How to set up and run EtherNet/IP CIP Safety communication on Kawasaki Robotics with Cubic-S module?
From this article you will learn:
- how the CIP Safety protocol works in Ethernet/IP,
- what you need to perform the communication configuration,
- how to configure and connect your robot,
- how to configure the connection on the Safety controller,
- how to configure the inputs and outputs of the Cubic-S safety module,
- how to create a simple test program,
- when to consider Ethernet/IP with the CIP Safety protocol.
Learn the basics of setting up and running Ethernet/IP CIP Safety communication using the Kawasaki Robotics robot with Cubic-S module and SICK safety controller as an example. Also learn how to create a simple test program to verify the connection.
How does the CIP Safety protocol work with Ethernet/IP?
The CIP Safety protocol is an extension of the CIP (Common Industrial Protocol) standard to transfer data related to safety systems. The protocol is implemented in the equivalent of the application layer of the TCP/IP model. As such, it is not dependent on the lower layers of this model.?This type of architecture has made it possible to use the 'black channel' concept defined in IEC 61508. This makes it possible to use a theoretically unsuitable channel (e.g., lack of redundancy) to transmit safety signals.
The implementation of safety functions solely in the end devices allows the use of any network architecture and equipment. The protocol itself does not prevent communication errors, but has mechanisms implemented to detect these errors. The error detection function is implemented in the safety end devices, which check the correctness and timing of the data packet received.?Based on these parameters, appropriate actions are taken to handle them.
When is it worth considering Ethernet/IP with CIP Safety? See the information at the end of this article.
What you need to carry out the communication configuration? The test platform
To carry out the configuration we used:
1. Kawasaki Robotics BA006L robot with E01 controller.
2. Cubic-S safety module with EtherNet/IP CIP Safety option (40217-G154).
3. Sick FX3 modular safety controller with modules.
4. Software: CS-Configurator v 4.01
Configuration and connection of Kawasaki Robotics
Physical connection
The port supporting the Ethernet/IP CIP Safety protocol is located on the 1VA card. This port also supports the EtherNet/IP software built into the controller. Use an Ethernet cable of cat5E or higher for the connection.
Configuring Kawasaki Robotics
Once the Cubic-S option with EtherNet/IP CIP Safety protocol has been activated on the robot, it is necessary to configure the network address where communication will take place.
In the Kawasaki Robotics Teach Pendant, go to Menu Aux. Function-> 6. Input/Output Signal:
Next, select the 8th Signal Allocation:
In the next step, go to Software EtherNet /IP setting.
Set the EtherNet /IP Safety IP address in the field marked with a red frame. The set IP address must be from the same subnet as the address on the left.?Save the settings and confirm by pressing the Enter key on the Kawasaki Robotics Teach Pendant keyboard. After changing the addresses, restart the controller.
Connection configuration on the SICK controller
Kawasaki Robotics robot network parameters
The parameters required to configure the connection from the robot side are as follows:
Only basic configuration and adding the device to the project will be presented. For more in-depth information, please refer to the manual for the Flexi Soft product series on SICK's website.
Adding an EtherNet/IP CIP Safety device (robot) to a project
Once you have created a project and established a connection to the safety controller, you need to add the Kawasaki Robotics robot safety module to the project.
The Generic EtherNet/IP CIP Safety device is added to the project (by double-clicking).
Double-click to open the device and enter the data as below.
In the IP address field, enter the address set in the Robot Menu under Input/Output -> Signal Allocation -> Software EtherNet/IP settings.
The device name is an identification name - it has no influence on the connection.
Enter the following parameters in the configuration window:
-?????????Supplier = 601
-?????????Product type = 100
-?????????Product code = 1
-?????????Main version = 1
-?????????Additional version = 1
-?????????Version check: "Compatible module".
In the next program tab (Standard requirements), set the recommended RPI to 20 ms.
In the connections tab, set the following parameters:
- Connection path: "is generated automatically".
- Controller safety input: Producing Assembly = 772, Consuming Assembly = 1024, Assembly Size = 4
- Driver safety output: Producing Assembly = 1024, Consuming Assembly = 900, Assembly Size = 4
- Configuration assembly = 1024
The configuration of the new module has been completed. The GEPR communication module of the controller still needs to be configured.
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Configuring GEPR communication module
From the project's main window, open the controller configuration and navigate to the communication module (GEPR) tab.
The tag name is the name to distinguish the device in the project.
We generate or insert the SNN (Safety Network Number) value from the project (depending on whether the value was previously set). All devices belonging to one EtherNet/IP network with safety functions have the same SNN.
We set the network address of the communication module and rewrite it to the device. The device must be on the same subnet as the network on the Cubic-S module.
In the Connection creation tab, allocate the signals from the Cubic-S module to the safety controller.
Drag the yellow elements onto the + tags in the CPU module. This will create a connection between the modules.
In the Connection overview, determine the packet cyclicity and acceptable losses.?The result is a response time, which we include in the system response time.
RPI (requested packet interval) - defines the frequency of data sending, Kawasaki Robotics recommends data exchange no more frequently than every 20 ms.
Maximum number of lost packets - defines the acceptable number of consecutively lost data packets. The cause of packet loss can be network overflow with remaining data.
Network delay - tolerance for the deviation between the predicted packet delivery time and the actual packet delivery time.
Network response time - is the maximum time that passes between successive updates of input and output data. It is calculated from the following formula.
?
Response time = RPI x maximum number of lost packets + RPI x (Network delay/100)
Go to the EtherNet/IP services tab. At the top of the window, select services for external devices.
Set the IP address the same as in the Cubic-S module on the Kawasaki Robotics robot.
Then click 'Load' from the device (note: the SICK controller and the Kawasaki Robotics robot must be connected to each other directly or via a switch).
We can now press 'Save TUNID to xxx.xxx.xxx.xxx' (this is where the EtherNet/IP CIP Safety network address of the Kawasaki Robotics robot is).
After this operation, restart the Kawasaki Robotics robot and upload the configuration to the SICK safety controller.
TUNID (Target Unique Node Identifier) - this is the unique ID of the adapter device (slave) in the EtherNet/IP CIP safety network, which is assigned by the network scanner (master). The ID is used as one of the control mechanisms for the transmission of communication protocol data packets.
Configuring the inputs and outputs of Kawasaki Robotics
Use the CS-Configurator software to configure the network inputs and outputs for the Cubic-S module.
After connecting to the Cubic-S module using the USB cable, go to Panel Tree View and then Safety I/O.
There, allocate the individual safety functions to the safe inputs and outputs. A full description of how to do this can be found in the Cubic-S Instruction Manual. Contact us if you don't have it. ?
Configure the inputs and outputs from Kawasaki Robotics in the test program as follows:
To do this, double click the box with 'Network Input1'. In the right-hand window, select the safety function you are interested in and then click 'Allocate'.?The security function will be associated with input 1. Confirm the selection with 'Apply'.
After this operation, confirm the changes to the input allocation using the 'Update' button in the bottom right corner of the screen. Use similar operations to allocate Constant monitoring area to output 1.
(A risk analysis must first be carried out, against which the selected functions must be parameterised accordingly).
Verification of the correct connection
Verifying the connection on the Kawasaki Robotics side
To verify the validity of the connection, start the additional parameters monitor and select '93. Network Safety Input Signal'.
When the lights next to the Network and Module parameters are solid green, this means that a stable connection has been achieved between the SICK controller and the Kawasaki Robotics robot. If the status of the lights is different, please refer to the "Manual for Cubic-S Network Safety Input/Output".
Test program on the safety controller
By going to the Logic Editor tab in the Safety Designer, we can create a simple program to exchange one safety function each to and from the Kawasaki Robotics robot.
An example program sending and receiving one signal each might look like the following (note: for a safety signal in Kawasaki Robotics to be considered valid, two consecutive bits must be assigned to the robot's inputs, e.g., for robot safety input 1 we set bit 0.0 and 0.1).
When is it worth considering Ethernet/IP with CIP Safety protocol?
Using the Cubic-S module with the CIP Safety protocol increases the available amount of Kawasaki Robotics' safe inputs and outputs by another 16 signals.
We have also achieved reduced wiring and simplified connection - the Cubic-S safety module and the safety controller simply connect via an Ethernet cable. Reducing the number and length of cables is important, especially for large machines and extensive workstations.
The solution described provides a high level of system safety and reliability - the CIP Safety protocol is certified in the following categories:
An additional benefit is that traditional safety switches, latches and limit switches can be used by plugging them into an EtherNet/IP hub with CIP Safety. There is no need to route wires from each safety switch to the inputs of the Safety controller, simply plug them into the existing network infrastructure of the station.
The use of passwords for modifications, as well as individual identification numbers for safety actuators, makes it impossible for unauthorized operation of the security system.?
Among other things, the following are used to protect against tampering:
Dedicated network devices are not needed to use the described protocol - the use of a 'black channel' and the implementation of security functions only in the end devices allows the use of any architecture and network equipment.
This type of architecture is independent of the transmission medium, allowing even wireless transmission such as Wi-Fi or 5G to be used. This allows mobile robots to be easily plugged into station security systems. Wireless distributed I/O Hub on remote parts of workstations can also be used, simplifying workstation wiring.
It is easy to expand the safety system as the application grows. Adding another device is simply a matter of plugging it into the network and configuring it in the project. No changes to the electrical design are required.
Would you like to know more? Contact us by email [email protected]
Author of article: Piotr Kaczorowski, Industrial Robotics Specialist at ASTOR
Ingeniero Electronico / Programador PLC
1 个月Hello good morning, do you have the Cubic-S Instruction Manual?
Engineer at LARRAIOZ Electrónica Industrial
1 年Nice documentation. thank you for sharing!
Does anyone require any project support for Kawasaki or Fanuc or Yaskawa Industrial Robots. Looking for permanent or fixed contracts. Grab me while I am still here.
1 年Many thanks for sharing this basic setup instruction.