SimpleConnect makes use of dedicated inputs and outputs for commonly used devices within a typical welding related robotic system. These “dedicated” inputs and outputs typically have not been user accessible but with SimpleConnect, these IO are made available for user access be it monitoring inputs or directly driving outputs. This article will explore the individual inputs and outputs mapped to the dedicated IO and made available on the DirectConnect IO boards. Details on the individual DirectConnect boards can be found in the following article where it will discuss the various board configurations, IO types, and the physical connection points!
In the following we’ll discuss the various IO signals, how to access them in INFORM, and the logic behind their operation.
Robot Input Mapping:
| Physical Input#: | CIO Mapping Logic: | Universal Input: | Signal Description: |
| 20010 |
STR #70017 BMOV #20010,2,05050 |
4033 (#05050) | External Start |
| 20011 | 4034 (#05051) | External Hold | |
| 20012 | 4035 (#05052) | Master Job Call | |
| 20013 | 4036 (#05053) | External Alarm Reset | |
| 20014 | 4037 (#05054) | External Servo On | |
| 20015 | 4038 (#05055) | Air Pressure Sensor#1 | |
| 20016 | 4039 (#05056) | Water Flow Sensor #1 | |
| 20017 | 4040 (#05057) | Water Flow Sensor #2 | |
| 20020 | 4041 (#05060) | Gas Flow Sensor#1 | |
| 20021 | 4042 (#05061) | Gas Flow Sensor#2 | |
| 20022 | 4043 (#05062) | Gas Flow Sensor#3 | |
| 20023 | 4044 (#05063) | Gas Flow Sensor#4 | |
| 20024 | 4045 (#05064) | Wire Shortage Sensor#1 | |
| 20025 | 4046 (#05065) | Wire Shortage Sensor#2 | |
| 20026 | 4047 (#05066) | Wire Shortage Sensor#3 | |
| 20027 | 4048 (#05067) | Wire Shortage Sensor#4 |
"START" Input Logic:
STR #28310 //OPERATOR STATION#1 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK
AND #22711 //START FROM OP STATION 1 – INPUT #2146
STR #28311 //OPERATOR STATION#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK
AND #22751 //START FROM OP STATION 2 – INPUT #2178
OR-STR
STR #28312 //OPERATOR STATION#3 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK
AND #22791 //START FROM OP STATION 3 – INPUT #2210
OR-STR
STR #28313 //OPERATOR STATION#4 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK
AND #22831 //START FROM OP STATION 4 – INPUT #2242
OR-STR
STR #28200 //YAI PLC MAP ENABLED
AND #21280 //YAI PLC: EXTERNAL START – INPUT #1002
OR-STR
STR #78341
OR #28204 //TIP CHANGE OP-STATION#1 ENABLED
OR #28205 //TIP CHANGE OP-STATION#2 ENABLED
AND #78341 //TIP CHANGE BOX(S) INITIATED EXTERNAL CYCLE START
OR-STR
AND #50073 //SERVO ON
AND-NOT #50070 //OPERATING
OUT #78320 //SIMPLECONNECT BASED EXTERNAL START LOGIC
//
STR #20010 //EXTERNAL INPUT FOR START (Added Rev 1.2.3)
OR #78320 //SIMPLECONNECT BASED EXTERNAL START LOGIC
OUT #70010 //EXTERNAL START
"HOLD" Input Logic:
STR #28310 //OPERATOR STATION#1 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK
AND #22711 //START FROM OP STATION 1 – INPUT #2146
STR #28311 //OPERATOR STATION#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK
AND #22751 //START FROM OP STATION 2 – INPUT #2178
OR-STR
STR #28312 //OPERATOR STATION#3 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK
AND #22791 //START FROM OP STATION 3 – INPUT #2210
OR-STR
STR #28313 //OPERATOR STATION#4 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK
AND #22831 //START FROM OP STATION 4 – INPUT #2242
OR-STR
STR #28200 //YAI PLC MAP ENABLED
AND #21280 //YAI PLC: EXTERNAL START – INPUT #1002
OR-STR
STR #78341
OR #28204 //TIP CHANGE OP-STATION#1 ENABLED
OR #28205 //TIP CHANGE OP-STATION#2 ENABLED
AND #78341 //TIP CHANGE BOX(S) INITIATED EXTERNAL CYCLE START
OR-STR
AND #50073 //SERVO ON
AND-NOT #50070 //OPERATING
OUT #78320 //SIMPLECONNECT BASED EXTERNAL START LOGIC
//
STR #20010 //EXTERNAL INPUT FOR START (Added Rev 1.2.3)
OR #78320 //SIMPLECONNECT BASED EXTERNAL START LOGIC
OUT #70010 //EXTERNAL START
"MASTER JOB CALL" Input Logic:
STR #20012 //EXTERNAL INPUT FOR MASTER JOB CALL (Added Rev 1.2.3)
STR #28200 //YAI PLC MAP ENABLED
AND #21283 //INPUT 1004
OR-STR
OUT #40070 //EXTERNAL MASTER JOB CALL
"ALARM RESET" Input Logic:
STR #20013 //YEC'S ALARM RESET PHYSICAL INPUT
STR #28310 //OPERATOR STATION#1 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK
AND #22712 //ALARM RESET FROM OP STATION#1 - INPUT #2147
STR #28311 //OPERATOR STATION#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK
AND #22752 //ALARM RESET FROM OP STATION#2 - INPUT #2152
STR #28200 //YAI PLC MAP ENABLED
AND #21284 //YAI PLC: EXTERNAL ALARM RESET (INPUT 1005)
OR-STR
OR-STR
OR-STR
OUT #40014 //ALARM RESET
"SERVO ON" Input Logic:
STR #20014 //EXTERNAL INPUT FOR EXTERNAL SERVO ON (Added Rev 1.2.3)
STR #28310 //OPERATOR STATION#1 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK
AND #22710 //SERVO ON FROM OP STATION - INPUT #2145
STR #28311 //OPERATOR STATION#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK
AND #22750 //SERVO ON FROM OP STATION - INPUT #2177
STR #78340 //TIP CHANGE BOX(S) INITIATED EXTERNAL SERVO ON
STR #28200 //YAI PLC MAP ENABLED
AND #21281 //YAI PLC: EXTERNAL SERVO ON (INPUT 1002)
OR-STR
OR-STR
OR-STR
OR-STR
OUT #40045 //EXTERNAL SERVO ON
"SYSTEM AIR PRESSURE" Input Logic & Alarm:
STR #28194 //SYSTEM AIR PRESSURE SENSOR ENABLED
AND-NOT #02160 //CARRIAGE#1 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1721)
AND-NOT #02161 //CARRIAGE#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1722)
AND-NOT #20015 //AIR PRESSURE SENSOR#1 INPUT IN DEDICATE INPUT
AND #50073 //SERVOS ON
TMR M053,30 //ALLOWABLE AIR PRESSURIZATION TIME (3 SECONDS).
OUT #79773 //USER ALARM 60: "SYS AIR PRESSURE LOW(IN#4038=0)"
"WATER FLOW SENSOR#1" Input Logic & Alarm:
STR #28000 //R1 CONFIGURED
AND #28180 //WATER FLOW SWITCH#1 ENABLED
AND #70066 //ARC OCCUR
AND-NOT #20016 //WELDER#1 WATER FLOW SENSOR INPUT IN DEDICATE INPUT
TMR M062,50 //DEBOUNCE TIMER TO ALLOW FOR AIR BUBBLE DUE TO SWITCH CHANGE.
OUT #79704 //USER ALARM 5: "WATER FLOW#1 FAULT(IN#4039=0)"
"WATER FLOW SENSOR#2" Input Logic:
STR #28001 //R2 CONFIGURED
AND #28181 //WATER FLOW SWITCH#2 ENABLED
AND #70266 //ARC OCCUR
AND-NOT #20017 //WELDER#2 WATER FLOW SENSOR INPUT IN DEDICATE INPUT
TMR M063,50 //DEBOUNCE TIMER TO ALLOW FOR AIR BUBBLE DUE TO SWITCH CHANGE.
OUT #79705 //USER ALARM 6: "WATER FLOW#2 FAULT(IN#4040=0)"
"GAS FLOW SENSOR#1" Input Logic & Alarm:
STR #28000 //R1 CONFIGURED
AND #28164 //R1 GAS FLOW SWITCH ENABLED
AND #70066 //ARC OCCUR
AND #70040 //R1 ARC OCCURENCE CHECK (ARC ESTABLISHED)
TMR M054,10 //DEBOUNCE TIMER
STR-NOT #02160 //CARRIAGE#1 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1721)
AND-NOT #02161 //CARRIAGE#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1722)
AND-NOT #05060 //GAS FLOW SENSOR#1 (UNIVERSAL IN#4041)
STR #02160 //CARRIAGE#1 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1721)
AND #02120 //R1 ASSIGNED TO CARRIAGE#1
AND-NOT #03015 //CARRIAGE#1 GAS FLOW SENSOR INPUT#1 (INPUT# 2406)
OR-STR
STR #02161 //CARRIAGE#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1722)
AND #02124 //R1 ASSIGNED TO CARRIAGE#2
AND-NOT #03055 //CARRIAGE#2 GAS FLOW SENSOR INPUT#1 (INPUT# 2438)
OR-STR
AND-STR
OUT #79706 //USER ALARM 7: "GAS FLOW#1 FAULT(IN#4041=0)"
"GAS FLOW SENSOR#2" Input Logic & Alarm:
STR #28001 //R2 CONFIGURED
AND #28165 //R2 GAS FLOW SWITCH ENABLED
AND #70266 //ARC OCCUR
AND #70240 //R2 ARC OCCURRENCE CHECK (ARC ESTABLISHED)
TMR M055,10 //DEBOUNCE TIMER
STR-NOT #02160 //CARRIAGE#1 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1721)
AND-NOT #02161 //CARRIAGE#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1722)
AND-NOT #05061 //GAS FLOW SENSOR#2 (UNIVERSAL IN#4042)
STR #02160 //CARRIAGE#1 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1721)
AND #02121 //R2 ASSIGNED TO CARRIAGE#1
AND-NOT #03025 //CARRIAGE#1 GAS FLOW SENSOR INPUT#2 (INPUT# 2414)
OR-STR
STR #02161 //CARRIAGE#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1722)
AND #02124 //R2 ASSIGNED TO CARRIAGE#2
AND-NOT #03065 //CARRIAGE#2 GAS FLOW SENSOR INPUT#2 (INPUT# 2446)
OR-STR
AND-STR
OUT #79707 //USER ALARM 8: "GAS FLOW#2 FAULT(IN#4042=0)"
GAS FLOW SENSOR#3 Logic & Alarm:
STR #28002 //R3 CONFIGURED
AND #28166 //R3 GAS FLOW SWITCH ENABLED
AND #70466 //ARC OCCUR
AND #70440 //R3 ARC OCCURENCE CHECK (ARC ESTABLISHED)
TMR M056,10 //DEBOUNCE TIMER
STR-NOT #02160 //CARRIAGE#1 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1721)
AND-NOT #02161 //CARRIAGE#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1722)
AND-NOT #05062 //GAS FLOW SENSOR#3 (UNIVERSAL IN#4043)
STR #02161 //CARRIAGE#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1722)
AND #02121 //R3 ASSIGNED TO CARRIAGE#2
AND-NOT #03055 //CARRIAGE#2 GAS FLOW SENSOR INPUT#1 (INPUT# 2438)
OR-STR
STR #02161 //CARRIAGE#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1722)
AND #02124 //R2 ASSIGNED TO CARRIAGE#2
AND-NOT #03065 //CARRIAGE#2 GAS FLOW SENSOR INPUT#2 (INPUT# 2446)
OR-STR
AND-STR
OUT #79710 //USER ALARM 9: "GAS FLOW#3 FAULT(IN#4043=0)"
GAS FLOW SENSOR#4 Logic & Alarm:
STR #28003 //R4 CONFIGURED
AND #28167 //GAS FLOW SWITCH#4 ENABLED
AND #70666 //ARC OCCUR
AND #70640 //R4 ARC OCCURENCE CHECK (ARC ESTABLISHED)
TMR M057,10 //DEBOUNCE TIMER
STR-NOT #02160 //CARRIAGE#1 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1721)
AND-NOT #02161 //CARRIAGE#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1722)
AND-NOT #05063 //GAS FLOW SENSOR#4 (UNIVERSAL IN#4044)
STR #02161 //CARRIAGE#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1722)
AND-NOT #02126 //R3 ASSIGNED TO CARRIAGE#2
AND #02127 //R4 ASSIGNED TO CARRIAGE#2
AND-NOT #03055 //CARRIAGE#2 GAS FLOW SENSOR INPUT#1 (INPUT# 2438)
OR-STR
STR #02161 //CARRIAGE#2 CONFIGURED AS PART OF SIMPLE CONNECT NETWORK (INPUT# 1722)
AND #02126 //R3 ASSIGNED TO CARRIAGE#2
AND #02127 //R4 ASSIGNED TO CARRIAGE#2
AND-NOT #03065 //CARRIAGE#2 GAS FLOW SENSOR INPUT#2 (INPUT# 2446)
OR-STR
AND-STR
OUT #79711 //USER ALARM 10: "GAS FLOW#4 FAULT(IN#4044=0)"
WIRE SHORTAGE SENSOR#1 Logic & Alarm:
STR #28000 //R1 CONFIGURED
AND #28160 //WIRE SHORTAGE SENSOR#1 ENABLED
AND #70066 //ARC OCCUR
AND #70040 //R1 ARC OCCURENCE CHECK (ARC ESTABLISHED)
TMR M058,100 //DELAY TIMER
STR-NOT #01950 //CARRIAGE#1 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND-NOT #01951 //CARRIAGE#2 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND-NOT #05064 //WIRE SENSOR#1 (UNIVERSAL IN#4045)
STR #01950 //CARRIAGE#1 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND #02120 //R1 ASSIGNED TO CARRIAGE#1
AND-NOT #03016 //ROBOT CARRIAGE#1 - WIRE PRESENCE SENSOR #1
OR-STR
STR #01951 //CARRIAGE#2 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND #02124 //R1 ASSIGNED TO CARRIAGE#2
AND-NOT #03056 //ROBOT CARRIAGE#2 - WIRE PRESENCE SENSOR #1
OR-STR
AND-STR
OUT #79712 //USER ALARM 11: "WIRE SENSOR#1 EMPTY(IN#4045=0)"
WIRE SHORTAGE SENSOR#2 Logic & Alarm:
STR #28001 //R2 CONFIGURED
AND #28161 //WIRE SHORTAGE SENSOR#2 ENABLED
AND #70266 //ARC OCCUR
AND #70240 //R2 ARC OCCURENCE CHECK (ARC ESTABLISHED)
TMR M059,100 //DELAY TIMER
STR-NOT #01950 //CARRIAGE#1 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND-NOT #01951 //CARRIAGE#2 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND-NOT #05065 //WIRE SENSOR#2 (UNIVERSAL IN#4046)
STR #01950 //CARRIAGE#1 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND #02121 //R2 ASSIGNED TO CARRIAGE#1
AND-NOT #03026 //ROBOT CARRIAGE#1 - WIRE PRESENCE SENSOR #2
OR-STR
STR #01951 //CARRIAGE#2 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND #02125 //R2 ASSIGNED TO CARRIAGE#2
AND-NOT #03066 //ROBOT CARRIAGE#2 - WIRE PRESENCE SENSOR #2
OR-STR
AND-STR
OUT #79713 //USER ALARM 12: "WIRE SENSOR#2 EMPTY(IN#4046=0)"
WIRE SHORTAGE SENSOR#3 Logic & Alarm:
STR #28002 //R3 CONFIGURED
AND #28162 //WIRE SHORTAGE SENSOR#3 ENABLED
AND #70466 //ARC OCCUR
AND #70440 //R3 ARC OCCURENCE CHECK (ARC ESTABLISHED)
TMR M060,100 //DELAY TIMER
STR-NOT #01950 //CARRIAGE#1 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND-NOT #01951 //CARRIAGE#2 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND-NOT #05066 //WIRE SENSOR#3 (UNIVERSAL IN#4047)
STR #01951 //CARRIAGE#2 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND #02126 //R3 ASSIGNED TO CARRIAGE#2
AND-NOT #03056 //ROBOT CARRIAGE#2 - WIRE PRESENCE SENSOR #1
OR-STR
AND-STR
OUT #79714 //USER ALARM 13: "WIRE SENSOR#3 EMPTY(IN#4047=0)"
WIRE SHORTAGE SENSOR#4 Logic & Alarm:
STR #28003 //R4 CONFIGURED
AND #28163 //WIRE SHORTAGE SENSOR#4 ENABLED
AND #70666 //ARC OCCUR
AND #70640 //R4 ARC OCCURENCE CHECK (ARC ESTABLISHED)
TMR M061,100 //DELAY TIMER
STR-NOT #01950 //CARRIAGE#1 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND-NOT #01951 //CARRIAGE#2 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND-NOT #05067 //WIRE SENSOR#4 (UNIVERSAL IN#4048)
STR #01951 //CARRIAGE#2 ACTIVE CONNECTION TO SIMPLE CONNECT NETWORK
AND #02127 //R4 ASSIGNED TO CARRIAGE#2
AND-NOT #03066 //ROBOT CARRIAGE#2 - WIRE PRESENCE SENSOR #2
OR-STR
AND-STR
OUT #79715 //USER ALARM 14: "WIRE SENSOR#4 EMPTY(IN#4048=0)"
Wire Sensor Disabled in SimpleConnect but "Detected" Message Logic :
STR-NOT #28160 //WIRE SHORTAGE SENSOR#1 ENABLED
AND #05064 //WIRE PRESENT SENSOR#1 (UNIVERSAL IN#4045)
STR-NOT #28161 //WIRE SHORTAGE SENSOR#2 ENABLED
AND #05065 //WIRE PRESENT SENSOR#2 (UNIVERSAL IN#4046)
STR-NOT #28162 //WIRE SHORTAGE SENSOR#3 ENABLED
AND #05066 //WIRE PRESENT SENSOR#3 (UNIVERSAL IN#4047)
STR-NOT #28163 //WIRE SHORTAGE SENSOR#4 ENABLED
AND #05067 //WIRE PRESENT SENSOR#4 (UNIVERSAL IN#4048)
OR-STR
OR-STR
OR-STR
OUT #79851 //USER MESSAGE#34, WIRE PRESENCE SENSOR DETECTED BUT ALARM DISABLED