Outputs SlipSheetMagazine

3.4.21 OutputsField
Usage
OutputField is used for mapping the cell field outputs.
Structure
Name Type Component to map output of...
doUnlockDoor1 Bool Unlockdoor1.

doGreenStackLight1 Bool Greenlamponstacklight1.
doYellowStackLight1 Bool Yellowlamponstacklight1.
doRedStackLight1 Bool Redlamponstacklight1.
doGreenStackLight2 Bool Greenlamponstacklight2.
doYellowStackLight2 Bool Yellowlamponstacklight2.
doRedStackLight2 Bool Redlamponstacklight2.
doGreenPB_CMB1 Bool Greenlampbuttononpanelbox1.
doYellowPB_CMB1 Bool Yellowlampbuttononpanelbox1.
doBluePB_CMB1 Bool Bluelampbuttononpanelbox1.


3.4.22 OuputsInfeeder
Usage
OutputInfeeder is used for mapping the inputs of outfeeder device.
Structure
RobotOnArea Bool Robotisinsideinfeederarea.

Bool Requesttoprepareanewpickingformaton
NewFormatRequest outfeeder.
Byte Quantityofitemstoprepareoninfeederfor
QtyItemsFormat1 thepickingformat1.
Byte Pickingformattypetoprepareonthe
CurrentFormatID infeeder.

3.4.23 OuputsOutfeeder
Usage
OutputOutfeeder is used for mapping the outputs of outfeeder device.
Structure
RobotOnArea Bool Robotisinsideoutfeederarea.

PalletPresent Bool Sensorpalletpresentonoutfeeder.
PalletFull Bool Palletisfull.
Validated Bool Outfeederisvalidatedforproduction.
NewPalletLoaded Bool Signalrobotplaceanewpalletonoutfeeder.

3.4.24 OuputsPalletMagazine
Usage
OutputPalletMagazine is used for mapping the outputs of pallet magazine station.
Structure
RobotOnArea Bool Robotisinsidepalletmagazinearea.

StackPresent Bool Sensorstackpresentonstation.
Validated Bool Magazineisvalidatedforproduction.
NewStackLoaded Bool Signalanewstackofpalletsisloaded.

3.4.25 OuputsSlipSheetMagazine
Usage
OutputSlipSheetMagazine is used for mapping the outputs of slip sheet magazine

station.
Structure
RobotOnArea Bool Robotisinsideslipsheetmagazinearea.

StackPresent Bool Sensorstackpresentonstation.
Validated Bool Magazineisvalidatedforproduction.
NewStackLoaded Bool Signalanewstackofslipsheetsisloaded.

3.4.26 SafetyInterface
Usage
SafetyInterface is used for mapping the cell safeties.
Structure
Name Type Component to hold status of...
Door1 SafetyStatusDevice Celldoor1.

DoorExtDevice SafetyStatusDevice Celldoorofexternaldevice.
EStp1 SafetyStatusDevice Cellemergencybutton1.

SafetyStatusDevice Cellemergencyofexternal
EStpExternalDevice device.
EStpRobot SafetyStatusDevice Cellemergencyofrobot.
EStpInfeeder1 SafetyStatusDevice Infeeder1emergencystop.
EStpInfeeder2 SafetyStatusDevice Infeeder2emergencystop.
DoorsInfeeder1 SafetyStatusDevice Infeeder1doors.
DoorsInfeeder2 SafetyStatusDevice Infeeder2doors.
EStpOutfeeder1 SafetyStatusDevice Outfeeder1emergencystop.
EStpOutfeeder2 SafetyStatusDevice Outfeeder2emergencystop.
DoorsOutfeeder1 SafetyStatusDevice Outfeeder1doors.
DoorsOutfeeder2 SafetyStatusDevice Outfeeder2doors.

Name Type Component to hold status of...
EStpPallet SafetyStatusDevice Palletmagazinestation

Magazine emergencystop.
DoorsPallet SafetyStatusDevice Palletmagazinestationdoors.
Magazine
EStpSlipSheet SafetyStatusDevice Slipsheetmagazinestation
Magazine emergencystop.
DoorsSlipSheet SafetyStatusDevice Slipsheetmagazinestation
Magazine doors.

3.4.27 SafetyStatusDevice
Usage
SafetyStatusDevice is used for mapping status of safety devices.
Structure
Name Type Component to map safety sensor...
SOK_Rst Bool Okandreset.

SOK Bool Ok.
Discrepancy Bool Channeldiscrepancy.
Null Bool Null.

3.5 Memory Map
This chapter describes the memory map of the PLC program.


3.5.1 Constants
Usage
Constant variables are used for configuration purpose.
Variables
Name Type It is used to...
DRYCYCLE Bool Activatedrycyclemode.

INMEDIATESTOPSELECTED Bool Toselectrobotimmediatestoptype.
Toselectrobotstopatendofinstruction
STOPAFTERINSTRUCTION Bool type.

3.5.2 Addressable flag area (%M)
Usage
This memory area it is used for mapping the robot interface.
Variables
Address It is used to...
Storethevalueoftherobotoutputs.
From %MX0.0.0 to %MX0.39.7 Namestructure:diR1%NAME%
Assignvaluetorobotinputs.
From %MX0.64.0 to %MX0.103.7 Namestructure:doR1%NAME%

3.5.3 Global variables
Overview
Global variables are used to store all the data of the program.
Variables
Name Type Description
CellData CellDataMap Itisusedtoholdthecelldata.

Safety SafetyInterface Itisusedtomapcellsafeties.
Field IOMappingField Itisusedtomapfielddevices.
SlipSheetMagazine IOMapping
Itisusedtomapslipsheetmagazine
SlipSheetMagazine interface.
PalletMagazine IOMapping
Itisusedtomappalletmagazine
PalletMagazine interface
Infeeder1 IOMapping
Itisusedtomapinfeeder1
Infeeder interface.
Infeeder2 IOMapping
Itisusedtomapinfeeder2
Infeeder interface.
Outfeeder1 IOMapping
Itisusedtomapoutfeeder1
Outfeeder interface.
Outfeeder2 Itisusedtomapoutfeeder2

IOMapping
Outfeeder interface.

Squarewave.
Pulse0 Bool TimeH=0.1sec,TimeL=0.1sec
Bool Squarewave.
Pulse1 TimeH=0.2sec,TimeL=0.2sec
Bool Squarewave.
Bool Squarewave.
Bool Squarewave.
Bool Squarewave.
Pulse5 TimeH=1sec,TimeL=1sec
Bool Squarewave.
Bool Squarewave.
Pulse7 TimeH=2sec,TimeL=2sec
BitTo0 Bool AlwaysTRUE.
BitTo1 Bool AlwaysFALSE.

4 Safety PLC Program
4.1 Introduction
This chapter describes the PLC Safety program for the PalletPack and includes:
x A reference to built-in program.
x A description of the IO map.

4.2 Built-in program
Scope of the program
PalletPack safety program is ready to control:

x 4 emergency push buttons
x 4 cell doors.
Safety concepts
PalletPack safety program follows some rules and concepts:

x When a door is open it is not possible to operate robot and other devices in
automatic mode.
x When an emergency is active it is not possible to operate robot and other
devices.
x Once a door is closed it is necessary to push reset button to confirm safe
status.
x Every reset button is associated to one door and cannot reset any other
door.
x To recover system from an emergency it is necessary to release the
emergency switch and push on any of the reset buttons.

4.3 IO Map
Fail safe inputs
Address Name Signal from...
I0.0 diEStop1_Ch1 Channel1ofemergency1.

Channel1fromanexternaldevice
I0.4 diEStopExtDevice_Ch1 emergency.
Channel1fromanexternaldevice
I0.5 diEStopExtDevice_Ch2 emergency.
I0.6 diEStopRobot_Ch1 Channel1ofemergencyfromrobot.
I0.7 diEStopRobot_Ch2 Channel2ofemergencyfromrobot.
I0.30 diDoor1_Ch1 Channel1ofdoor1.
I0.31 diDoor1_Ch2 Channel2ofdoor1

I0.36 diDoorExternalDevice_Ch1 Channel1ofexternaldevicedoor.
I0.37 diDoorExternalDevice_Ch2 Channel2ofexternaldevicedoor.
I0.40 diResetDoor1 Resetpushbutton1.
Resetpushbuttonofexternal
I0.43 diResetDoorExternalDevice device.
I0.44 Spare Notused.

Non fail-safe outputs
Address Name Signal to...

Inform control PLC about status of
IQ0.10 doEStop1OK emergency 1.
IQ0.11 doEStop2OK emergency 2.
IQ0.12 doEStopExternalDeviceOK external device emergency.
Inform control PLC about status of robot
IQ0.13 doEStopRobotOK emergency.
Inform control PLC about status of door
IQ0.14 doDoor1OK 1.
IQ0.15 doDoor2OK 2.
IQ0.16 doDoor3OK 3.
IQ0.17 doDoorExtDeviceOK external device door.
IQ0.20 Spare Not used.
IQ0.25 Dynamic A Dynamic signal A.

IQ0.26 Dynamic B Dynamic signal B.
IQ0.27 Dynamic C Dynamic signal C.
Non fail-safe outputs
Address Name Signal to...

Q0.0 doSpare1 Spare
Q0.1 doSpare2 Spare
Q0.2 doGStop General stop via expansion relay
Q0.3 doAStop Automatic stop via expansion relay
Q0.4 doSpare4 Spare
Q0.5 doSpare5 Spare

5 Interfaces
5.1 Robot
This chapter contains a description of the interface between PLC and robot with
PalletWare.

5.1.1 Inputs
List of inputs
rdiMotOnStart DI It orders motors on and start.
rdiMotorOn DI It orders motors on.
rdiStartMain DI It orders start at main.
rdiResetEstop DI It resets Emergency Stop.
rdiPLCLifeBit DI It can be used to monitor PLC communication
rdiQuickStop DI It orders a quick stop.
rdiStopInstr DI It orders a stop at end of instruction.
rdiProductionMode DI High to select production mode.

Order number.
rgiOrderRequest GI
Length: 8 bits.
Job number to run on flow 1.
rgiF1JobNumber GI
Length: 16 bits.
Job number to run on flow 2.
rgiF2JobNumber GI
Length: 16 bits.
It is connected to LED out of infeeder 1 of
DI
rdiOutOfInfeeder1 CellHMI.
It is connected to LED out of infeeder 2 of
DI
rdiOutOfInfeeder2 CellHMI.
It is connected to LED out of oufeeder 1 of

DI
rdiOutOfOutfeeder1 CellHMI.
It is connected to LED out of oufeeder 2 of
DI
rdiOutOfOutfeeder2 CellHMI.
It is connected to LED out of slip sheet
DI
rdiOutOfSlipSheetMag magazine of CellHMI.
It is connected to LED out of pallet magazine
DI
rdiOutOfPalletMag of CellHMI.
rdiPickPlaceItemFlow1 DI It oders to pick and place item on flow 1.
rdiPickPlaceItemFlow2 DI It oders to pick and place item on flow 2.
rdiFlow1Ready DI It shows status of flow 1.
rdiFlow2Ready DI It shows status of flow 2.

It orders flow 1 to break after robot place next
DI
rdiFlow1BreakAfterItem item.
It orders flow 1 to break when robot finishes
DI
rdiFlow1BreakAfterLayer stacking the current layer.
DI It orders flow 1 to break when robot finishes

rdiFlow1BreakAfterPallet stacking the current pallet.
It orders flow 2 to break after robot place next
DI
rdiFlow2BreakAfterItem item.
It orders flow 2 to break when robot finishes
DI
rdiFlow2BreakAfterLayer stacking the current layer.
DI It orders flow 2 to break when robot finishes

rdiFlow2BreakAfterPallet stacking the current pallet.
It orders flow 1 to stop job after robot place
DI
rdiFlow1StopAfterItem next item.
It orders flow 1 to stop job when robot finishes
DI
rdiFlow1StopAfterLayer stacking the current layer.
DI It orders flow 1 to stop job when robot finishes

rdiFlow1StopAfterPallet stacking the current pallet.
It orders flow 2 to stop job after robot place
DI
rdiFlow2StopAfterItem next item.
It orders flow 2 to stop job when robot finishes
DI
rdiFlow2StopAfterLayer stacking the current layer.
DI It orders flow 2 to stop job when robot finishes

rdiFlow2StopAfterPallet stacking the current pallet.
rdiAllowLoadPalletOutfeed1Inf DI It allows robot to load pallet on outfeed 1.
rdiAllowLoadPalletOutfeed2Inf DI It allows robot to load pallet on outfeed 2.

It is connected to LED Cell running of
DI
rdiCellRunningInf CellHMI.
It is connected to LED Cell Access running of
DI
rdiCellAccessInf CellHMI.
It is connected to LED Cell Safeties of
DI
rdiCellSafetiesInf CellHMI.
rdiCellFaultsInf DI It is connected to LED Cell Faults of CellHMI.
rdiCellPause DI It is connected to LED Cell Pause of CellHMI.

It is connected to LED Cell Emergency Stop
DI %EMERGENCY_STOP_NUMBER% of
rdiCellEStop%NUMBER%Inf CellHMI.

It is connected to LED Infeeder 1 ready of
DI
rdiInfeeder1ReadyInf CellHMI.
rdiInfeeder1ASInf DI To inform about status of infeeder 1 fencing.
To inform about status of infeeder 1
DI
rdiInfeeder1ESInf emergency stop.
rdiInfeeder1FaultedInf DI To inform about status of infeeder 1 fault.
It is connected to LED status of format 1 on
DI
rdiInfeeder1ItemSensor1Inf infeeder 1 of CellHMI.
DI
DI
It is connected to LED Infeeder 2 ready of
DI
rdiInfeeder2ReadyInf CellHMI.
rdiInfeeder2ASInf DI To inform about status of infeeder 2 fencing.
To inform about status of infeeder 2
DI
rdiInfeeder2ESInf emergency stop.
rdiInfeeder2FaultedInf DI To inform about status of infeeder 2 fault.
DI
DI
DI
It is connected to LED Outfeeder 1 ready of

DI
rdiOutfeeder1ReadyInf CellHMI.
It is connected to LED Outfeeder 1 empty of
DI
rdiOutfeeder1EmptyInf CellHMI.
It is connected to LED Outfeeder 1 full of
DI
rdiOutfeeder1FullInf CellHMI.
It is connected to LED Outfeeder 1 present of
DI
rdiOutfeeder1PresentInf CellHMI.
It is connected to LED Outfeeder 1 enabled of
DI
rdiOutfeeder1EnabledInf CellHMI.
It is connected to LED Outfeeder 2 ready of
DI
rdiOutfeeder2ReadyInf CellHMI.
It is connected to LED Outfeeder 2 empty of
DI
rdiOutfeeder2EmptydInf CellHMI.
It is connected to LED Outfeeder 2 full of
DI
rdiOutfeeder2FullInf CellHMI.
It is connected to LED Outfeeder 2 present of
DI
rdiOutfeeder2PresentInf CellHMI.
It is connected to LED Outfeeder 1 enabled of
DI
rdiOutfeeder2Enabled CellHMI.

It is connected to LED slip sheet magazine
DI
rdiSlipSheetMagReadyInf ready of CellHMI.
DI
rdiSlipSheetMagPresentInf present of CellHMI.
DI
rdiSlipSheetMagEnabledInf enabled of CellHMI.
It is connected to LED pallet magazine ready
DI
rdiPalletMagReadyInf of CellHMI.
It is connected to LED pallet magazine
DI
rdiPalletMagPresentInf present of CellHMI.
It is connected to LED pallet magazine
DI
rdiPalletMagEnabledInf enabled of CellHMI.
It is connected to LED flow 1 running of
DI
rdiFlow1RunningInf CellHMI.
It is connected to LED flow 1 on pause of
DI
rdiFlow1PauseInf CellHMI.
It is connected to LED flow 2 running of
DI
rdiFlow2RunningInf CellHMI.
It is connected to LED flow 2 on pause of
DI
rdiFlow2PauseInf CellHMI.
It orders to reset memory of pallet magazine
DI height and start searching from top of the
rdiRstHeightPalletMag stack.
It orders to reset memory of slip sheet
DI magazine height and start searching from top
rdiRstHeightSlipSheetMag of the stack.

5.1.2 Outputs
List of ouputs

It informs about a production execution error
DO on robot.
rdoError System output.
DO High when robot is on emergency stop state.
rdoEmStop System output.
DO High when robot is on emergency stop state.
rdoRunchOk System output.
DO High when robot is on motors on state.
rdoMotOnState System output.
DO High when robot is on motors off state.
rdoMotOffState System output.
DO High when main task is executing.
rdoTaskExecuting System output.
DO High when robot is on automatic mode.
rdoAutoOn System output.
rdoSpare7 DO Spare
Order acknowledgement.
GO
rgoOrderAck 8 bits.
Feedback of loaded job on flow 1.
GO
rgoFlow1JobNumber 16 bits.
Feedback of loaded job on flow 2.

GO
rgoFlow2JobNumber 16 bits.
Feedback job position.
GO
rgoPosNum 8 bits.
rdoUnloadingFault DO It gets high when an unloading error occurs.
rdoItemOnGripper DO It gets high when an item is on gripper.
rdoMonitorGripper DO It request to monitor item on gripper.

DO It informs robot is going out of infeeder 1.
rdoLoadAuthInfeeder1 Pulse.Lenght=1sec.
DO It informs robot is going out of infeeder 2.
rdoLoadAuthInfeeder2 Pulse.Lenght=1sec.
DO It informs robot has placed a new pallet on
outfeeder 1.
rdoLoadConfOutfeeder1 Pulse. Length=1sec.
DO It informs robot has placed a new pallet on
outfeeder 2.
rdoLoadConfOutfeeder2 Pulse. Length=1sec.
DO It confirms robot has changed of flow.
rdoFlowChanged Pulse. Length=1sec.

DO It gets low when robot enters on infeeder 1
area.
rdoOutOfInfeeder1 Only when robot is executing program.
DO It gets low when robot enters on infeeder 2
area.
rdoOutOfInfeeder2 Only when robot is executing program.
DO It gets low when robot enters on outfeeder 1
area.
rdoOutOfOutfeeder1 Only when robot is executing program.
DO It gets low when robot enters on outfeeder 2
area.
rdoOutOfOutfeeder2 Only when robot is executing program.
DO It gets low when robot enters on slip sheet
stack station area.
rdoOutOfSlipSheetMag Only when robot is executing program.
DO It gets low when robot enters on pallet stack
station area.
rdoOutOfPalletMag Only when robot is executing program.
rdoOnFlow1 DO It informs robot is executing flow 1.
rdoOnFlow2 DO It informs robot is executing flow 2.
rdoFlow1Infeeder1Selected DO It informs infeeder 1 is selected on flow 1.
rdoFlow1Outfeeder1Selected DO It informs outfeeder 1 is selected on flow 1.
rdoFlow1Outfeeder2Selected DO It informs outfeeder 2 is selected on flow 1.

rdoFlow2Outfeeder1Selected DO It informs oufeeder 1 is selected on flow 2.
rdoFlow2Outfeeder2Selected DO It informs oufeeder 2 is selected on flow 2.
rdoRbtAtHome DO It gets high when robot is at Home position.

DO It gets high when robot is at Out of line
rdoRbtAtOutOfLine position.
rdoRbtAtAccess DO It gets high when robot is at Access position.
DO It confirms the memory of pallet magazine
height has been reset and robot will search
from top of the stack.
rdoHeightPalletMagRst Pulse. Length=1sec.
DO It confirms the memory of slip sheet
magazine height has been reset and robot
will search from top of the stack.
rdoHeightSlipSheetMagRst Pulse. Length=1sec.

DO It informs user has confirmed the pallet 1 is
empty.
rdoUserConfEmptyPallet1 Pulse. Length=1sec.
DO It informs user has confirmed the pallet 2 is
empty.
rdoUserConfEmptyPallet2 Pulse. Length=1sec.
DO It informs a command has been sent.
rdoCommandRequest Pulse. Length=1sec.
GO Command Request.
rgoTpCommand 8 bits.
GO Command Data.
rgoTpCommandData 16 bits.
GO It informs layer number robot is stacking on
flow 1.
rgoFlow1Onlayer 8 bits.
GO It informs item number robot is stacking on
flow 1.
rgoFlow1OnItem 8 bits.
GO It informs about the quantity of items to
prepare for format 1 on flow 1.
rgoFlow1Format1QtyItems 8 bits.
GO It informs about the format type to prepare on
rgoFlow1NextFormat infeeder used on flow 1.
GO It informs about the format type to prepare on
rgoFlow2NextFormat infeeder used on flow 2.

DO It informs robot has placed an item when
running flow 1.
rdoFlow1ConfEndItem Pulse. Length=1sec.
DO It informs robot has finished stacking a layer
when running flow 1.
rdoFlow1ConfEndLayer Pulse. Length=1sec.
DO It informs robot has finished stacking a pallet
rdoFlow1ConfEndPallet Pulse. Length=1sec.
DO It informs robot has placed an item when
running flow 2.
rdoFlow2ConfEndItem Pulse. Length=1sec.
DO It informs robot has finished stacking a layer
rdoFlow2ConfEndLayer Pulse. Length=1sec.
DO It informs robot has finished stacking a pallet
rdoFlow2ConfEndPallet Pulse. Length=1sec.
DO It request to prepare next format on flow 1.
rdoFlow1NextItemReq Pulse. Length=1sec.
DO It request to prepare next format on flow 2.
rdoFlow2NextItemReq Pulse. Length=1sec.
DO It confirms batch has finished on flow 1.
rdoEndBatchConfFlow1 Pulse. Length=1sec.
DO It confirms batch has finished on flow 2.
rdoEndBatchConfFlow2 Pulse. Length=1sec.

5.1.3 Group Inputs Values
rgiOrderRequest
When value is... It requests robot...

3 To stop.
4 To go home position and stop.
5 To go access position and stop.
6 To go out of line position and stop.
7 To stop at pick position when running flow 1.
8 To stop at pick position when running flow 2.
11 To stop at drop position when running flow 1.
12 To stop at drop position when running flow 2.
19 To end cycle. All flows.
20 To end cycle flow 1.
21 To end cycle flow 2.
22 To attend custom order 1.

rgiF1JobNumber
When value is... Means run...

Any Job number on flow 1.
rgiF2JobNumber
When value is... Means run...

Any Job number on flow 2.

5.1.4 Group Ouputs Values
rgoOrderAck
When value is... It acknowledges order...

3 Robot stop.
4 Go home position and stop.
5 Go access position and stop.
6 Go out of line position and stop.
7 Stop at pick postion when running flow 1.
8 Stop at pick position when running flow 2.
11 Stop at drop position when running flow 1.
12 Stop at drop position when running flow 2.
19 End cycle. All flows.
20 End cycle flow 1.
21 End cycle flow 2.
22 Custom order 1.
23 Custom order 2.
24 Custom order 3.
25 Custom order 4.

rgoF1JobNumber
When value is... Means...

Any The number of job loaded on Flow 1.
rgoF2JobNumber
When value is... Means...

Any The number of job loaded on Flow 2.

rgoPosNum
When value is... It means robot is at...

3 Stop.
4 Home position.
5 Access position.
6 Out of line position.
7 Stop at pick for flow 1.
11 Stop at drop for flow 1.
17 Waiting for flow selection.
18 Waiting for job selection.
22 Custom order 1.
23 Custom order 2.
24 Custom order 3.
25 Custom order 4.

rgoTpCommand
When value is... On CellHMI user has pushed button...

1 Start button.
2 Reset.
3 Stop.
4 Robot to Home.
5 Access request.
6 Robot to Out of line.
22 Custom order 1.
23 Custom order 2.
24 Custom order 3.
25 Custom order 4.
27 Break cycle after robot placed an item. All flows.
28 Break cycle after robot finishes stacking current layer. All flows.
29 Break cycle after robot finishes stacking pallet. All flows.
30 Start batch on flow 1.

31 Resume flow 1.
32 Stop batch on flow 1 after item is placed.
33 Stop batch on flow 1 after robot finishes stacking current layer.
34 Stop batch on flow 1 after robot finishes stacking current pallet.
35 Break cycle after robot placed an item. Flow 1.
36 Break cycle after robot finishes stacking current layer. Flow 1.
37 Break cycle after robot finishes stacking pallet. Flow 1.
38 Start batch on flow 2.
39 Resume flow 2.
40 Stop batch on flow 2 after item is placed.
41 Stop batch on flow 2 after robot finishes stacking current layer.
42 Stop batch on flow 2 after robot finishes stacking current pallet.
43 Break cycle after robot placed an item. Flow 2.
44 Break cycle after robot finishes stacking current layer. Flow 2.
45 Break cycle after robot finishes stacking pallet. Flow 2.

When value is... On CellHMI user has pushed button...
46 Enable outfeeder 1.
47 Enable outfeeder 2.
48 Enable pallet magazine.
49 Enable slip sheet magazine.
50 Format 1 ready on flow 1.


5.2 Human Machine Interface (HMI)
Overview
The communication with robot CellHMI takes place through robot interface.
For further information refer to 5.1 Robot on page 112.

5.3 Infeeders
This chapter contains a description of the interface between PLC and the infeeder.

5.3.1 Inputs
List of inputs
Type A signal to inform...

Bit Infeeder is ready for production.
Bit There is a fault on infeeder.
Bit Infeeder is in automatic mode.
Bit There is an item on infeeder.

5.3.2 Outputs
List of inputs
Type A signal to...

Bit Inform robot is inside infeeder area.
Bit Request a new format to infeeder.
Byte Inform about the number of items for picking format 1.
Byte Inform about the picking format to prepare on infeeder.

5.4 Outfeeders
This chapter contains a description of the interface between PLC and the
outfeeder.

5.4.1 Inputs
List of inputs

Bit Outfeeer is ready for production.
Bit There is a fault on infeeder.
Bit Outfeeder is in automatic mode.
Bit There is a pallet detected on outfeeder.

5.4.2 Outputs
List of outputs
Type A signal to...

Bit Inform robot is inside outfeeder area.
Bit Inform the current pallet is full.
Bit Inform the outfeeder is validated for production.
Bit Inform robot has placed a new pallet.
Bit Inform there is a pallet on outfeeder.

5.5 Pallet Magazine
This chapter contains a description of the interface between PLC and the pallet
magazine.

5.5.1 Inputs
List of inputs

Bit Pallet magazine is ready for production.
Bit There is a fault on pallet magazine station.
Bit Pallet magazine is in automatic mode.
Bit Stack is detected on station.
Bit Pallet magazine is validated for production.

5.5.2 Outputs
List of outputs
Type A signal to...

Bit Inform robot is inside station area.
Bit Inform stack of pallets is present.
Bit Inform the pallet station is validated for production.
Bit Inform a new stack is loaded.

5.6 Slip Sheet Magazine
This chapter contains a description of the interface between PLC and the slip sheet
magazine.

5.6.1 Inputs
List of inputs

Bit Slip sheet magazine is ready for production.
Bit There is a fault on slip sheet magazine station.
Bit Slip sheet magazine station is in automatic mode.
Bit Stack is detected on station.
Bit Slip sheet magazine is validated for production.

5.6.2 Outputs
List of outputs
Type A signal to...

Bit Inform robot is inside station area.
Bit Inform stack of slip sheets is present.
Bit Inform the slip sheet station is validated for production.
Bit Inform a new stack is loaded.

5.7 Field Devices
This chapter contains a description of the interface between PLC and field devices.

5.7.1 Inputs
List of inputs
Type A signal for...

Bit Reset push button on panel box 1.
Bit Start push button on panel box 1.
Bit Access push button on panel box 1.
Bit Pause push button on panel box 1.
Bit Automatic mode switch on panel box 1.

5.7.2 Outputs
List of outputs
Type A signal to...

Bit Unlock door 1.
Bit Unlock door 2.
Bit Unlock door 3.
Bit Unlock door 4.
Bit Unlock door 5.
Bit Activate green push button lamp on panel box 1.
Bit Activate yellow push button lamp on panel box 1.
Bit Activate blue push button lamp on panel box 1.
Bit Activate green light on stack light 1.

Bit Activate yellow light on stack light 1.
Bit Activate red light on stack light 1.

5.8 Safety PLC
This chapter contains a description of the interface between PLC and the safety
PLC.

5.8.1 Inputs
List of inputs
Type A signal to inform about status of...

Bit Emergency stop 1.
Bit Emergency stop 2.
Bit Emergency stop of external device.
Bit Emergency stop robot.
Bit Cell door 1.
Bit Cell door 2.
Bit Cell door 3.
Bit Cell door of external device.

5.8.2 Outputs
List of outputs
None

ABB AB
ROBOTICS
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592
3AEJ04PalletPack, Revision 2.0, en

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PalletPack Integrator Reference Manual PDF

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The information in this manual is subject to change without notice and should not be

© Copyright 2010 Asea Brown Boveri, S.A. All right reserved

© Copyright 2010 Asea Brown Boveri, S.A. All right reserved.

1 PalletPack Application 10

3 PLC Program 15

3.3.11 General_Command_Summary ....................................................................................................... 41

3AEJ04PalletPack Revision: 2.0 5

3.4.4 DataFlow .......................................................................................................................................... 73

© Copyright 2010 Asea Brown Boveri, S.A. All right reserved

5.1 Robot .......................................................................................................................................................... 112

6 3AEJ04PalletPack Revision: 2.0

5.5.1 Inputs ............................................................................................................................................. 134

3AEJ04PalletPack Revision: 2.0 7

About this manual

This manual should be used during installation, commissioning, configuration of a

Who should read this manual?

This manual is intended for:

The reader should be familiar with:

© Copyright 2010 Asea Brown Boveri, S.A. All right reserved

8 3AEJ04PalletPack Revision: 2.0

The manual is organized in the following chapters:

1. PalletPack Application Introduction to PalletPack., Bill of materials,

3. PLC Program A description of PalletPack PLC program including:

5. Interfaces Description of the interfaces of PalletPack.

PalletWare Application Manual 3AEJ04 PalletWare

ABB Control Builder CD including both AC500 and 1SAP190100R0002

1.0 First issue.

2.0 Review safety interface

3AEJ04PalletPack Revision: 2.0 9

A pre-engineered package of standard products that are brought together,

PalletPack contains 4 components:

© Copyright 2010 Asea Brown Boveri, S.A. All right reserved

PalletPack Control PLC PalletPack Safety PLC

Palletizing robot PalletWare Software

10 3AEJ04PalletPack Revision: 2.0

Structure of this chapter

This chapter lists the PalletPack bill of materials.

Product Type Quantity Description

3AEJ04PalletPack Revision: 2.0 11

The picking formats

In PalletPack every area which might be occupied for robots or machines is

Device Related to...

© Copyright 2010 Asea Brown Boveri, S.A. All right reserved

12 3AEJ04PalletPack Revision: 2.0

3AEJ04PalletPack Revision: 2.0 13

PalletWare is robot software running on the IRC5 controller for palletizing

PalletWare Application Manual.

© Copyright 2010 Asea Brown Boveri, S.A. All right reserved

14 3AEJ04PalletPack Revision: 2.0

Structure of this chapter

3AEJ04PalletPack Revision: 2.0 15

Call tree diagram

© Copyright 2010 Asea Brown Boveri, S.A. All right reserved

16 3AEJ04PalletPack Revision: 2.0

Structure of this chapter

This chapter describes the different program organization units (POU).

3AEJ04PalletPack Revision: 2.0 17

It is used to generate timing pulse variables to be used on the program as time

Processing global variables

© Copyright 2010 Asea Brown Boveri, S.A. All right reserved

18 3AEJ04PalletPack Revision: 2.0

This POU handles everything related to flows and current cycle.

Processing global variables