AAM 5ref 151 10 Robot Integration

Equipment Specification Manual (ESM) – Special Machines (Type C)
SECTION 10
ROBOT INTEGRATION
TABLE OF CONTENTS
10.1 GENERAL ............................................................................................................................... 1

10.1.1 Purpose ........................................................................................................................................................... 1
10.1.2 Robot selection................................................................................................................................................ 1
10.1.3 Scope ............................................................................................................................................................... 1
10.1.4 Supplier Support Requirements ...................................................................................................................... 1
10.2 MECHANICAL UNIT REQUIREMENTS ....................................................................................... 2
10.2.1 Working Environment ..................................................................................................................................... 2
10.2.2 Mechanical Drives: .......................................................................................................................................... 2
10.2.3 Work Space ..................................................................................................................................................... 3
10.2.4 Mechanical Space Requirements .................................................................................................................... 4
10.2.5 Payload ............................................................................................................................................................ 4
10.2.6 Repeatability ................................................................................................................................................... 4
10.2.7 Collision Detection .......................................................................................................................................... 5
10.2.8 Mounting Flexibility:........................................................................................................................................ 5
10.2.9 Transportation ................................................................................................................................................. 5
10.2.10 End Effectors (End of Arm Tooling - EOAT) ..................................................................................................... 5
10.2.11 Serviceability ................................................................................................................................................... 5
10.2.12 Preventive Maintenance ................................................................................................................................. 6
10.2.13 Robot Anchoring.............................................................................................................................................. 6
10.3 CONTROL UNIT REQUIREMENTS ............................................................................................. 6
10.3.1 Input Power ..................................................................................................................................................... 6
10.3.2 Working Environment ..................................................................................................................................... 6
10.3.3 Expandability ................................................................................................................................................... 6
10.3.4 User Interface .................................................................................................................................................. 6
10.3.5 Memory ........................................................................................................................................................... 6
10.3.6 Networking Communications .......................................................................................................................... 7
10.3.7 Servo Amplifier ................................................................................................................................................ 7
10.3.8 Mounting Flexibility ......................................................................................................................................... 7
10.4 SOFTWARE REQUIREMENTS ................................................................................................... 7
10.4.1 Languages and Environments ......................................................................................................................... 7
10.4.2 Ease of Teaching .............................................................................................................................................. 9
10.4.3 Program and Position Testing and Debugging ................................................................................................ 9
10.4.4 Power Failure Recovery ................................................................................................................................. 10
10.5 GENERAL ROBOT REQUIREMENTS ........................................................................................ 10
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10.5.1 Forging Robot Specifications ......................................................................................................................... 10

10.5.2 Welding Robot Specifications ........................................................................................................................ 11
10.6 SAFEGUARDED SPACE REQUIREMENTS ................................................................................. 11
10.6.1 General Safeguarded Space Requirements ................................................................................................... 11
10.6.2 Safeguarded Space Layout ............................................................................................................................ 11
10.6.3 Perimeter Guarding ....................................................................................................................................... 11
10.7 SYSTEM SAFETY INTERLOCK REQUIREMENTS ........................................................................ 12
10.7.1 General Interlock Requirements ................................................................................................................... 12
10.7.2 Definition of Terms ........................................................................................................................................ 12
10.7.3 General Robot Integration Communication .................................................................................................. 13
10.7.4 Hardwired Safety Circuits – Emergency Stop Integration ............................................................................. 13
10.7.5 Hardwired Safety Circuits – Safety Gate Integration..................................................................................... 14
10.7.6 Hardwired Safety Circuits - External Equipment Cell Access ........................................................................ 14
10.7.7 Hardwired 24VDC Integration – Connectors and Wiring .............................................................................. 14
10.7.8 Programming Safety Precautions .................................................................................................................. 15
10.8 CODE DEVELOPMENT GUIDELINES ........................................................................................ 15
10.8.1 Code Structure .............................................................................................................................................. 15
10.8.2 Motion ........................................................................................................................................................... 16
10.8.3 Start Method ................................................................................................................................................. 16
10.8.4 I/O.................................................................................................................................................................. 16
10.8.5 Robot Input/Output Signals To/From PlC...................................................................................................... 17
10.8.6 Mastering/Robot Calibration ........................................................................................................................ 18
10.8.7 Speed Override .............................................................................................................................................. 18
10.8.8 Path Segments ............................................................................................................................................... 19
10.8.9 Resume/Recovery ......................................................................................................................................... 20
10.8.10 Full Recovery ................................................................................................................................................. 20
10.9 PROGRAM CONTROL............................................................................................................ 22
10.9.1 PLC Control Programming Actions ................................................................................................................ 22
10.9.2 Robot Interface with PLC ............................................................................................................................... 22
10.9.3 Robot Gripper Operation .............................................................................................................................. 23
10.9.4 Fault Code Handling/Messages ..................................................................................................................... 23
10.9.5 HMI Manual Robot Page ............................................................................................................................... 23
10.10 ROBOT INTEGRATION WITH EXTERNAL EQUIPMENT ............................................................. 23
10.10.1 Process Interlock Signals - General................................................................................................................ 23
10.10.2 Process Interlock Signals – Discrete Wiring ................................................................................................... 23
10.10.3 Process Interlock Signals - Discrete Wiring over Distributed I/O .................................................................. 24
10.10.4 Process Interlock Signals – Produced Consumed Model Wiring ................................................................... 24
10.10.5 Process Interlocks and Definitions ................................................................................................................ 24
10.10.6 Other Integration Considerations ................................................................................................................. 25
10.10.7 Integrated Equipment Documentation ......................................................................................................... 26
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ROBOT INTEGRATION
10.1 GENERAL
10.1.1 PURPOSE
The purpose of this section is to provide a standardized guide for the selection and application
of industrial robots and robot controllers. An Industrial robot as defined by ISO 8373:
An automatically controlled, reprogrammable, multipurpose manipulator programmable in
three or more axes, which may be either fixed in place or mobile for use in industrial
automation applications.
 Reprogrammable: whose programmed motions or auxiliary functions may be changed
without physical alterations;
 Multipurpose: capable of being adapted to a different application with physical
alterations;
 Physical alterations: alteration of the mechanical structure or control system except for
changes of programming cassettes, ROMs, etc.
 Axis: direction used to specify the robot motion in a linear or rotary mode
10.1.2 ROBOT SELECTION
The Supplier shall select a robot based on the environment and application. AAM approval of
robot manufacturer and model is required. AAM reserves the right to provide the selected
robot to the Supplier for integration.
10.1.3 SCOPE
This section includes specifications for robots and robot systems. Robot systems include the;
robot, end-effectors (or end of arm tooling, EOAT), and all other machinery, equipment,
devices, external auxiliary axes or sensors supporting the robot performing its task. Specific
applications, EOAT, and safety requirements shall be considered during the selection process.
Application areas that this section may be applied to include:
 Materials handling or assembly process robots
 Welding robots
 Paint, adhesive or sealant application robots
10.1.4 SUPPLIER SUPPORT REQUIREMENTS
10.1.4.1 Systems Integration Capability. The Supplier shall have in house or subcontract staff that is
familiar and experienced with industrial robot systems integration and robot end-effector
design.
10.1.4.2 Robot Programmers. The Supplier robot programmers shall be certified as trained by the
robot manufacturer or other certification organization, and be familiar with the selected
robots.
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10.1.4.3 Robot Simulation. Simulation of major motions, reach studies, time studies shall be included
as part of the AAM design approval process. Full program simulations may be required if
identified in the AAM RFQ, or if recommended by the Supplier. The extent of proposed
simulation shall be included in the Supplier’s proposal.
10.1.4.4 Documentation. The documentation requirements of Section 6 and Section 11 apply to the
robot system. The documentation for robot systems shall include a space study and
documentation as described in 10.2.3 Work Space, 10.2.4 Mechanical Space Requirements,
and 10.6 Safeguarded Space Requirements. Software unique to the application shall be
confirmed and approved by the AAM Controls Engineer.
10.1.4.5 Training. The training requirements of Section 4 apply to the robot system. The training
documentation shall include specific considerations of the integrated robot system.
10.2 MECHANICAL UNIT REQUIREMENTS

The selected industrial robot shall be approved by the AAM Lead Manager for all applications.
10.2.1 WORKING ENVIRONMENT
The robot system shall be selected to withstand the AAM facility environment considering
temperature, humidity, adjacent processes, lighting, etc. The selection should include
anticipated redeployment or future use for the selected robot. Following are minimum
environmental requirements.
10.2.1.1 Temperature. All robots and EOAT shall withstand an ambient temperature range of 0 - 45°C
(32 - 113°F) without supplementary devices (e.g. motor cooling fans).
10.2.1.2 Humidity. All robots and EOAT shall withstand up to 75 % relative humidity (non-condensing)
under normal conditions and up to 95 % relative humidity (non-condensing) for periods less
than one (1) month.
10.2.1.3 Intrusion Protection. All robots and EOAT shall be selected based on the application
environment including consideration of liquid intrusion (e.g. die casting, investment casting,
and water-jet cutting), air borne particles (e.g. de-burring and de-flashing), heat (e.g. forging),
or other application specific environment constraints. Robots shall include appropriate Index
of Protection (IP) rating as defined by the International Electromechanical Commission (IEC).
The IP rating shall be applied to the mechanical unit, cables leading from the controller to the
robot, and controller. The preferred solution is that the selected robot complies with the IP
rating without secondary protection devices such as protective boots and covers.
10.2.1.4 Vibration. Robots shall withstand up to 4.9 m/s2 (0.5 g) rms vibration level at the mounting
interface.
10.2.2 MECHANICAL DRIVES:
10.2.2.1 Motors. All robots shall use electricity as their primary motive power source. Electric motors
shall be capable of heat dissipation without secondary systems for 100 % of the design duty
cycle. All drive motors shall:
 Be sealed from external contamination (no frameless motor types).
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 Be maintenance-free.
 Be self-cooled.
 Be brushless AC.
 Have integrally mounted pulse encoder.
 Have integrally mounted brake.
 Be as short in length as possible to minimize movement restrictions or to increase robot
density.
 Not exhibit cogging at slow speeds.
10.2.2.2 Feedback Devices. Each robot shall retain position in the event of unanticipated loss of power.
Positional data shall be retained if a robot axis is manually repositioned with power off.
Robots shall not require calibration at power-up, pulse encoders shall be absolute optical type.
Battery-backed positioning memory shall last at least one (1) year without line power.
10.2.2.3 The robot selection should consider the application and the requirements for transmission of
motion at maximum payload that includes;
 Position accuracy appropriate for the application
 Minimal backlash
 Minimal payload vibration
 High duty cycle
 Rigid mechanisms
 High endurance against shock loads
10.2.2.4 Brakes. All axes (vertical, horizontal, rotational, etc.) shall include fail safe (apply with loss of
power) electrically actuated mechanical brakes, the brakes shall engage automatically with any
loss of power. All brakes shall be capable of manual release or manual movement if main
power is lost. Brakes shall be capable of stopping motion at full speed at full payload at full
extension to comply with the safety requirements of the application.
10.2.3 WORK SPACE
10.2.3.1 Maximum Reach. The reach capability of the robot should exceed the operating requirements
of the application with adequate margin to accommodate changes during development.
10.2.3.2 Axis Limits. All major axes shall have mechanical axis limiting devices that include both
hardwired limit switches and hard-stops. The mechanical axis limit devices define the three
dimensional Restricted Space. Mechanical axis limiting devices shall be provided by the robot
manufacturer and mounted per manufacturer recommendations. The restricted space should
be minimized and consider all safety requirements and robot damage.
10.2.3.3 Axis limit devices shall be provided by the robot manufacturer, collision detection, guarding, or
other devices shall not be used as motion limiting devices that define the restricted space.
10.2.3.4 The use of non-mechanical safety rated motion limiting devices requires AAM approval.
10.2.3.5 All axes (major and minor) shall have user-settable software limits.

10.2.4 MECHANICAL SPACE REQUIREMENTS

The Robot installation drawing shall include a three dimensional identification of the
Maximum Space, Restricted Space, and Operating Space for each application (reference the
following definitions). The representation shall include the robot, end effector, and gripped
part in a position that defines the maximum envelope. The restricted space is defined where
the robot motion actually stops, not by where a stop is initiated.
Maximum Space: Space which can be swept by the moving parts of the robot as defined by
the manufacturer, including the end-effector, workpiece, festooning, and any other
components attached.
Restricted Space: Space within the maximum space that can be swept by the moving parts of
the robot restricted by limiting devices (axis stops), including the end-effector, workpiece,
festooning, and any other attached components in motion.
Operating Space: Space within the restricted space that represents programmed motions for
the operation, including the end-effector, workpiece, festooning, and any other attached
components in motion.
Safeguarded Space: Space defined by the perimeter and other (integrated equipment) safety
guarding.
10.2.5 PAYLOAD
10.2.5.1 All payload calculations shall be based on the combined weight of all moving components at
maximum weight including the work pieces, end-effectors, valves, clutches, etc. The robot
shall provide adequate payload margin to accommodate development changes. The payload
dynamic and static loads, calculated at maximum speed and acceleration, shall not exceed the
manufacturer specifications on any axis.
10.2.5.2 The moments of inertia shall be calculated based on the combined inertia of all moving
components at maximum material condition including the work pieces, end-effectors, valves,
clutches, etc. with the maximum center of gravity distance from the axis evaluated. The
moments of inertia dynamic loads, calculated at maximum speed and acceleration, shall not
exceed the manufacturer specifications on any axis. The robot shall provide adequate
moment of inertia margin to accommodate development changes.
10.2.5.3 Secondary Equipment Mounting Points shall utilize robot manufacturers drilled and tapped
mounting points in their castings for secondary equipment (e.g. pneumatic valve packages for
end-effectors). Secondary equipment that is in motion shall be included in all payload and
inertia calculations. Where physical packaging constraints permit, the secondary equipment
may be mounted on the furthest joint with the EAOT.
10.2.6 REPEATABILITY
All robots shall meet or better the repeatability requirements of the application. Repeatability
figures shall be in accordance with industry accepted conventions, for example ISO, JISB 6330,
and JISB 8432.

10.2.7 COLLISION DETECTION

The Robot shall include collision detection (overcurrent or sensors) capable of detecting and
interpreting excessive force, and automatically stopping the motion and relaxing the force at
the obstruction. Collision detection shall not be applied as a motion limit method.
10.2.8 MOUNTING FLEXIBILITY:
Robot mounting shall minimize the floor space required, optimize path trajectory, ease service
or preventative maintenance, and minimize installed cost. The selected robot model shall be
operable in the applied mounting orientation, and mounted per the manufacturer’s
recommendations. Preference should be given to robot models that can be installed in more
than one mounting configuration. The Supplier shall consider; payload, speed, lubrication
requirements, and other specifications on a particular robot model and include robot
manufactured options as required. Wrist faceplates shall conform to ISO standards.
10.2.9 TRANSPORTATION
Robots shall have lifting eyebolts or forklift pockets clearly marked for transportation and
installation. The robot shall be prepared for shipment per the manufacturer
recommendations with end-effectors removed as required.
10.2.10 END EFFECTORS (END OF ARM TOOLING - EOAT)
End Effectors should be designed as light weight rigid structures. The design shall consider the
maximum speed and emergency stop conditions for work-piece retention. The end effector
design shall include part presence sensing, and part clamped and unclamped detection. All
cables and fluid connections shall include cable management through the full range of motion.
End-effectors and the control system design shall be such that:
 Any loss or change in the delivered energy (e.g. electrical, pneumatic, etc.) does not
allow release of the payload.
 Wrist mounting and EOAT properly align and are securely retained with locking
fasteners.
 Removable or detachable tools are securely retained under all motion conditions.
 Any detachable (tool exchange) action is restricted to specific locations with conditions
controlled.
 If safety is not compromised, the end effector power should be available without robot
motion for troubleshooting.
10.2.11 SERVICEABILITY
All robots shall have easily removable access panels for normal servicing convenience (an
exception applies to clean room units). All intra-arm cabling that connects major components
shall be labeled and use quick disconnects.

10.2.12 PREVENTIVE MAINTENANCE

The selected restricted space shall consider access for maintenance of the robot and end
effectors without the removal of axis limiting devices. If hour tracking is required, tracking
shall measure servo-energized time (not power-on time) and may be tracked in the controller.
All lubrication points shall be clearly identified and accessible. (This includes proper PM
instructions from robot manufacturer for lubrication.)
10.2.13 ROBOT ANCHORING
Floor mounted robots shall be provided with a separate mounting plate or riser. The supplier
shall define the foundation requirements and define all anchoring requirements based on the
full reach and speed capacity of the robot.
10.3 CONTROL UNIT REQUIREMENTS

10.3.1 INPUT POWER
All input supply shall include a separate dedicated disconnect and accommodate the following
range based on the AAM facility requirements:
 380/415/480 VAC +10, -15 % three-phase
 50 or 60 Hz, +1 Hz
10.3.2 WORKING ENVIRONMENT
All controllers shall comply with Section 10.2.1. Controller enclosures and teach pendants
shall be designed to provide an adequate degree of protection indoors against dust, falling
dirt, and dripping non-corrosive liquids in the spirit of NEMA Standard 250 Type 12.
10.3.3 EXPANDABILITY
All controllers shall be expandable in anticipation of future needs. Expansion can take on
many forms, but typically the controller should have an available auxiliary side cabinet or
expandable modular I/O.
10.3.4 USER INTERFACE
All robots shall be supplied with a teach pendant. The teach pendant shall employ a three (3)-
position enabling device.
10.3.5 MEMORY
Internal memory may use any combination of DRAM, FROM, or CMOS, but system software,
system variables, and user files shall reside in static memory, whereas working memory may
be dynamic. Battery-backed memory shall last at least one (1) year with line power removed.
Bubble memory is unacceptable. Memory shall accommodate 1,000 user locations in standard
configuration.
10.3.5.1 All controllers shall interface with an external device for the backing-up of files, e.g. PCMCIA
card, USB port, dedicated disk drive, Windows® compatible PC. Bubble memory and tape
drives are unacceptable.

10.3.5.2 Controllers shall be able to upload and download files during program execution. The
controllers shall have software capability to create backup image of whole controller.
10.3.6 NETWORKING COMMUNICATIONS
10.3.6.1 Ethernet. All controllers shall have at least one (1) Ethernet port standard, with additional
ports available optionally.
10.3.6.2 RS-232. All controllers shall have at least one (1) RS-232 port available.
10.3.6.3 Third-Party Product Networking. All controllers shall be able to support EtherNet/IP.
 EtherNet/IP is ODVA conformance approved and AAM performance approved. All other
field buses shall be approved by the assigned AAM Controls Engineer.
10.3.6.4 Input/Output - User Configurable: All controllers shall offer a user-configurable I/O
system that permits:
 Analog I/O to provide access to data with input/output voltages within a certain range.
 Digital I/O to provide access to data on a single input or output line.
 Group I/O to provide access to data on multiple input or output signal lines concurrently.
 Robot end-effector I/O to provide access to data on the end-effector specific connector.
 Standard operator panel I/O.
 User operator panel I/O to provide data access by a remote device, for example, a remote
operator panel for control of the robot - eighteen (18) inputs minimum, twenty-four (24)
outputs minimum.
 PLC I/O to permit the transfer of I/O signal status information to and from PLCs.
 Remote mounting up to 100 m (328 ft.).
10.3.6.5 Input/Output - Process-Specific. For certain non-I/O intensive applications, process-specific
I/O may be used.
10.3.7 SERVO AMPLIFIER
Servo amplifiers shall:
 Be digitally controlled (not analog)
 Have a user-adjustable time-out feature
10.3.8 MOUNTING FLEXIBILITY
Robot connection cables shall:
 Be at least 7 m (23 ft.) long standard
 Be labeled at both ends
 Be water and corrosion resistant
 Use quick disconnects at the robot end
10.4 SOFTWARE REQUIREMENTS
10.4.1 LANGUAGES AND ENVIRONMENTS

10.4.1.1 Software. Software shall be available in packages tailored for specific application areas. For
example, a material handling software package shall be available that would be applicable in

most material handling, material removal, and assembly applications. Counterpart packages
include arc welding, dispensing, painting, spot welding, etc. Each package shall be designed
for ease of use by employing menu-driven prompts in terminology and techniques specific to
the respective application area. Each package shall have a common, underlying environment,
have a similar look and feel to minimize operator training between packages, and assist the
user to:
 Set up the information required for the application.
 Program the application.
 Test the program.
 Run production.
 Display and monitor process information.
10.4.1.2 Program Environment. When application-specific packages are not appropriate or powerful
enough, a programming environment capable of handling virtually any robotic application is
permitted with AAM Controls Engineer approval. This form of high-level programming
language uses symbols and descriptive command statements an operator can read. Other
distinguishing characteristics from the application-specific packages should include the
capability for:
 At least sixteen (16) axes of control
 Multi-user operating system to allow execution of at least four (4) concurrent users
 User-defined associated data for path motions
 File data types with built-in utility routines
 User-defined data structures
 Controls structures for loops and branch selections
 Procedure and function routines
 Real-time input or output monitoring via local or global condition handlers
 Calculated positioning
 Read and write to the teach pendant
 Relative position operations
 Discrete point-to-point and continuous-path motion types
 Interference check and space check options for multiple robots in one (1) cell operation
 Built-in dictionary and associated utility routines (help application to define robot function
etc.)
 Automatic error logging and retrieving
 Written AAM Controls Engineer approval is required for use of internal robot PLC
functionality
10.4.1.3 Capability. Either the application-specific packages or the high-level programming
environment capable of performing a series of instructions, constructs for conditional
statement execution, positional motion, arithmetic, comparative logic, looping, nested or
recursive routines, and multi-tasking operations, etc.
10.4.1.4 Program Editing.

 On-line. All controllers shall allow on-line editing via the teach pendant. All controllers
shall allow programs to be edited and positional data modified during program execution.
 Write Protection. All controllers shall have a software lockout that prevents unauthorized
editing of on-line application programs.
 Off-line. Software packages for programming and point teaching off-line shall exist.
These packages shall consist of program code creation and editing on a Windows®
compatible PC and three (3)-dimensional interactive graphics simulation on a Windows®
compatible PC.
10.4.2 EASE OF TEACHING
10.4.2.1 Position. All controllers shall automatically create templates that have default parameters for
each motion position taught. These parameters include:
 Motion type (joint, linear, circular).
 Position type (position or position register).
 Automatic position number.
 Speed (expressed in percentages, in./min, deg/sec, mm/sec, cm/min, sec)
 Termination type (graduated from a full deceleration / stop / reacceleration to no
deceleration).
 Acceleration control.
 Each parameter shall be settable independently.
10.4.2.2 Frames. All controllers shall support four frame types: world, tool, user, and jog.
Requirements are as follows:
 World Frame: Default frame of robot which is unique and cannot be changed.
 Tool Frame: A user defined frame that has the tool center point at its origin; up to five (5)
different tool frames may be created and stored in memory; shall be creatable by simply
teaching three (3) approach points to define location, simply teaching three (3) location
and three (3) orientation points to define direction vector, or by direct numerical entry
when data are available.
 User Frame: A user defined frame that is the reference frame for all recorded positional
data in a program; up to five (5) different user frames may be created and stored in
memory; shall be creatable by simply teaching three (3) approach points to define
location, simply teaching three (3) location and one origin points to define the reference
of the frame, or by direct numerical entry when data are available.
 Jog Frame: A user-defined frame for use in non-orthogonal jogging; multiple jog frames
may be created and stored in memory; up to five (5) different jog frames may be created
and stored in memory; shall be creatable by simply teaching three (3) points to denote the
origin and plane of the frame, or by direct numerical entry when data are available.
10.4.3 PROGRAM AND POSITION TESTING AND DEBUGGING
Testing and debugging are essential during the programming and position teaching phase in
order to validate logic and motion. Production should commence only after thorough testing,

debugging, and validation. All controllers shall have the following testing and debugging
capabilities:
10.4.3.1 Single Step. This technique permits running individual program instructions one (1) at a time.
Single step testing can be done two (2) ways:
 Forward executes one (1) instruction or subprogram one (1) step at a time in the forward
flow of the program.
 Backward executes the preceding motion instruction one (1) step at a time.
10.4.3.2 Routine. This technique permits running individual program instructions one (1) at a time, but
each routine is executed as one (1) step.
10.4.3.3 Continuous. This technique permits running a program from beginning to end without
stopping.
10.4.3.4 Simulating I/O. This technique permits the forcing of inputs or outputs without signals actually
entering or leaving the controller. This is essential to test and debug program logic and motion
when I/O devices and signals are not set up.
10.4.3.5 Machine Lock. This technique allows the program to run without any robot motion.
10.4.3.6 Tool Disable (Dry Run). This technique allows the program to run without activating the end-
effector.
10.4.3.7 Step Path Node. This technique permits the program to pause after each path node in a path
statement.
10.4.4 POWER FAILURE RECOVERY
In the event of a black-out or brown-out, follow the recovery procedure mentioned in the code
development guidelines section.
10.5 GENERAL ROBOT REQUIREMENTS

The controller should be supplied with collision detection. The detection shall E-stop the robot
in the event of an accidental collision to limit damage to the EOAT robot, and peripheral
equipment. Collision detection shall not be applied as a motion or axis limiting method. The
use of programmable switches is not allowed for any robot EOAT. The EOAT for material
handling shall require open/close gripper switches and part present switch(s).
10.5.1 FORGING ROBOT SPECIFICATIONS
The list below applies to robots used in forging applications:
 The EOAT shall operate in an ambient temperature of up to 260C (500F). The contact
tooling shall be made of alloy grade material to sustain the heat up to 1,204C (2,200F).
 The EOAT should be shielded to protect the grippers and pipes from graphite or the
metallic contaminations.
 Robosuit or equivalent is recommended to protect the robot from graphite
contamination. Contact Roboworld, Inc. for details.
 The robot shall be programmed to automatically unload hot forgings when a transfer cycle
is interrupted.

 The part present sensors shall be integrated inside the grippers, and not exposed to the
environment.
10.5.2 WELDING ROBOT SPECIFICATIONS
See Section 14 – Welding Equipment.
10.6 SAFEGUARDED SPACE REQUIREMENTS

10.6.1 GENERAL SAFEGUARDED SPACE REQUIREMENTS
The safety requirements for all robots and robot systems should follow the guideline in
American National Standard for Industrial Robots and Robot Systems – Safety Requirements,
ANSI/RIA 15.06-2012, Part 2. The safety requirements defined in Section 2 and Section 11 of
this specification apply to robot systems and equipment.
10.6.2 SAFEGUARDED SPACE LAYOUT
The Robot system layout (floor plan) is an important element of risk reduction. The
safeguarded space that is beyond the restricted space shall be developed and documented
considering and including as appropriate the following:
 Include all objects in and around the safeguarded space to scale and referenced to a
facility landmark (e.g. building column).
 Include a three dimensional representation of the restricted space and operating space
with consideration of clearance to obstacles, machinery, and other stationary objects.
 Identify traffic paths for material entering and leaving the safeguarded space for entry
guarding (e.g. tunnel guards).
 Identify personnel traffic routes considering pedestrian traffic and safe access and space
for robot teaching, maintenance, tool change, inspection, etc.
 Identify all cable routing, cable trays, festooning, and floor obstacles for slip, trip, and fall
hazard considerations.
 Define the location of emergency stops, safety lock-outs, teach pendant stowage,
operator interfaces (HMI’s, OK to enter, etc.), and access doors.
 Consider visibility of the entire safeguarded space for personnel that are enabling door
interlocks and enabling power to the robot and other equipment and machinery within
the safeguarded space.
 Allow for tasks to be performed outside the safeguarded space when practical
(maintenance, observation, etc.).
10.6.3 PERIMETER GUARDING
10.6.3.1 Perimeter Safety guarding shall comply with ANSI/RIA 15.06 and OSHA regulations. The
perimeter guarding in combination with other guarding (machine, conveyor, etc.) defines the
safeguarded space (reference section 8 for space definitions). The perimeter shall consider
the maximum extent of the restricted space as hazardous space. The restricted space is
defined where the robot motion actually stops, not by where a stop is initiated. The perimeter

guarding shall consider all hazards including other machinery, falling or ejected objects,
operating environment, and the stop time of motions.
10.6.3.2 Perimeter guarding shall be securely installed and comply with the reach over, under, around,
and through requirements of Section 2. Perimeter guarding shall suit the environment, be of
rigid construction, and be a minimum of 1.4 m (4.6 ft.) from adjacent walking surfaces.
10.6.3.3 Access doors, gates, etc. open-close “swing path” shall not cross into the restricted space.
10.6.3.4 Light Curtains, safety mats, or other Electro-sensitive protective equipment (ESPE) shall not be
used as perimeter guarding..
10.6.3.5 Axis limiting switches shall be included on all major axis (see 10.2.3.2). AAM Controls
Engineering approval is required if switches are not mounted on the axes.
10.6.3.6 A request to enter function shall be installed to allow an operator access inside the cell when
needed. If the HMI panel is not within reach, an enclosure with an indicator light and a
selector switch shall be mounted by the safeguarded space main entry for a request to enter.
10.6.3.7 The robot disconnect shall be mounted close to the entry of the robot cell.
10.6.4.8 A proper bracket and mount for the teach pendant and cable shall be installed next to the
entry of the cell.
10.6.3.9 The guarding safety gate interlock switch shall include a mechanical override facing inside the
guarding to permit override for egress from within the safeguarded space.
10.7 SYSTEM SAFETY INTERLOCK REQUIREMENTS

10.7.1 GENERAL INTERLOCK REQUIREMENTS
The integrator shall read and understand local, state, and federal regulations (i.e. OSHA, NFPA
79, ISO) for the AAM using facility. All equipment being interlocked use category three (3) or
better safety relays. Refer to the latest approved components list for acceptable components.
10.7.2 DEFINITION OF TERMS
 Hardwired Safety Circuits: circuits that function outside of the PLC and are used for
monitoring safety critical conditions. All safety circuits shall comply with local, state, and
federal regulations (i.e. OSHA, NFPA 79).
 Channel: an electrically closed circuit that continually monitors the components tied into
the circuit. Redundant channels are required for all safety circuits to comply with local,
state, and federal safety standards.
 Emergency Stop: a condition that halts the equipment operations and typically is caused
by a catastrophic equipment failure or by manual intervention.
 Safeguarded space: work envelope or area of the robot that is surrounded by a protective
barrier providing controlled and safe access to the work area (see 10.2.3).
 Process Interlock Signals: signals back and forth between the integrated equipment that
are generally PLC driven and function for automating the moving of material back and
forth between integrated equipment that follow a process defined protocol.
 External Equipment: any process or material handling equipment that is being integrated
to the robot. An external piece of equipment includes but is not limited to machining

centers, lathes, grinders, welders, gauges and other testing equipment, conveyors,
washers, etc.
10.7.3 GENERAL ROBOT INTEGRATION COMMUNICATION
Integration of any equipment shall use both hardwired safety circuits and process interlock
signals.
10.7.3.1 All equipment integrations shall include a touch safe twenty-four (24) pin bulk head style
connector for each integrated piece of equipment hardware safety circuits and 24VDC source
for both pieces of connecting equipment.
10.7.3.2 All hardwired safety circuits shall be a minimum of category three (3) and comply with local,
state, and federal regulations (e.g. OSHA, NFPA 79).
10.7.3.3 Process interlock signals between the robot and an external piece of equipment shall be
exchanged between the robot controlling PLC and the external equipment PLC. Direct
communication from the robot controller to the external equipment requires AAM written
approval.
10.7.4 HARDWIRED SAFETY CIRCUITS – EMERGENCY STOP INTEGRATION
10.7.4.1 The hardwired emergency stop circuit wiring shall meet specific requirements of the
application or components that are being integrated.
10.7.4.2 A risk assessment for the equipment integration shall determine if the emergency stop of
either the robot or an integrated piece of equipment requires the other integrated piece to go
into an emergency stop state. Some equipment integrations will require that all integrated
equipment stop either controlled or immediately for safety purposes. Contact the AAM
Controls Engineer for assistance in determining which type of integration should be
implemented.
10.7.4.3 For integrations that require all integrated pieces of equipment to stop with an emergency
stop condition;
 Safety circuits shall be category three (3) or better hardwired circuits implemented to
comply with local, state, and federal regulations (e.g., OSHA, NFPA 79).
 Two (2) channels of the emergency stop safety relay are monitored by both the robot and
the integrated piece of equipment. An emergency stop on either the robot or the
integrated piece of equipment will cause both the robot and equipment to enter an
emergency stop state
10.7.4.4 For integrations that do not require all integrated equipment to stop with an emergency stop
condition, the hardwired emergency stop channels shall be wired to the PLC as inputs to be
used to supersede other process interlock signals. With this type of installation, either piece of
equipment shall use the emergency stop status to disregard other process interlock signals
from a piece of equipment that is in an emergency stop state.

10.7.5 HARDWIRED SAFETY CIRCUITS – SAFETY GATE INTEGRATION

The safety gate circuit shall continually monitors all entry doors and access points to the cell
work area. Status of all safety gates and access points shall be passed to the integrated
equipment such that when the cell is accessible, all hazardous motion is halted for all
integrated equipment.
state, and federal regulations (i.e., OSHA, NFPA 79).
10.7.5.2 Energy shall be removed from all non-safe motion actuators of integrated equipment when
the cell is accessible. This includes but is not limited to pneumatic/hydraulic actuators,
servo/spindle motion, conveyors and other motors, etc.
10.7.6 HARDWIRED SAFETY CIRCUITS - EXTERNAL EQUIPMENT CELL ACCESS
For integrated equipment that include access panels or maintenance doors that may allow
access to the robot work cell, an additional safety circuit shall be installed to halt the robot
when these access points are open.
state, and federal regulations (i.e., OSHA, NFPA 79).
10.7.6.2 The access and maintenance doors of the integrated equipment shall be monitored in the
robot emergency stop safety relay.
10.7.7 HARDWIRED 24VDC INTEGRATION – CONNECTORS AND WIRING
A bulk head style touch safe twenty-four (24) pin connector shall be used for each piece of
integrated equipment. Reference the latest approved components list (Appendix D).
10.7.7.1 All safety circuit wiring shall be 24VDC.
10.7.7.2 The integrated piece of equipment shall provide proper short circuit protection in the main
electrical enclosure for all branch circuits that leave the panel for integration purposes.
Reference the latest revision of the NFPA 79 for branch circuit fusing information.
10.7.7.3 All hardwired interlock wiring shall terminate to a terminal strip first before it is wired to any
electrical component that is being integrated.
10.7.7.4 Zero (0) VDC common shall be run from all integrated equipment and terminated to the
terminal strip for diagnostic purposes, and comply with the following;
• All wire spares shall be terminated on a terminal strip.
• Interlock wiring in an enclosure where the source does not originate shall have the correct
wire color association. Please reference the current revision of the NFPA 79 specifications
for correct wire colors.
• External wiring from the interlocked equipment shall retain its wire number up to the bulk
head connector. Wiring after the bulk head connector shall be labeled in accordance to
the sheet and line location of the interlock connections sheet. Reference the current AAM
standard drawing requirements for more information on proper wire labeling.
• A 25 Multi-conductor numbered cable shall be used.

• The first twenty-four (24) wires of the multi conductor cable shall be terminated to the
associated pin on the bulk head connector.
• The 25th wire of the cable shall be used for ground. This ground shall connect to the bulk
head ground connector.
10.7.8 PROGRAMMING SAFETY PRECAUTIONS
The programming safety measures are included to prevent damage to machine tools and
external devices.
10.7.8.1 The system should be programmed to back-check limit switches in the work cell to verify they
have not failed and are properly functioning.
10.7.8.2 Implement “failure routines” in programs that will provide appropriate robot actions if an
external device or another robot fails.
10.7.8.3 Use handshaking to synchronize robot and external device operations. Handshaking refers to
a request and acknowledge signal to and from the robot. For example, the robot requests to
enter a hazard area. The PLC acknowledges the request and grants permission; the robot then
signals the PLC it has entered the hazard area.
10.7.8.4 Program the robot to check the condition of all external devices or limit switches during an
operating cycle.
10.8 CODE DEVELOPMENT GUIDELINES

10.8.1 CODE STRUCTURE
Code Shell
1. Main Program looping
● Material Handler
● Sealer
● Welder
● Paint
2. Subroutines
● Path Segments (Group input and output GO/GI) w/ Registers
3. Macros/Macro Table
● Contain No Robot Motion
● Open_Gripper#
● Close_Gripper#
4. Check Routines
● Check Position
- Joints - Identify Zone or space check
- TCP (tool center point)
- Part/No Part
● Check_GripperState
● Check_IO
● Check_Status

5. Initialization Routines
● Initialization Input and Output Routines
6. Recovery (See Recovery Section 10.9.10)
● Mov_Home
● Mov_Maintenance
● Move_Pounce
● Home_IO
● Reset ALL
7. Background Routines
10.8.2 MOTION
The robot shall have instructions for linear, joint, and circular motion including position
information, velocity, acceleration parameters, and comment field.
o Pick Positions
 L PR[] 500mm/s Fine
o Linear Approach Position
 L PR[] 1200mm/s Cnt10
o Joint Motion
 J PR[] 2000mm/s Cnt100
Offset programming in the main routines shall be approved by the AAM Controls Engineer.
Vision offsets are the exception since the vision application requires VR registers to perform
the calculated offsets.
10.8.3 START METHOD
AAM preferred: (MAIN Program)
 The PLC can call program to run using a bit strobe sequence. (Program Number Select)
 Inside the Robot Main Program the data moves from a group input to a register (e.g. R[8]
= GI[2]), which is Group word, input Two. (PLC will use: Group word output Two for
program calls. Using this value, program will start with jump commands to the required
line number in the program.)
 The Main Program will be setup as follows:
 Main (program)
 Program Select
 Style Select
10.8.4 I/O
Input/Outputs (Local I/O, Remote I/O, or Ethernet IP I/O)
10.8.4.1 UOP signals are user operated signals normally used to remotely control the robot.

10.8.4.2 Digital I/O are used for EOAT control, interlocks, status, fault codes (GO for faults that require
8 or more bits)
10.8.4.3 Robot I/O are used for EOAT control and device specific only to the robot (only used with the
permission of an AAM Controls Engineer).
10.8.4.4 Group I/O are used for decision control to monitor or advance into the next sequence or
anything that requires a numerical feedback that requires eight (8) or more bits (positional
feedback, etc.).
10.8.5 ROBOT INPUT/OUTPUT SIGNALS TO/FROM PLC
Refer to the standard drawing package for designated I/O points.
Register/Position Register ( R[ ]/PR[ ])
 PR[1…5] Common Points
● PR[1:Home]
● PR[2:Maintenance]
 Reserve PR[5- 19] Used for recovery program and check position program
 Vision Position, Positions/Offsets
● PR[20…39] Application 1: Pick Place
● RR[50…69] Application 4: Pick Place
● …
● PR[199] Master Position
 Registers
● R[5] Speed Override
● R[10] Used for recovery program and check position program
● R[#...#] Segments/Group Exchange
● R[#...#] Flags
● R[#...#] Vision
● R[#...#] Zones
● R[#...#] Collision Guard Sensitivity
● Frames
User Frames and UTOOL Frames
 Set U Tool and U Frame at beginning of Subroutine

Example:
!Set the tool and frame ;
UFRAME_NUM=1 ;
UTOOL_NUM=1 ;
10.8.6 MASTERING/ROBOT CALIBRATION

Acceptable mastering techniques include:
 To a fixture.
 To Zero (0) degrees.
 Single axis.
 Quick mastering.
 Supply a mastering capability with robot cell provided.
 Permanent mastering jig or built in mastering feature.
10.8.6.1 Mastering Methods
 Mastering to a Robot Zero position, robot needs to have the zero position marked on the
robot for each axis. (This action shall be done after robot is relocated and before touch up
the points for the program.)
 Mastering to a Fixture (The zero position needs to be set at a known Fixture Position.)
 Mastering documentation for the application shall be provided.
 Record Axis Encoder value in robot controller Registers.
10.8.6.2 Comments/Headers
 Commenting inside the program is required
o Program Headers as well as provide small description about program.
o Position Register, I/O’s, Data Register shall be commented.
o Collision Guard ON or OFF will depend on application, parts and end of arm
tooling. Clarification shall be given by the AAM Controls Engineer.
 Set Register for Sensitivity Changes R[#].
10.8.7 SPEED OVERRIDE

Speed Overrides: Set data registers for overrides and use these registers in subprogram Call,
Recovery speed shall be reduced and not exceed 25 %.
Example: 1: OVERRIDE=R[5 :SPEED OVERRIDE]
Subprogram: Override

10.8.8 PATH SEGMENTS

A path segment is a group output from the robot to the PLC that is used to inform the PLC
which part of the robot path is being executed. Whenever the robot is not at home, it shall
indicate a valid path segment to the PLC.
 Code Segment Structure:
 Request to Continue:
 Command from PLC to Robot
 Send data or value (running robot program number) to PLC and compare
this value in the PLC to match program number called; if it does not match
then send immediate stop command to robot and generate fault for the
operator. Reset group output word value in the robot after PLC
acknowledgement and set complete bit to PLC.
 Robot shall always wait for a request to Continue.

10.8.8.1 Example of a Main Program:
! OPXXX MAIN
LBL[10] ‘Jump instruction’
! MACHINE 1 UNLOAD
GO[1] = 0 ‘Program Decision Echo‘ IF G[1] = 22, CALL UNLD_M1
GO[2] = 0 ‘Part Style Echo‘ ! RECOVERY
IF G[1] = 3, CALL RECOVERY
!OPERATOR POUNCE ! HOME
IF G[1] = 50, CALL PNC_OP IF G[1] = 1, CALL HOME
!OPERATOR PICK ! MAINTENANCE
IF G[1] = 51, CALL PICK_OP IF G[1] = 2, CALL MAINT
!MACHINE 1 POUNCE
IF G[1] = 20, CALL PNC_M1 WAIT 0.1(sec)
!MACHINE 1 LOAD
IF G[1] = 21, CALL LD_M1 JMP[10]
 Sub Programs Structure:

 Set frames.
 Verify Gripper State and Position.
 Position Check Routines before Initiating Sequence .The robot should check it’s
location before ever moving and handle the fault accordingly (Make sure robot is in
Pounce or Home Position before moving).
 Motion Control OR Planning Action.
 Detect Failures.
 There should not be a loop in the subprogram, if one is needed it shall be coded
with ‘timeout’ and exit the loop(s) and generate faults for diagnostics.

10.8.8.2 Example of Move Programs:

UTOOL_NUM=2
!POUNCE OPERATOR GO[3]=0
IF R[10:POS NUM]=30,CALL PNC_M1 J PR[51:OP PICK P1] 100% FINE
GO[1:PROGRAM ECHO]=50 R[10:POS NUM]=51
GO[3]=R[10:POS NUM]
UTOOL_NUM=2
GO[3]=0 !PICK OP P2
J PR[50:OP POUNCE] 100% CNT60 GO[2:STYLE ECHO]=2
R[10:POS NUM]=50 WAIT DI[32]=ON
GO[3]=R[10:POS NUM]L PR[51] R[41] UTOOL_NUM=2
GO[3]=0
!PICK OP P1 J PR[52:OP PICK P2] 100% FINE
GO[2:STYLE ECHO]=1 R[10:POS NUM]=52
WAIT DI[32]=ON GO[3]=R[10:POS NUM]
10.8.9 RESUME/RECOVERY
Based on state of the robot (grippers, location, station state, etc.) allow the user to ‘Resume’
the station and continue with its path from the point of interruption. Recovery’ is similar to
‘Resume’ except the robot will abort the current program and back out and move to a
designated pounce position when ‘homed’; and the PLC will recall the last program executed
to continue with the station cycle.
10.8.10 FULL RECOVERY
10.8.10.1 Recovery can only be initiated in Manual Mode, once initiated the current program is aborted
and the main program will be called and the ‘Recovery’ will be selected.
10.8.10.2 Recovery will be based on a Current Position data register to keep track of the robot positions.
10.8.10.3 Robot will evaluate gripper status and the Current Position data register and reverse the path
of entry.
10.8.10.4 If the teach pendent is enabled, the PLC controller will be flagged, and the Robot will lose its
known position flag in the PLC; recovery from the TP will be required to ‘home’ the robot.
10.8.10.5 Load current positions and based on location and gripper state, using Position Registers to
step back out of the program.
10.8.10.6 Program should be modular so that the same program could be written for all robots.
10.8.10.7 Robot will un-jam itself by applying small offsets or use Position Register to step out of the
program.
10.8.10.8 After the robot has recovered; the robot shall reset bits sent over to the PLC. Housekeeping
Program will run after the robot has completed its homing routine cycle. This will allow the
user to reinitialize the station and with all parts back in place before the cycle started and
restart the entire cycle from the beginning.
10.8.10.9 E-Stop abort all programs (restart main program).

One push button for Homing/Recovery from the HMI; the operator should not touch the
Teach Pendent for recovery operation.*
10.8.10.10 Use dedicated position registers and data registers for Home/Recovery program.
10.8.10.11 On top of the sub-program give the description for the registers and position register.
10.8.10.12 The omission of the remote one button recovery will require written approval from the
AAM Electrical Engineer. Omissions would include situations which could result in
equipment damage, such as stud weld faults.
Recovery/Home Example:
!RECOVERY LBL[200]
GO[1:PROGRAM ECHO]=4 UTOOL_NUM=1
GO[3]=0
IF R[10:POS NUM]=1,JMP LBL[900] J PR[20:M1 POUNCE] 15% FINE
IF R[10:POS NUM]=2,JMP LBL[900] R[10:POS NUM]=20
GO[3]=R[10:POS NUM]
IF R[10:POS NUM]=50,JMP LBL[100] JMP LBL[999]
IF R[10:POS NUM]=51,JMP LBL[100]
IF R[10:POS NUM]=52,JMP LBL[100] LBL[250]
UTOOL_NUM=1
IF R[10:POS NUM]=20,JMP LBL[200] GO[3]=0
IF R[10:POS NUM]=22,JMP LBL[250] GO[3]=R[10:POS NUM]
LBL[300]
IF R[10:POS NUM]=30,JMP LBL[300] UTOOL_NUM=1
IF R[10:POS NUM]=34,JMP LBL[350] GO[3]=R[10:POS NUM]
JMP LBL[999]
!ERROR NO POS NUM FOUND
JMP LBL[999] LBL[350]
UTOOL_NUM=1
LBL[100] GO[3]=0
UTOOL_NUM=2 J PR[30:M2 POUNCE] 15% FINE
GO[3]=0 R[10:POS NUM]=30
J PR[50:OP POUNCE] 15% FINE GO[3]=R[10:POS NUM]
R[10:POS NUM]=50 JMP LBL[999]
GO[3]=R[10:POS NUM]
JMP LBL[999] LBL[900]

UTOOL_NUM=1 GO[3]=0
GO[3]=0 J PR[20:M1 POUNCE] 15% FINE
J PR[1:HOME] 100% CNT60 R[10:POS NUM]=20
R[10:POS NUM]=1 GO[3]=R[10:POS NUM]
GO[3]=R[10:POS NUM]
JMP LBL[300]
LBL[999]
LBL[300]
UTOOL_NUM=2
!HOME GO[3]=0
GO[1:PROGRAM ECHO]=1 J PR[50:OP POUNCE] 15% FINE
PR[6]=LPOS R[10:POS NUM]=50
GO[3]=R[10:POS NUM]
LBL[900]
UTOOL_NUM=1
IF R[10:POS NUM]=50,JMP LBL[900] J PR[1:HOME] 15% FINE
R[10:POS NUM]=1
!ERROR NO POS NUM FOUND GO[3]=R[10:POS NUM]
JMP LBL[999] JMP LBL[999]
LBL[200] LBL[999]
UTOOL_NUM=1
10.9 PROGRAM CONTROL

10.9.1 PLC CONTROL PROGRAMMING ACTIONS
Robot will be controlled from a PLC, this includes Start Cycle, Homing/Recovery, Stop Cycle,
and Program abort. The HMI shall have a dedicated Screen for the Robot functions.
10.9.2 ROBOT INTERFACE WITH PLC
Robot should have an intelligent interface to communicate with the PLC. This interface will
eliminate Robot hard wire interlocks with the control. Such intelligent interface shall be
EtherNet/IP. E-stop and Fence/Safety Gate circuits will be hard-wired to robot panel along
with Station E-stop.

10.9.3 ROBOT GRIPPER OPERATION

Set a macro to control Robot Grippers using Tool 1 for Open Gripper and Tool 2 on teach
pendent for Close Gripper.
10.9.4 FAULT CODE HANDLING/MESSAGES
If a fault is activated from the robot controller, it then shall be output to PLC, the output will
remain high until PLC has replied with a fault reset output to the robot controller. If user
alarms are required, then a Group word output (e.g. 25) for faults from the Robot will flag the
PLC. A program macro with the fault reset assigned to it will clear any user faults codes
flagged by the robot. This program will contain no motions so it can be activated any time
while the robot is in auto. Also, the fault message shall be displayed on the robot controller
and the Panel view display.
10.9.5 HMI MANUAL ROBOT PAGE
Robot should have soft push button for manual moves on HMI i.e. Home/Recovery, Move to,
Pick Location, etc. Obtain a sample home page from the AAM Controls Engineer for reference.
10.9.5.1 Robot process status shall be displayed on HMI.
10.9.5.2 Robot should have the UOP signals for troubleshooting problems.
10.10 ROBOT INTEGRATION WITH EXTERNAL EQUIPMENT

10.10.1 PROCESS INTERLOCK SIGNALS - GENERAL
Process interlocks may be implemented three different methods:
 Discrete I/O wiring directly from PLC to PLC.
 Discrete I/O wiring via distributed I/O utilizing EtherNet/IP technology.
 EtherNet/IP produced/consumed model for PLC to PLC communication. When using
this method, process signals should be as simple as possible.
Legacy and specialized equipment may not have EtherNet/IP compatibility and require too
many process interlocks for the discrete wiring. Contact the AAM Controls Engineer for
direction on integration of legacy control systems.
10.10.2 PROCESS INTERLOCK SIGNALS – DISCRETE WIRING
Discrete wiring requires more physical wiring, but may make sense for integrating equipment
with a limited number of interlock signals. This type of installation requires additional bulk
head connections and wire directly to PLC rack mounted I/O cards as follows:
 Additional bulk head style connectors shall be used for all discrete process interlocks.
Reference the latest AAM approved components list for acceptable components.
 Zero (0) VDC common from both interlocking pieces of equipment shall be run and
terminated on the terminal strip for diagnostic purposes.
 PLC Isolated relay output cards shall be used for equipment interlocking outputs.

 A minimum of sixteen (16) inputs and sixteen (16) outputs shall be used for process
interlock signals.
 15 % of both inputs and outputs shall be spare for future additions.
10.10.3 PROCESS INTERLOCK SIGNALS - DISCRETE WIRING OVER DISTRIBUTED I/O
Discrete wiring with distributed I/O modules use communication devices attached to I/O
modules and communicate the I/O status to the PLC via communication cable. This
architecture reduces wiring and provides added flexibility future added I/O. This approach is
recommended when integrating multiple pieces of equipment.
 The automation or robot PLC should be the controller of the distributed I/O
communication modules and not the integrated equipment.
 The distributed I/O should be installed into the integrated piece of equipment as close to
the PLC as possible to limit wiring usage and provide easier diagnostics.
 The equipment that is providing the distributed I/O communication module shall also
supply the 24VDC source and common to power the communication module.
 24VDC power wiring shall be connected via the twenty-four (24) pin bulk head connector.
 15 % of both inputs and outputs shall be spare for future additions.
 A minimum of sixteen (16) inputs and sixteen (16) outputs shall be used for process
interlock signals.
10.10.4 PROCESS INTERLOCK SIGNALS – PRODUCED CONSUMED MODEL WIRING
This is the AAM preferred interlocking model that minimizes hardwiring and provides the most
flexibility of the three interlocking models.
 Cat 5e or better cabling shall be used.
 If a central switch is being currently being used to create a local area network then
Ethernet wiring shall run from both pieces of equipment to be interlocked to the central
switch. Depending on the criticalness of the process interlocks redundant Ethernet wiring
may be required.
 If a central switch does not exist an Ethernet crossover cable shall be run between the
network switches of the integrated equipment.
 The Ethernet cable shall not have any splices or disconnects.
 Only manufactured cables to AAM requirements shall be used.
10.10.5 PROCESS INTERLOCKS AND DEFINITIONS
Process interlocks vary from integration to integration. Below is a list of example process
interlocks and their definitions. These interlock descriptors should be used when applicable.
 Robot Clear: indication that the robot is clear of the interlocked piece of equipment.

 Equipment Clear: indication to the robot automation that the equipment is safe to
interface with. This interlock may consider many equipment conditions before providing
this signal.
 Machine Ready for Unload/Anticipate: indication that the equipment is ready for a part or
material to be removed or will be ready soon. The interfacing robot may use this signal to
prepare for unloading the equipment, however should not actually interface with the
equipment until the equipment clear indication is given.
 Machine Ready for Load/Anticipate: indication that the equipment is ready to receive a
part or will be ready soon. The interfacing robot may use this signal to prepare for loading
the equipment, however should not actually load the equipment until the equipment
clear indication is also given.
 Part Unload Complete: indication to the interlocked equipment that a part has been
unloaded.
 Part Load Complete: indication to the interlocked equipment that a part has been loaded.
 Part Type: indication given by either the robot or the interlocked equipment that
indicates which part is being loaded or unloaded. This is typically an integer value (1-n)
and should be set before the load or unload interlock is provided.
10.10.6 OTHER INTEGRATION CONSIDERATIONS
Where a robot interfaces with multiple pieces of equipment it is critical to maintain the robot
awareness of the equipment that is ready to process new material. Unload/load anticipate
signals can be used to reduce cycle time however a timeout shall exist in the event that a
machine faults, stops, etc. This timeout will allow the robot to abort the current operation and
service a piece of equipment that is ready to receive the material.
10.10.6.1 A light curtain is recommended on equipment when integrating a robot with multiple pieces of
equipment that have unsafe motion. This allows access to the integrated work cell without
stopping the equipment operations. It also allows for manual operation of the equipment and
provides a hardware measure to indicate that the robot is clear of the equipment before
performing equipment functions.
10.10.6.2 In the case that the integrated piece of equipment enters an emergency stop state while the
automation is interfacing with it, the robot shall halt and ignore all other process signals from
the integrated piece of equipment. Either the equipment needs to be pulled out of its
emergency stop condition to allow the robot to continue, providing all other process interlock
signals are ok, or the robot recovery procedure needs to be executed. Refer to paragraph
10.8.9 for more information on robot recovery.
10.10.6.3 Where a robot is interfacing with multiple pieces of equipment it may be important for some
of the hardwired safety circuits to be on the line side of the main disconnect to allow

maintenance to power down a piece of equipment for repairs while still monitoring key safety
components.
10.10.6.4 Additional logic, wiring, and hardware modifications will need to be made to all equipment
being interlocked. Responsibility for these modifications varies and needs to be discussed with
the AAM Controls Engineer.
10.10.6.5 For integrations that require a limited number of process interlock signals, the integrator may
use the remaining connections on the 24 pin hardwired connection with AAM Controls
Engineering approval.
10.10.6.6 When transferring data between equipment, (i.e., part type, serial number, etc.) use non-
volatile memory for recovery purposes in the event of a facility or equipment power failure.
Diagnostics
 HMI interlocking screens shall be provided on both the HMI for the robot and the
integrated equipment.
 Sequence screens shall be provided that indicate current active status.
 Sequence faults shall be added where an integrated piece of equipment communicates
improperly or inaccurately.
10.10.7 INTEGRATED EQUIPMENT DOCUMENTATION
Each drawing set shall have a separate page that shows the interlocking connections between
the equipment being interlocked.
10.10.7.1 The interlocking connections sheet from each piece of equipment shall show that equipment
wire labeling, and the wire labeling and color codes for the interlocked equipment.
10.7.10.2 Sheets that are affected by the interlock wiring shall be updated to reflect the integration
additions.
10.7.10.3 Interlock definitions document shall be provided to the AAM Controls Engineer. These
definitions shall be agreed upon by all active parties responsible for the integration of the
equipment.

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Equipment Specification Manual (ESM) – Special Machines (Type C)

10.1 GENERAL ............................................................................................................................... 1

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10.5.1 Forging Robot Specifications ......................................................................................................................... 10

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10.2 MECHANICAL UNIT REQUIREMENTS

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10.2.4 MECHANICAL SPACE REQUIREMENTS

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10.2.7 COLLISION DETECTION

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10.2.12 PREVENTIVE MAINTENANCE

10.3 CONTROL UNIT REQUIREMENTS

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10.4 SOFTWARE REQUIREMENTS

10.4.1 LANGUAGES AND ENVIRONMENTS

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10.5 GENERAL ROBOT REQUIREMENTS

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10.6 SAFEGUARDED SPACE REQUIREMENTS

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10.7 SYSTEM SAFETY INTERLOCK REQUIREMENTS

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10.7.5 HARDWIRED SAFETY CIRCUITS – SAFETY GATE INTEGRATION

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10.8 CODE DEVELOPMENT GUIDELINES

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10.8.6 MASTERING/ROBOT CALIBRATION

 Commenting inside the program is required

o Program Headers as well as provide small description about program.

o Position Register, I/O’s, Data Register shall be commented.

 Set Register for Sensitivity Changes R[#].

10.8.7 SPEED OVERRIDE

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10.8.8 PATH SEGMENTS

 Command from PLC to Robot

 Robot shall always wait for a request to Continue.

 Sub Programs Structure:

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10.8.8.2 Example of Move Programs:

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10.9 PROGRAM CONTROL

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10.9.3 ROBOT GRIPPER OPERATION

10.10 ROBOT INTEGRATION WITH EXTERNAL EQUIPMENT

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