OVRS-4A Cell Interface

Automation
OVRS-4A
Standard Robot Interface
Section A: Cell Interface
Version 1.0
February 2018
Opel Automobile GmbH
OV ME Strategy
Author(s):
Andreas Gilles — Opel Automobile GmbH Automobile GmbH /
ME PPA Automatino
Fernando de Pablo — Opel Automobile GmbH Automobile GmbH /
ME PPA Automatino
Forward questions and comments to:

Bahnhofsplatz I
Mail Code IPC 42-74
D-65423 Ruesselsheim am Main
Andreas Gilles
Document revisions:
Date Revision By Revision history
2018-02 1.0 Marcin Rydzek Initial
February 2018 OVRS-4A 1 of 31

Version 1.0 Cell Interface OVRS-4A Cell Interface.docx
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Table of Contents
1 GENERAL ................................................................................................................................. 3
1.1 Scope ...................................................................................................................................................................... 3
1.2 Purpose................................................................................................................................................................... 3
1.3 Intended Audience ............................................................................................................................................... 3
2 MODES ..................................................................................................................................... 4
3 CELL CONTROLLER INTERFACE SIGNALS ......................................................................... 5

3.1 Robot System Signals ........................................................................................................................................... 5
3.2 Signal Definitions .................................................................................................................................................. 5
3.2.1 Robot Inputs (Cell Controller Outputs) .................................................................................................. 5
3.2.2 Robot Outputs (Cell Controller Inputs) .................................................................................................. 8
3.3 Timing Charts ....................................................................................................................................................... 11
3.4 Cell Controller ........................................................................................................................................................ 0
4. ROBOT SOFTWARE REQUIREMENTS ............................................................................ 12

4.1 Mainline Shell ....................................................................................................................................................... 12
4.1.1 Home Check ......................................................................................................................................... 12
4.1.2 Housekeeping ...................................................................................................................................... 12
4.1.3 Special Functions ................................................................................................................................. 13
4.1.4 Run Style ............................................................................................................................................... 13
4.1.5 Robot Mode .......................................................................................................................................... 13
4.2 Style Programs .................................................................................................................................................... 13
4.2.1 Style Table ............................................................................................................................................ 13
4.2.2 Style Program Structure ....................................................................................................................... 13
4.2.3 Service Style Programs......................................................................................................................... 14
4.3 Programming Instructions .................................................................................................................................. 16
4.3.1 Enter Interference Zone ....................................................................................................................... 16
4.3.2 Exit Interference Zone ......................................................................................................................... 16
4.3.3 Set Path Segment ................................................................................................................................. 16
4.3.4 Request Continue ................................................................................................................................. 17
4.4 DCD programs (DCDPICK, DCDDROP) .............................................................................................................. 17
4.5 Manual Functions ................................................................................................................................................ 17
4.6 Fault and Alert Handling .................................................................................................................................... 17
4.6.1 Fast Fault Recovery .............................................................................................................................. 18

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1 General
1.1 Scope
This specification contains all I/O and software requirements associated with Opel Vauxhall’ standard robot to
cell controller interface to ensure compatibility with VS Common Controls Software OVCS-2. This specification
is for Global 3 robots only. Requirements for prior versions of global robots can be found under the archive sec-
tion of the global robot specifications page.
This specification is non-process specific. I/O and software functional requirements for individual processes
(e.g. spot welding, material handling, etc.) are contained in additional sections of ORS4.
1.2 Purpose
The ORS-4 specification documents the standard interface between robots and other purchased equipment
used by Opel Vauxhall. It is intended to complement the technical specifications that are maintained sepa-
rately for the robots and peripheral equipment in Opel Automobinle GmbHprocesses.
1.3 Intended Audience
This document is intended for robot suppliers, controls engineers involved in the design of software for the
standard robot interface, and Opel Vauxhall’ robot application software developers.

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2 Modes
1. Process Enabled/Disabled
This mode includes the ‘Process On Request’ inputs from the cell controller. In Interlock
mode, the robot shall use the status of these signals to place the process equipment in the
appropriate mode. In “Interlock” mode with “Process Off”, a “Major Fault” from the pro-
cess equipment shall not prevent execution of the robot style program.
2. Tryout
This mode indicates that no part is to be processed and that the robot shall not check the
status of part present inputs. In Interlock mode, the cell controller dictates Tryout mode
with the status of the ‘Tryout Mode Request’ bit.
3. Interlock/Isolate
Interlock and Isolate are valid modes only when the robot is in Automatic. In Interlock the
robot shall respond to initiate signals from the cell controller. In Isolate, the cell controller
will only initiate a robot as a result of a request from the robot. In Isolate, process modes
for peripheral equipment may be selected from the teach pendant.
4. Bypass Process
This mode requires the ‘Process X Bypass Request’ inputs from the cell controller. The ro-
bot must respond back to the PLC with the ProcessXBypassed bit. The PLC will hold the ro-
bot if the signals are in a mismatched state. In Bypass Process mode, the robot will ignore
the process equipment. This is intended to allow the user to bypass the process equipment
and allow the robot to continue to perform MH functions. This mode can be selected at the
HMI while the cell is in manual from the Robot Functions screen with the robot in the home
position.

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3 Cell Controller Interface Signals
3.1 Robot System Signals
There shall be no more than eight input and eight output system level signals required for proper robot opera-
tion. The vendor and Vehicle Systems shall jointly determine which 8 outputs and 8 inputs are appropriate from
among the available signals required in ORS-1.
3.2 Signal Definitions
3.2.1 Robot Inputs (Cell Controller Outputs)
1. Initiate Style Program: A signal indicating that the robot shall read and process the style and op-
tion bits.
2. Style Bits (1,2,4,8,16,32,64,128): Binary combination 8 signals indicating up to 255 styles to be de-
coded.
3. Option Bits (A,B,C,D,E): Discrete signals indicating up to three individual options of the specified
style.
4. Decision Code Bits (1,2,4,8,16,32): Binary combination of 6 signals indicating up to 63 specific oper-
ations within the style are to be performed.
5. Tryout Mode Request: A signal indicating a request to enter the Tryout mode.
6. Path Segment Bits (1,2,4,8,16,32,64,128): Binary combination of 8 bits indicates the PLC handshake
of the portion of robot path being executed. The segment will only be echoed when the conditions
are clear to move to the next segment, otherwise the value will be zero.
7. Process X On Request: A signal indicating a request to turn on process 1 or 2. When low,

the robot shall place the process 1 or 2 equipment into “off” mode.
8. Process X Bypass Request: A signal indicating a request to bypass process 1 or 2.
9. Di_TCCapsCC_Mode: (Used for weld gun tool changing only) - A signal that indicates that the gun
the robot is about to pick up already has new caps.
10. Interference Zone (1,2,3,….12) Clear To Enter: Discrete signals indicating a specific interference
zone is clear to enter.
11. Path Segment Continue: A signal indicating the robot is clear to proceed into the next path seg-
ment.
12. Equipment Remote Reset: A signal indicating a cell level reset is requested for approved equip-
ment faults such as water saver faults.

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13. Ack. Rack Complete: A signal from the PLC that acknowledges that the rack is full for racking appli-
cations or empty for unracking applications. Used for racking and unracking of parts using vision or
seek and find methods.
14. Check Rack Status: An Input from the PLC that indicates the rack needs to be rechecked due to a
perimeter guard interruption or rack exchange. Used for racking or unracking of parts using vision
or seek and find methods.
15. Next Tool ID (7-Bit Group Input): A signal containing the Tool ID code for the next recipe or style
needed at the onset of an automatic tool change. The “Next Tool ID” is a binary number between 0
and 127 that identifies the end of arm of tooling for the next recipe or die set.
16. Next Tool Type (3-Bit Group Input): A signal containing the Tool Type code for the next recipe or
style needed at the on-set of an automatic tool change. The “Next Tool Type” is a binary number
between 0 and 7 that identifies the type of end of arm of tooling for the next recipe.
17. Bypass Tool Check: A signal indicating that the robot software shall not check the Tool ID signals on
the tool side of the tool changer.
18. Bypass Side X: A signal indicating that part present sensing along with vacuum and or gripper func-
tionality on Channel X/Side X of the EOAT shall be ignored (VP Vacuum Made X on Node 36, and
Part Present X on Node 34). X represents either side 1 or side 2.
19. Fault Response Code (3-Bit Group Input): A signal containing a code for the response to unique
M/H faults from the HMI (Human-Machine Interface) through the cell controller or PLC.
20. Remote Fault Recovery: A signal indicating where the M/H fault recovery is handled. When set high
the recovery can be done remotely from the HMI, and when it is set low the recovery can be done
locally in the robot teach pendant.
21. Double Sheet Detected: A signal used in robotic destacking from the PLC indicating that the thick-
ness of the metal encountered is not equal to a preset value, which in turn indicates that double
sheets or no sheets are detected. This signal is used in conjunction with the “StackSearch” signal, to
find the top of a stack (see Stack-Search signal definition). This signal is also used to determine or
indicate that more than one sheet (or blanks) has been picked up by the robot.
22. Stack Search: A signal for detecting the top of the stack. When this bit is set high, the robot moves
from a clear point above the stack down in the Z direction, at slow speed, until the “Double Sheet
Detected” input or one or both “Part Present on Robot” signals turn high. The robot then moves
further down until the robot gets a good grip of the blank(s), and stores that position as a
Searched Pick position. In subsequent cycles where stack search is not required, the robot moves to
the Searched Pick position at regular (or maximum) speed. The Searched Pick position is updated
every cycle by subtracting the thickness of the blank that gets removed from the stack.
23. Robot Percent Override (6-Bit Group Input): A signal containing a percent value for the robot over-
ride. This percent override value is either calculated by the PLC, or manually adjusted on the fly
from the HMI. The percent override is rounded to the nearest 5%. Once the robot is at 100% speed
by the user the HMI unit can enable remote control of the speed override.

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24. New Rack X: A signal input from the cell controller indicating that a new empty rack is introduced
on side 1 (front or right side) or side 2 (rear or left side) to be inspected (for correct rack ID, rack is
open, and rack is not damaged) using machine vision.
25. Recipe Rack Type (4-Bit Group Input): A signal input from the cell controller indicating the recipe
stored rack type.
26. Current Group (3-Bit Group Input): A signal input from the cell controller that is used to specify the
current rack group in which a racking robot has to drop the next part. This signal is also used to
specify the current stack from which a destacking robot will pick the next blank(s). The cell control-
ler keeps track of the current group (group in a rack or blank stack) that is being used. The current
group may also be altered manually from the cell HMI, or in the PLC using sensory feedback for part
presence and part count.
27. Bypass New Rack Check: A signal input from the cell controller commanding the robot not to per-
form a “New Rack Check,” using machine vision, on the rack when it (the rack) is introduced to the
line.
28. Bypass Pick Vision Offset: A signal input from the cell controller commanding the robot not to ob-
tain the Pick Offset(s) from vision, for robot guidance before picking the part from the Pick station
(e.g., conveyor or centering table.) A zero offset will be applied to the robot
“move to Pick” commands that normally use the vision Pick Offset(s).
29. Bypass Pre-Drop Rack Clear Check: A signal input from the cell controller commanding the robot
not to perform a “Rack Clear Check” using machine vision, a check that is performed prior to drop-
ping a part in the rack.
30. Bypass Post-Drop Rack Clear Check: A signal input from the cell controller commanding the robot
not to perform a “Rack Clear Check” using machine vision, a check that is performed after drop-
ping a part in the rack.
31. Bypass Vision Drop Offset: A signal input from the cell controller commanding the robot not to ob-
tain the Drop Offset(s) from vision, for robot guidance before dropping the part in the
Drop station (e.g., press or conveyor). A zero offset will be applied to the robot “move to Drop”
commands that normally use the vision Drop Offset(s).
32. Number of Parts in Current Group (7-Bit Group Input): A signal input from the cell controller speci-
fying the part count in the current rack group that the robot is loading.
33. Stack Pick Position X Offset: A signal input from the cell controller commanding a linear (transla-
tional) offset of the robot Pick position by a fixed distance, in the X direction of the active robot
coordinate frame. This signal is commanded by operator through HMI buttons to manually correct
the Pick position of destacking robots due to deviations in the stack position from the nominal posi-
tion. The default offset is typically set at a fine value of 5 mm. This signal is used mainly in desta-
cking applications.
34. Stack Pick Position Y Offset: A signal input from the cell controller commanding a linear (transla-
tional) offset of the robot pick position by a fixed distance, in the Y direction of the active robot
coordinate frame. This signal is commanded by operator through HMI buttons to manually correct

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the Pick position of destacking robots due to deviations in the stack position from the nominal posi-
tion. The default offset is typically set at a fine value of 5 mm. This signal is used mainly in desta-
cking applications.
35. Stack Pick Position R Offset: A signal input from the cell controller commanding an angular (rota-
tional) offset of the robot pick orientation by a fixed angle, about the Z axis in the active robot co-
ordinate frame. This signal is commanded by operator through HMI buttons to manually correct the
pick orientation (about the vertical axis) of destacking robots due to deviations in the stack orien-
tation from the nominal orientation. The default angular offset value is typically set at 1 degree.
This signal is used mainly in destacking applications.
36. Stack Pick Position Coarse Offset: A signal input from the cell controller indicating that a coarse
value of the offset shall be applied instead of the default fine values. When set to high, the robot
uses larger offset values than if this signal is set to low. Typically, the coarse offset values are set at
25mm for linear offset and 3 degrees for angular offsets. This signal is used mainly in destacking
applications.
37. Stack Pick Position Negative Offset: A signal input from the cell controller indicating that a nega-
tive offset shall be applied. When set to high, the robot applies negative linear offsets in the X or Y
directions, or negative rotations R about the Z axis, all with respect to the active robot coordinate
frame. This signal is used mainly in destacking applications.
38. Reset Stack Pick Position Offset: An optional signal from the cell controller commanding the robot
to reset all manual offsets to the stack pick positions. When this signal is set to high, all manual
stack pick offsets are set to zero. This signal is used mainly in destacking applications.
39. Active Camera (3-Bit Group Input): An optional signal input from the cell controller indicating the
active camera that needs to be processed (e.g. calibrated or checked). This signal is used mainly
for camera calibration where only selected cameras are calibrated. Note that these bits are op-
tional and are only set for non-destacking robots that use moving cameras (e.g. on linear units.)
40. Active Camera Position (4-Bit Group Input): An optional signal input from the cell controller indi-
cating the active camera position of the active camera that needs to be processed. This signal is
typically used for calibration of moving cameras (e.g. on linear units), and is used when selected
cameras are calibrated one at a time. Note that these bits are optional and are only set for non-
destacking robots that use moving cameras.
41. Washer Cleaner Offline/Oiler Offline: Inputs indicating that equipment is offline.
42. Air Nozzle Enabled / Power Level Bits: Inputs from devices that process aluminum for metal form-
ing, both regulated and not regulated.
3.2.2 Robot Outputs (Cell Controller Inputs)
1. At Home: A signal indicating that the robot is within a user specified distance from the home posi-
tion.
2. In Cycle: A signal indicating that a style program is being performed. This signal is asserted as an
acknowledgment that a valid style has been received. This signal shall stay asserted until the style
program is complete, aborted or returned from pounce.

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3. Task OK: A signal indicating that the processing of the part is OK. This signal shall be set low upon
a style initiate as an anti tie-down measure, and it shall be asserted upon the continue from
pounce. This signal shall be set low when the process is disabled or has encountered a questionable
state (e.g. a skipped weld, continue dry).
4. Manual Style Request: A signal indicating that the cell controller shall read the manual style bits,
manual option bits and manual decision codes to determine which style is being requested from
the robot.
5. Process Equipment Not Control Stopped: A signal indicating that the process controllers for pro-
cess 1 OR process 2 are not control stopped. This output shall be low only when the “Not Control
Stopped” input from both process controllers is low.
6. Manual Style Bits (1,2,4,8,16,32,64,128): Binary combination 8 signals indicating up to 255 styles to
be requested in Isolate. In Interlock, the robot shall use these bits for style echo to the cell control-
ler. The robot shall set the outputs only from within execution of the style program.
7. Manual Option Bits (A,B,C,D,E): Discrete signals indicating a specific option under the specified
style is requested in Isolate. In Interlock, the robot shall use these bits for option echo to the cell
controller.
8. Manual Decision Code Bits (1,2,4,8,16,32): Binary combination of 6 bits indicating that a specific
operation within the style is to be performed.
9. Robot In Interlock: A signal indicating that the robot is in Interlock mode.
10. Robot In Isolate: A signal indicating that the robot is in Isolate mode.
11. Tryout Mode: A signal indicating that the robot is in Tryout mode.
12. Tool Change Cap Change Mode: A signal from the PLC that indicates that the weld gun the robot is
picking up had caps changed while in the tool change nest and to bypass the tip wear check.
13. Process X Enabled: Signals indicating that the robot has placed the process 1 or 2 equipment into
the “on” mode.
14. Process X Bypassed: Signals indicating that the PLC has requested to bypass process 1 or 2 up to
and including the communication with the process controller.
15. Process X Fault: Signals indicating that a major error has occurred within process 1 or 2.
16. Process X Alert: Signals indicating that a minor error has occurred within process 1 or 2.
17. Process X Alert 2: Signals indicating that maintenance is required on process 1 or 2

equipment.
18. Process X Out Of Tolerance: Signals indicating that process 1 or 2 has detected an out of tolerance
condition. This signal shall be used in dispense applications for indication of Process 1 Flow Meas-
urement Bypassed.

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19. Process X Equipment Message 1-24: These signals are to be used to define process specific bits
(Gun specific tip change requests, tip dresser faults, water saver faults, drum empty, head not
faulted, etc…). Each bit is redefined per type of process.
20. Servo Gun Process X Tip Replacement Request: A signal indicating that the tips for process 1 or 2
servo gun equipment need replacement based on tip wear measurement.
21. Servo Gun Approaching Tip Replacement: A signal indicating that the servo gun tips will need to
be replaced soon.
22. Fast Fault Recovery Active: A signal indicating that the Fast Fault Recovery mode is active, and
that the robot may be moving to a service location.
23. Material Handling Fault: A signal from the robot indicating that a fault has occurred within the ma-
terial handling equipment of the robot.
24. Robot Clear Of Interference Zone (1,2,3,….12): Discrete signals from the robot indicating it is clear
of the interference zone requested.
25. One Spot Welded: A signal indicating that the robot has successfully completed a weld spot in
weld mode.
26. Path Segment Bits (1,2,4,8,16,32,64,128): Binary combination of 8 bits which indicate the portion of
the robot path being executed.
27. Path Segment Request To Continue: A signal from the robot to the cell controller that requests per-
mission to continue onto the next path segment.
28. Manual Intervention Request: A signal indicating that manual intervention is required at the ro-
bot.
29. Tool Number Bits (1,2,4,8,16,32,64,128): Binary combination of 8 bits indicating which gun is at-
tached to the tool changer.
30. Tool Present in Nest 1: A signal output to the cell controller indicating that a tool is present in Nest 1
(typically the nest that is close to the robot.) The tool present status is determined using machine
vision.
31. Tool Type in Nest 1 (3-Bit Group Output): A signal output to the cell controller indicating the tool
type in Nest 1 as determined using machine vision.
32. Tool Present in Nest 2: A signal output to the cell controller indicating that a tool is present in Nest 2
(typically the nest that is far away from the robot.) The tool present status is determined using ma-
chine vision.
33. Tool Type in Nest 2 (3-Bit Group Output): A signal output to the cell controller indicating the tool
type in Nest 2 as determined using machine vision.
34. Current Tool Type on Robot (3-Bit Group Output): A signal to the cell controller containing the Cur-
rent Tool Type on the robot. This is a binary number between 0 and 7 which is assigned based on
the Tool Number that is read through node on the tool side of the tool changer (see ORS-4 Section

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E.) When node is disabled or not available, the Current Tool Type is specified by a software value
that is set at Tool Pick.
35. Vision Offset OK: A signal output to the cell controller indicating that “vision offset(s)” for pick or
drop have been successfully determined, and that the offsets are valid (i.e., within the limits, etc.)
36. Tool Present on Robot: A signal output to the cell controller indicating whether a tool is present on
the tool changer. This signal shall be high whenever any tool is detected. This signal shall be inter-
connected with the material handling signal(s), otherwise, it shall be continuously updated.
37. Robot Part Present Side X: A signal output to the cell controller indicating that a part is present on
side/channel 1 or 2 of the tool.
38. Robot Override Control Enabled: A signal output to the cell controller indicating that the robot
override control is enabled, and the conditions for the override control (100 percent override and
robot in AUTO or EXT mode) are met.
39. Application Fault Number (8-Bit Group Output): A signal output to the cell controller containing a
code to each unique application message for M/H, tool change, racking and vision faults. These ap-
plication faults shall be binary numbers between 0 and 255.
40. Robot TCP (Tool Center Point) Position (8-Bit Group Output): A signal output to the cell controller
containing the current robot TCP position in the X direction of a user defined frame which corre-
sponds to the direction of line flow. The TCP position is rounded up to the nearest
100 mm with a maximum value of 12800. The last bit is parity bit that identifies whether the TCP
value is positive or negative. This signal shall be updated in real-time at the robot highest refresh
rate.
41. New Rack Check OK: A signal output to the cell controller indicating that the “New Rack
Check” or inspection has been successfully completed for the rack(s) on side 1 (typically the front or
right side), and that the rack is validated.
3.3 Timing Charts
The following timing diagrams illustrate the relationship of the signals described in this section.

Figure 1: Single Application with No Errors
(1) Only if a decision is required

Figure 2: Style Initiation Sequence
3.4 Cell Controller
Table 1: Cell Controller Outputs/ Robot Inputs (Global 3)
Robot Input Description Signal Name

In1 System Level Signals—Robot Specific
In9 (Reserved) (Reserved)
In10 Tryout Mode Request TryoutModeReq
In11-In19 (Reserved) (Reserved)
In20 Option Bit A OptionBitA
In21 Option Bit B OptionBitB
In22 Option Bit C OptionBitC
In23 Option Bit D OptionBitD
In24 Option Bit E OptionBitE
In25 Style (Bit 1) StyleBit1
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In35 Initiate Style Program (Cycle Start) InitiateStyle
In36 Equipment Remote Reset EqptRemoteRes
In37 Interference Zone 1 Clear to Enter ClearToEntrZone1

In49 Decision code( Bit 1) DecisionCodeBit1
In50 Decision code (Bit 2) DecisionCodeBit2
In55 Cycle Stop Request CycleStopReq
In56 Path Segment Request to Continue PathSegReqToCont
In57 Path Segment (Bit 1) PathSegmentBit1
In64 Path Segment (Bit 128) for future PathSegmentBit128
In65 Process 1 On Request Process1OnReq

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In66 Process 1 Bypass Request Proc1BypassReq

In67 - In96 Process 1(Reserved) Proc1 (Reserved)
In97 Process 2 On Request Process2OnReq
In98 Process 2 Bypass Request Proc2BypassReq
In99 - In128 Process 2(Reserved) Proc2 (Reserved)
In129 - In200
(Reserved) (Reserved)
In201 di_TCCapsCC_Mode di_TCCapsCC_Mode
In202 - In208
In209 Ack. Rack Complete Ack. Rack Complete
In210 Check Rack Status Check Rack Status
In211 Vision Reserved Vision Reserved
In212 Vision Reserved Vision Reserved
In213 - In224
In225-In256 UserDefine225 - UserDefine256
Available—User Definable
In257 Next Tool ID (Bit 1) NextToolIDBit1

In265 Next Tool Type (Bit 1) NextToolTypeBit1
In268 Wait for vacuum made at Pick VacMadeAtPick
In269 Bypass Tool Check BypassToolCheck
In270 Bypass Side 1 BypassSide1
In271 Bypass Side 2 BypassSide2
In272 Other robot in Bypass OtherRbtBypass
In273 Fault Response Code (Bit 1) FltRspCodeBit1
In276 Remote Fault Recovery RemoteFltRecovry
In277 Double Sheet Detected DblShtDetected
In278 Stack Search StackSearch

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In279 Stack Search Disabled SearchDisabled

In280 Index Robot pick Position IndexRobotPick
In281 Adj Robot Override (Bit 1) AdjRobotOvrBit1
In287 Washer Cleaner Offline WasherOffline
In288 Oiler Offline OilerOffline
In289 New Empty Rack 1 NewRack1
In290 New Empty Rack 2 NewRack2
In291 - In292
In293 Recipe Rack Type (Bit 1) RecipRckTypeBit1
In297 Current Group (Bit 1) CurrentGroupBit1
In300 Bypass New Rack Vision Check BypNewRackChk
In301 Bypass Pick Vision Offset BypPickVisOffset
In302 Bypass Pre-Drop Rack Clear Check BypPreDrRkClrChk
In303 Bypass Post-Drop Rack Clear Check ByPstDrRkClrChk
In304 Bypass Drop Vision Offset BypDropVisOffset
In305 Num of Parts in Current Group (Bit 1) NumPrtCurGrpBt1
In312 Air Nozzle Enabled AirNozzleEnable
In313 Air Nozzle Power Level Bit1 AirNozzPowerBit1
In314 Air Nozzle Power Level Bit2 AirNozzPowerBit2
In315 Pick Position Manual Offset in X PickPosOffset X
In316 Pick Position Manual Offset in Y PickPosOffset Y
In317 Pick Position Manual Offset in Rz PickPosOffset R

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In318 Pick Position Manual Offset Coarse PickPosOffsetCrs

In319 Pick Position Manual Offset Negative PickPosOffsetNeg
In320 Pick Position Manual Offset Reset PickPosOffsetRst
In321 Active Camera Position (Bit 1) ActiveCamPosBit1
In325 Active Camera (Bit 1) ActiveCameraBit1
**Note: Shaded bits are for Metal Forming.
Table 2: Cell Controller / Robot Group Inputs
Signals Description Signal Name

In12 to In16 Style Style
In37 to In40 Decision Code DecisionCode
Notes:
1. In65 – In128 are reserved for process related inputs such as Tip Maintenance Request, Tip Change
Request for spot welding, Gun in Position bits for stud welding, Remote Start, Purge, and Shutdown
requests for dispense.
2. In129 – In200 reserved for future expansion of interface for additional processes, enhanced diag-
nostics and data transfers between PLC and Robot.
3. In225 – In256 can be user-defined for any inputs needed for custom applications.

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Table 3: Cell Controller / Robot Outputs (Global 3)
Description Signal Name

Robot Output
Out1 System Level Signals—Robot Specific
Out9 At Home AtHome
Out10 Tryout Mode TryoutMode
Out11 In Cycle InCycle
Out12 Robot In Interlock InInterlock
Out13 Robot In Isolate InIsolate
Out14 Manual Style Request ManualStyleReq
Out15 Equipment Not Control Stopped EqNotCtrlStopped
Out16 Task OK TaskOK
Out17 One Spot Welded OneSpotWelded
Out18 Fast Fault Recovery Active FFRActive
Out19 (Reserved) (Reserved)
Out20 Manual Option Bit A ManualOptionBitA
Out21 Manual Option Bit B ManualOptionBitB
Out22 Manual Option Bit C ManualOptionBitC
Out23 Manual Option Bit D ManualOptionBitD
Out24 Manual Option Bit E ManualOptionBitE
Out25 Manual Style (Bit 1) ManualStyleBit1

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Out33 Reserved Resevered

Out34 Simulated I/O SimulatedIO
Out35 Material Handling Fault MHFault
Out36 Material Handling Alert MHAlert
Out37 Robot Clear of Interference Zone 1 ClearOfZone1

Out49 Manual Decision code (Bit 1) ManDecCodeBit1
Out55 Manual Intervention Request ManInterventReq
Out56 Path Segment Request to Continue PathSegReqToCont
Out57 Path Segment (Bit 1) PathSegmentBit1
Out64 Path Segment (Bit 128) for future PathSegmentBit128
Out65 Process 1 Enabled Process1On
Out66 Process 1 Bypassed Process1Bypassed
Out67 Process 1 Fault Process1Fault
Out68 Process 1 Alert Process1Alert
Out69 Process 1 Alert2 Process1Alert2

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Out70 Process 1 Out of Tolerance Process1OutOfTol

Out71 Process 1 Reserved Process1Reserved
Out73 - Out96 doProc1Eq1Msg1doProc1Eq1Msg24

Process1EquipmentMessage1-24
Out97 Process 2 Enabled Process2On
Out98 Process 2 Bypassed Process2Bypassed
Out99 Process 2 Fault Process2Fault

Out100 Process 2 Alert Process2Alert
Out101 Process 2 Alert 2 Process2Alert2
Out102 Process 2 Out of Tolerance Process2OutOfTol
Out105-Out128 doProc2Eq2Msg1doProc2Eq2Msg24
Process2EquipmentMessage1-24
Out129 - Out192 (Reserved) (Reserved)
Out193 DCS Test Mode doDCSTestMode
Out194 Collision Guard Enabled doColGuardEnb
Out195 LVC Disabled doLVCDisabled
Out196 LVC Path Running in Normal Mode doLVCNormalMode
Out201 Servo Gun 1 Tip Replacement Request SG1TipChgReq
Out205 Servo Gun Approaching Tip Replacement

SGApprTipReplace
Out206 SGTorqueAlert doSGTorqueAlert
Out209 Racking Complete Racking Complete
Out210 Vision Fault Vision Fault
Out211 Vision Reserved Vision Reserved
Out212 Vision Reserved Vision Reserved
Out213-Out215 (Reserved) (Reserved)
Out216 Racking Fault RackingFault
Out217 Tool Number (Bit 1) doTCToolNumBit1

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Out225 - Out256 Available—User Definable UserDefine225 - UserDefine256
Out257 Tool Present in Nest 1 ToolPresInNest1
Out258 Tool Type in Nest 1 (Bit 1) ToolTypNest1Bit1

Out261 Tool Present in Nest 2 ToolPresInNest2
Out265 Current Tool Type on Robot (Bit 1) CurToolTypeBit1
Out268 Vision Offset OK VisionOffsetOK
Out269 Tool Present on Robot ToolPresOnRobot
Out270 Robot Part Present Side 1 RobotPartPres1
Out271 Robot Part Present Side 2 RobotPartPres2
Out272 Robot Override Control Enabled RbtOvCtrlEnbld
Out273 Application Fault Number (Bit 1) ApplFltNumBt1
Out281 Robot TCP Position (Bit 1) RbtTCPPosBit1

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Out289 New Rack 1 Check OK NewRack1CheckOK
Out290 New Rack 2 Check OK NewRack2CheckOK
Out291 Rack 1 Clear Rack1Clear
Out292 Rack 2 Clear Rack2Clear
Out293 Current Rack Type (Bit 1) CurRackTypeBit1
Out297 Advance Previous Press Auto Valve 1 AdvPrevPrsAV1

Out301 Return Previous Press Auto Valve 1 RetPrevPrsAV1
Out305 Advance Next Press Auto Valve 1 AdvNextPrsAV1
Out309 Return Next Press Auto Valve 1 RetNextPrsAV1
Out313 Clear of Pick Station ClearOfPick
Out314 Clear of Drop Station ClearOfDrop
Out315 Cycle Next Press At Drop Clear PrsCycleAtClear
Out316 Cycle Next Press At Drop PrsCycleAtDrop
Out317 Actual Pick Zone Bit1 ActPickZoneBit1
Out321 Open Air Nozzle1 OpenAirNozzle1

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Out329 Clear of Pick ClearOfPick
Out330 Actual Robot OverrideBit1 RbtOverrideBit1
Out337 Tool Change (Latch-Unlatch) Fault ToolChangeFault
Out341 Actual Translation X Offset ActualOffsetTx
Out342 Actual Translation Y Offset ActualOffsetTy
Out343 Actual Rotation Z Offset ActualOffsetRz
Out344 Actual Offset Sign ActualOffsetSign
Out345 Actual Pick Offset Bit1 ActualOffsetBit1
Out465 Top Cap Cartridge Present doTopCapCartridg
Out466 Bottom Cap Cartridge Present doBtmCapCartridg
Out467 Cap Present doCapPresentChk
Out481 - Out512 IDNS Safety Signature doIDNSSignbitsX
**Note: Shaded bits are for Metal Forming.

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Table 4: Cell Controller / Robot Group Outputs
Node address Description Signal Name

Out21 to Out26 Path Segment PathSegment
Out12 to Out16 Manual Style ManualStyle
Out37 to Out40 Manual Decision Code ManualDecCode
Out241 to Out256 User Definable UserDefinableGO
Notes:
1. Out65 – Out128 are used for process equipment messages specific to the type of process equipment.
2. Out169 – Out172 are predefined for stud applications as ‘Head 1 Not Faulted’ – ‘Head 4 Not Faulted’.
3. Out225 – Out256 can be user-defined for any outputs needed for custom applications.

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4. Robot Software Requirements
This portion of the application code is common across all processes.
4.1 Mainline Shell
The following functionality shall be preserved, but need not be implemented exactly as presented
here.
While at Home and in Automatic, the robot shall:
1. Execute the functionality described in section 4.1.1 Home Check

2. Execute the functionality described in section 4.1.2 Housekeeping
3. Execute the functionality described in section 4.1.3 Special Functions
4. Execute the functionality described in section 4.1.4 Run Style
5. Goto item #1 Above
Once the robot has completed a Style program and returned Home, it shall be capable of accepting
the next style initiate, and beginning the selected style program in no greater than 0.5 seconds.
4.1.1 Home Check
The robot shall:
1. Compare the current position of the robot with the taught home position. Calculate the diffe-
rence in position and orientation.
2. If the difference in position and orientation are within the definable limits, set ‘At Home’ sig-
nal.
3. If distance or orientation difference is greater than the definable limits, prompt the user to jog
the robot home.
4.1.2 Housekeeping
The robot shall initialize all cell controller Outputs per Table 5 below. For additional user selected I/O
initialization, a separate routine shall be provided.
Table 5: Housekeeping State

Signal(s) State
Style Bits Low
Decision Code Bits Low
Path Segment Bits Low
Manual Style Request Bits Low
FFR Active Low
Clear of Zone(s) High
Option Bits Low

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One Spot Welded Low

4.1.3 Special Functions
This routine allows the user to execute specific routines or commands from the shell loop. It shall be
possible to insert any user defined routine or programming instruction into the Special Functions por-
tion of the shell loop.
4.1.4 Run Style
1. In Automatic and Interlock, the robot shall monitor the initiate signal from the cell controller, per-
form the interface handshaking in Figure 1 and Figure 2, and call the appropriate style program.
2. If an invalid style is selected by the cell controller (i.e. not valid according to the style table configu-
ration), the robot shall indicate a fault. A fault reset shall take the robot back to the Mainline Shell.
3. In Isolate, if the robot receives an initiate for a style other than the one requested, the robot shall
indicate a fault. There are no fault recovery options for a manual style mismatch. A fault reset
shall take the robot back to the Mainline Shell.
4.1.5 Robot Mode
1. A means shall be provided to select between Interlock and Isolate line modes when the robot is in
Automatic.
2. Upon transition to Automatic, the robot shall default to Interlock mode.
3. Upon transition to T1 or T2, the robot shall default to Isolate mode.
4.2 Style Programs
4.2.1 Style Table
The robot shall have the ability to map a cell controller initiated style number to any valid robot style
program.
4.2.2 Style Program Structure
1. Program structure shall be implemented in a modular format, i.e. a “main” style program shall call
other programs for the respective parts of its task, such as part pickup 1, part pickup 2, application
process 1, application process 2, part dropoff 1 and part dropoff 2.
2. Provide a template which contains the standard logic for in-path decision making, pounce se-
quence, and any other I/O housekeeping that is required, that can be copied to the correct style
specific name for the path program. Restrict changing of the standard logic at the robot control-
ler.

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3. There shall be provisions for a common pounce to be shared between all styles, and a style specific
pounce which can be used if necessary. The corresponding return home from pounce functionality
shall be provided.
4. If a style program is selected in Teach mode and the robot is placed back in Automatic, upon com-
pletion of the style program, the robot shall return to the MAINLINE shell rather than returning to
the top of the style program.
4.2.3 Service Style Programs
The following programs shall be mapped via the style table as valid or invalid. Styles 25-49 are reserved
as service styles. Styles 25-34 are currently assigned and 35-49 are available for future service styles.
4.2.3.1 Repair (Style 31-34) Sequence
This routine executes motion to one of the four available repair positions, waits for a continue, and
then executes motion to the home position. See example code below:
1. Echo Style (31, 32, 33, or 34) to cell controller

2. SetSegment [2, 72, 74,or 76]
3. <User to program path from home to repair here>
4. wait for continue (cell controller or user input)
5. SetSegment [3, 73, 75, or 77]
6. <User to program path from repair to home here>
4.2.3.2 Cap Change (Style 27) Sequence
This routine resets steppers, water savers, and cap wear for servo guns and sets the request for tipdress
if the robot is configured to do a tipdress on cap change for all configured spot welding equipment. No
robot motion is executed in this style.
1. Echo Style 27 to cell controller

2. Set Segment [6]
3. Records cap change request per gun from cell interface.
4. Determines if gun type is Air or Servo.
5. If Air gun, skip to step 8.
6. If servo gun, cap wear is updated on all connected guns and the following is verified:
i. If the wear changes on requested guns, continue to step 7. ii. If the wear doesn’t
change on requested guns, the user is prompted if the caps were changed before con-
tinuing to step 7.
iii. If the wear changes on guns that are not requested for cap change, the user is
prompted if the caps were changed on those guns before continuing to step 7.
7. <Reset tip wear measurement on caps that were changed >
8. For air guns, check for water saver tripped or bypassed. If neither is detected, generate a fault
and prompt the user for acknowledgement prior to continuing.
9. < Resets the gun/steppers for the cap changed>
10. <Reset water savers>
11. <Request tip dress style from cell controller if “tip dress on cap change” has been configured +
Use “New Cap TD Schedule”>
12. <Reset cap change request bits>

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13. < Set Segment [0]
4.2.3.2.1 Pedestal Cap Change at the End of a Path Segment
The robot shall respond to a cap change command at any time the robot is waiting for a “Path Seg-
ment Continue”. Decision code 14 has been allocated for this purpose. This routine resets steppers,
resets water savers and sets the request for tipdress if tipdress on cap change has been configured.
1. Records cap change request per gun from cell interface.

2. Determines if gun type is Air or Servo.
3. If Air gun, skip to step 6.
4. If servo gun, cap wear is updated on all connected guns and the following is verified:
i. If the wear changes on requested guns, continue to step 5.
ii. If the wear doesn’t change on requested guns, the user is prompted if the caps were
changed before continuing to step 5.
iii. If the wear changes on guns that are not requested for cap change, the user is
prompted if the caps were changed on those guns before continuing to step 5.
5. <Reset tip wear measurement on caps that were changed >
6. For air guns, check for water saver tripped or bypassed. If neither is detected, generate a fault
and prompt the user for acknowledgement prior to continuing.
7. < Resets the gun/steppers for the cap changed>
8. <Reset water savers>
9. <Request tip dress style from cell controller if “tip dress on cap change” has been configured +
Use “New Cap TD Schedule”>
10. <Reset cap change request bits>
11. RequestContinue
4.2.3.3 Purge Sequence (Style 29 for Dispense Process 1, Style 30 for Dispense Process 2)
This routine shall be programmed by the user for implementation of an automatic material purge oper-
ation for dispensing systems.
1. SetSegment [4(Process 1) or 5 (Process 2)]

2. <user to program a path from home to purge position here>
3. Purge
4. <user to program a path from purge position to home here>
5. SetSegment [0]
4.2.3.4 Tip Cleaning Style Sequence
This routine shall be programmed by the user for implementation of tip dressing for spot welding ro-
bots.
1. SetSegment [4(Process 1) or 5 (Process 2)]

2. <User to program path from home to tip dress position here or advance dump for pedestal(s)>
3. Start TDMotor
4. TipDress [gun#X] 5. StopTDMotor
6. If adaptive welding capable, perform a resistance check.
7. <User to program path from tip dress to home here or retract dump for pedestal(s)>

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8. <Automatically initiate tip wear measurement for servo guns>

9. SetSegment [0]
4.2.3.5 Automatic Brake Check (Style 25)
This routine shall initiate the robots internal brake check functionality when commanded by the cell
controller. This routine shall only function in Auto mode.
1. Echo Style 25 to cell controller

2. SetSegment [8]
3. Run Brake Check Function
4. Acknowledge failure result if appropriate
5. Increment counter register
6. SetSegment [0]
4.2.3.6 Tool Changer Tool Exchange (Style 26)
This routine shall be programmed by the user for exchanging tools in nests for tool changer applica-
tions.
4.3 Programming Instructions
4.3.1 Enter Interference Zone
Actions:
1. Reset LeavingZone#
2. Post the message “Waiting for Interference Zone <Zone #> Clear to Enter” on the teach pen-
dant
3. Wait for Zone#Clear to be set by the cell controller
4. Post the message “Robot in Interference Zone <Zone #>” on the teach pendant
4.3.2 Exit Interference Zone
Actions:
1. Set LeavingZone#
2. Post the message ”Robot Clear of Interference Zone <Zone #>” on the teach pendant.
4.3.3 Set Path Segment
A means shall be provided to guarantee this instruction is executed within a programmable distance of
the preceding programmed position regardless of programmed termination type.
Actions:
1. Set PathSeg equal to Segment #

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2. Reset PathSegReqToCont
3. Post the message: ”Entering Path Segment <Segment #>” on the teach pendant
4.3.4 Request Continue
A means shall be provided to execute this instruction within a programmable time of reaching the pre-
ceding programmed position such that path program hesitation can be eliminated. If the Continue OK
indication is not received, path motion shall stop at the programmed position regardless of the pro-
grammed termination type. These requirements for Request Continue shall work in conjunction with
the requirements for Set Segment when programmed in succession.
Actions:
1. Reset PathSegReqToCont
2. Wait for PathSegContOK to be reset.
3. If path segment select from cell interface is equal to robot path segment output, the cell con-
troller has granted the look ahead. Skip to 7.
4. Set PathSegReqToCont
5. Post the message ”Waiting for Continue” on the teach pendant
6. Wait for PathSegContOK to be set by the cell controller
7. Capture DecisionCode and echo to cell controller via ManDecisionCode
8. Post the message “Decision Code <DecisionCode> Received” on the teach pendant 9. If Deci-
sionCode is 12, remote start and purge pedestal dispensers and return to the step 1.
10. DecisionCode is 13, performs inspection dress for all configured pedestal guns and return to
the step 1.
11. If DecisionCode is 14, cap change, then execute the pedestal cap change functionality, (see
section 4.2.3.2.1, Pedestal Cap Change ) and return to the step 1.
12. If Decision Code is 15 and the robot is in path segment 1, preform Return Home from Pounce.
4.4 DCD programs (DCDPICK, DCDDROP)
These routines shall only be called after a Request Continue. It shall be programed to call a program
based on a valid Decision Code captured during the Request Continue. Invalid Decision Codes should
display an error message and Request Continue. If in teach, the user shall be prompted to enter a valid
decision code.
4.5 Manual Functions
A means shall be provided to select the Interlock and Isolate modes while the robot is in Automatic.
4.6 Fault and Alert Handling
1. Upon the detection of a major fault (either by the process equipment or by the robot application
package), the robot shall:
a. Assert the ‘Process # Fault’ signal to the PLC

b. When in ‘interlock’ mode with ‘Process On Request’ input from the cell interface on, halt ro-
bot motion and process

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c. Display and indicate the major fault(s) and recovery options on the teach pendant d. Log
the faults
2. Faults and alerts shall be handled on a first-come first-served basis.
3. A fault shall occur when the expected handshaking between the robot controller and peripheral
equipment is disrupted.
4. For material handling faults, user shall be presented with the option of disabling the checking of
the input signal that caused the fault for a maximum of 20 job cycles. When selecting the disable
checking mode, the MH Alert bit is sent to the PLC.
5. Remote recovery shall be available for process faults, waiting for the correct state of a proximity
sensor / cylindicator input, such as part present, clamp or gun retract. The remote recovery option
shall retry the action or retest the fault condition upon receiving a robot specific system input from
the cell controller. Remote recovery shall not be available for some functions, which could result in
equipment damage, such as stud weld faults. These cases are explicitly stated in the process sec-
tions of ORS-4.
4.6.1 Fast Fault Recovery
An FFR option shall be presented for process faults that occur during style execution. Upon selecting the FFR
option, the robot shall move through the programmed path in no-process mode (see Table 6) to a user de-
fined position clear of the tooling. Once the fault has been corrected, the robot shall re-run the taught path
and complete the process. During FFR, the robot shall set the ‘FFRActive’ output on the cell interface. The
specific functionality is explicitly stated in the process sections of ORS-4.
Table 6: ‘No-Process’ Modes

Application FFR Application Mode Comments
Spot welding No-stroke & No-weld Activate Retract normally, as per program in-
structions
Dispensing Rerun (Wet) or Accept Part The FFR prompt for dispense shall be presented
to the user after the path is finished.
Stud welding No-stroke & No-weld
Arc welding No-weld & No-weave
4.6.1.1 Recovery Sequence
It shall be possible for the user to implement FFR for an entire process or for individual segments of a
process path. FFR for either dual carried or dual pedestal processes shall be supported for each pro-
cess independently. For a combination of material handling with a carried process, FFR shall be sup-
ported whether material handling occurs before or after the process.


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OVRS-4A Cell Interface

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February 2018 OVRS-4A 1 of 31

3 CELL CONTROLLER INTERFACE SIGNALS ......................................................................... 5

4. ROBOT SOFTWARE REQUIREMENTS ............................................................................ 12

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1.3 Intended Audience

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3 Cell Controller Interface Signals

3.1 Robot System Signals

3.2 Signal Definitions

3.2.1 Robot Inputs (Cell Controller Outputs)

7. Process X On Request: A signal indicating a request to turn on process 1 or 2. When low,

8. Process X Bypass Request: A signal indicating a request to bypass process 1 or 2.

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3.2.2 Robot Outputs (Cell Controller Inputs)

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9. Robot In Interlock: A signal indicating that the robot is in Interlock mode.

17. Process X Alert 2: Signals indicating that maintenance is required on process 1 or 2

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3.3 Timing Charts

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(1) Only if a decision is required

3.4 Cell Controller

Table 1: Cell Controller Outputs/ Robot Inputs (Global 3)

Robot Input Description Signal Name

In27 Style (Bit 4) StyleBit4

In46 Interference Zone 10 Clear to Enter ClearToEntrZone10

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In66 Process 1 Bypass Request Proc1BypassReq

In260 Next Tool ID (Bit 8) NextToolIDBit8

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In279 Stack Search Disabled SearchDisabled

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In318 Pick Position Manual Offset Coarse PickPosOffsetCrs

Table 2: Cell Controller / Robot Group Inputs

Signals Description Signal Name

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Table 3: Cell Controller / Robot Outputs (Global 3)

Description Signal Name

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Out33 Reserved Resevered

Out37 Robot Clear of Interference Zone 1 ClearOfZone1

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Out70 Process 1 Out of Tolerance Process1OutOfTol

Out73 - Out96 doProc1Eq1Msg1doProc1Eq1Msg24

Out99 Process 2 Fault Process2Fault

Out205 Servo Gun Approaching Tip Replacement

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Out221 Tool Number (Bit 16) doTCToolNumBit16

Out260 Tool Type in Nest 1 (Bit 4) ToolTypNest1Bit4

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Out288 Robot TCP Position (Bit 128) RbtTCPPosBit128

Out299 Advance Previous Press Auto Valve 3 AdvPrevPrsAV3

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Out323 Open Air Nozzle3 OpenAirNozzle3

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Table 4: Cell Controller / Robot Group Outputs

Node address Description Signal Name

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