Robot-PLC Variable Mapping Using Auto-Generated Definition Files
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Solution Overview
Problem
The existing methods for communicating variables between a programmable logic controller (PLC) and a robot controller require manual setting of data type definitions in both devices, which is time-consuming, and are limited by the specific models of the PLC and robot that can be used.
Innovation Solution
A robot controller that includes a storage for a basic file specifying the data type of variables, a definition file generating unit to create a readable file format for the PLC, a transfer unit for periodic digital communication, and a memory allocation unit to allocate memory regions based on the data type, facilitating easy setting and communication of variables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual setting of data type definition is performed in both PLC and robot controller, then communication between PLC and robot can be established, but the setting time becomes long
Solution Approach 1:
The robot controller pre-generates a definition file containing data type definitions based on stored basic files before actual communication begins. This preliminary preparation eliminates the need for manual setting during operation, thus reducing setting time while ensuring communication reliability.
Solution Approach 2:
The robot controller creates a copy of the basic file in a PLC-readable format (definition file) and transfers it to the PLC. This copying approach allows the PLC to automatically acquire the necessary data type definitions without manual intervention, solving both the time-consuming setup and communication establishment requirements.
2Extent of automation
If dedicated communication protocol is used to transfer data type definition, then automatic transfer can be achieved, but the compatible PLC and robot models are limited
Solution Approach 1:
The robot controller generates definition files in a universal PLC-readable format that can be read by various PLC models. The basic files storing data type definitions are maintained in a model-agnostic format, allowing the same system to work with different PLC and robot combinations without requiring dedicated protocols for each model pair.
Solution Approach 2:
The system changes the format parameter of the definition file to be compatible with PLC reading requirements while maintaining the core data type information. By adjusting the file format to a widely accepted PLC-readable standard, the system achieves broad model compatibility while maintaining automatic transfer capability.
3Manufacturing precision
If manual setting of data type definition is performed, then precise control over variable communication can be achieved, but the operation complexity increases
Solution Approach 1:
The robot controller automatically generates the definition file with precise data type definitions based on stored basic files, eliminating the need for operators to manually configure each variable. The system serves itself by automatically creating the necessary communication parameters, thus maintaining precision while reducing operational complexity.
Solution Approach 2:
The definition file acts as an intermediary between the robot controller's internal basic files and the PLC's communication interface. This intermediary automatically translates and formats the data type definitions, providing precise control over variable communication without requiring the operator to directly configure complex communication parameters.
Data Source
AI summary
A control device of a robot according to the present invention stores a basic file in which the data type of variables for communicating with a PLC is defined. The control device generates, on the basis of the basic file, a definition file in which the data type of the variables is defined in a file format which can be read by the PLC. The control device is formed so as to carry out periodic digital communication for transmitting information pertaining to the variables. The control device allocates, on the basis of the data type of the variables defined in the basic file, areas for variables in an input area and an output area of a memory that is included in a storage unit.