YAI Tip Change Interface / Tip Change Box / TCB

Part#(s):

Packaged Kits:

• 183573-1 : Accessory, Tip Change, Single Robot/One Enclosure
• 183573-2 : Accessory, Tip Change, Dual Robot/One Enclosure
• 183573-3 : Accessory, Tip Change, Triple Robot/Two Enclosures
• 183573-4 : Accessory, Tip Change, Quad Robot/Two Enclosures
• 183573-5 : Accessory, Tip Change, Triple Robot/Two Enclosures, Aw6300 Variant
• 183573-6 : Accessory, Tip Change, Dual Robot/Two Enclosures
• 183573-7 : Accessory, Tip Change, Single Robot/One Enclosure, M12 Option
• 183573-8 : Accessory, Tip Change, Dual Robot/One Enclosure, M12 Option
• 183573-9 : Accessory, Tip Change, Triple Robot/Two Enclosures, M12 Option
• 183573-10 : Accessory, Tip Change, Quad Robot/Two Enclosures, M12 Option 

Individual Enclosures:

• 183463-1 : Enclosure Assy, Tip Change with Operator Controls, Single Robot
• 183463-2 : Enclosure Assy, Tip Change with Operator Controls, Dual Robot, Robot 1 and 2
• 183463-3 : Enclosure Assy, Tip Change with Operator Controls, Dual Robot, Robot 3 and 4
• 183463-4 : Enclosure Assy, Tip Change with Operator Controls, Dual Robot, Robot 2 And 3
• 183463-5 : Enclosure Assy, Tip Change with Operator Controls, M12 Option, Single Robot
• 183463-6 : Enclosure Assy, Tip Change with Operator Controls, M12 Option, Dual Robot 1 and 2
• 183463-7 : Enclosure Assy, Tip Change with Operator Controls, M12 Option, Dual Robot 3 and 4

Image(s):

Single Robot version:

• Single Robot version - Standard view with door closed

• Single Robot version - Standard view with the door opened to show interior and pass through window

Dual Robot version shown:

• Same dimensions as single version, but addition of selector switch for Robot 1 or Robot 2 request

Side View:

Back view, with Mounting Squash Plates:

• Rear view shows squash plate mounting and hole cut out.

Overview:

The YAI Tip Change Interface is a complete solution that allows operators to access the robot’s torch for some maintenance operations, without entering the full robot’s enclosure.   The enclosure includes controls to easily call the robot to the appropriate metal access box for a safe, routine tip change.  Opening the door turns disables servo power which facilitates safe access to interaction with the robot.  This enclosure mounts on the fence (mesh or solid).  Buttons on the device allow wire to advance after the tip change and a shelf allows tools to be stored for easy access.  Buttons and indicators on the side of the are used to restart operation and provide indication on status regarding the robot’s approach and complete status.

NOTE:  To use the restart and servo on function when the door in closed, the robot must be in Remote Mode.  It is easy to overlook this requirement, but must be enforced for proper operation.

EtherNet/IP cables can be connected in series with other EtherNet/IP equipment such as other Simple Connect enabled devices. The enclosure Includes buttons for E-Stop, tip call, wire feed, and resume operation.

Solutions are available for 1-4 robot systems and electrical connections for ArcWorlds, advanced systems or bare arm top hats with the M12 Option interface board.

Components:

The optional accessory consists of several major hardware components:

1. Main Housing: This sheet metal housing provides mounting, enclosure, swing door and protection.  Protection in this case means protecting the robot from reaching through the fences and a side enclosure for wiring the controls.  In other views that follow, the side wiring panel will be investigated in more detail.
2. Swing Open Door with Latch: The door includes a pocket to easily grab and open the door with a gloved hand.  It is interlocked into a dual channel safety device to determine when the door is fully closed.  When closed the robots in the system can servo-on safety.  When the door is open, the servo on condition is held off, preventing robot motion.  This allows safe interaction with the torch without concern of unintentional motion.  Additional interaction between the robot job and concurrent I/O ladder sequences with the controls to only allow wire advance when the robot is within the tip change opening ‘window’ and controls a restart sequence when the tip change maintenance operation is completed.  When the door is closed the latch should be turned clockwise to hold the door closed in position.
3. Controls: A series of buttons, indicators and E-Stop button which are wired in the enclosure behind these devices.  These buttons are included in the solution: Wire Advance, Tip Change Request (with LED), and Tip Change Complete.  If the enclosure is shared with multiple robots there will be a selector switch with a name plate indicating the Robot Number for interaction.  The E-Stop button will stop the full cell when pressed.
4. EtherNet/IP-to-Discrete IO-Module: This commercially available device is assigned to a specific IP-address and loaded with a unique program determined as part of the SimpleConnect setup process. The program loaded into the device utilizes a SimpleConnect standard communication protocol and bit arraignment to establish and maintain communication to the robot controller. The program also defines how the available inputs and outputs are to be utilized for the application selected. More details surrounding this device can be found under the “Ethernet/IP to Discrete IO Module” topic below.
5. M23 Pwr/Net Module: This connectorized printed circuit board and connectors allows the Yaskawa custom cables to be connected quickly and provides a rugged connection point bringing power and EtherNet/IP to the device before relaying the same power and EtherNet/IP signals to the next device. This board also enables 24VDC to be supplied to the enclosure.
6. Squash plate mounting brackets: Allows convenient mounting to a fence (solid or mesh).

With the right-side panel open, this is the back view of the operator button panel, showing the backs of the buttons and the I/O module:

Sideway / ISO view:

Cable Connections:

EtherNet/IP to Discrete IO Module:

This interface includes a discrete IO converter to convert from EtherNet/IP to discrete I/O. This module has PNP inputs and outputs. There are 4 input and 4 output points on the module to control or interface with the tip change box controls. All points are PNP transistors (either for input or output purposes).

The IP-address and configuration of the various IO-points is accomplished via a program that is pushed into the module when initially deployed and set up via the SimpleConnect application. Further details on the contents of that program can be found in the “Software Details” section towards the bottom of this article.

IO-Mapping:

Robot Inputs (Tip Change Box EtherNet/IP module outputs):

The following table details the robot inputs generated at the tip change interface and sent to the robot controller. The table shows two possible tip change box stations that can be connected and the associated Universal and External Input addresses. Some inputs are a mirror of the commanded robot outputs & can be used in INFORM logic to ensure commands are being honored at the device.  (Up to 4 Tip Change Boxes are possible, currently no standard solutions require this many units.  To avoid overwhelming information only 2 devices will be detailed.  For additional information on station 3 or 4 contact Yaskawa Support.)

Robot Outputs (Tip Change Box /EtherNet/IP module inputs):

The following table details the robot outputs generated at the robot controller and sent to the tip change box’s EtherNet/IP module. The table shows that up to two different tip change boxes can be connected and in a system; the associated Universal and External Output addresses are also listed.  (Up to 4 Tip Change Boxes are possible, currently no standard solutions require this many units.  To avoid overwhelming information only 2 devices will be detailed.  For additional information on station 3 or 4 contact Yaskawa Support.)

LED Indicators:

The module has three LEDs that indicate the status of the device’s operation and network status. The LED and their statuses are listed below:

• BUS:

• P1 / P2:

• ERR:

Software Details - Details of the device program placed in the Tip Change Box interface:

The program placed within the Tip Change Box interface is built upon the “YAI SimpleConnect template” that’s utilized in all EtherNet/IP devices that utilize the EtherNet/IP IO-modules. 

• Main take aways from the “YAI SimpleConnect template” include:
  • Each IO-Module generates a 4-bit “Heartbeat” which is always incrementing & monitored by the robot to ensure that it’s constantly communicating with the robot
  • Each IO-Module reports a “Product_ID” value unique to what program loaded into the module
  • Each IO-Module generates two bits indicating if the IO-module is in a new or active alarm state
  • The robot reports a 3-bit “Identity” value which allows the device to know which instance it is in the event multiple instances of the same device exist.
  • The robot also reports 5-bits of current “operational status” (PLAY,TEACH,REMOTE,OPERATING,ALARM)
  • If an error is present at the IO-Module it will be reported to the robot and displayed on the teach pendant as an alarm or message based on its predetermined severity.
  • If an output is commanded from the robot but communication with the robot is lost while the output is on, the IO-module will automatically shut-off the output until communication with the robot is resumed.
• Tip Change Box specific additions to the template:
  • This device has NO customization or non-direct signal I/O routing. All I/O is mapped 1:1.
  • Concurrent I/O logic and INFORM robot jobs in the robot controller manages the generation of signals and requests to the Beacon to generate the servo on restart.

Extra Image(s):

Additional Info Links:

• https://knowledge.motoman.com/hc/en-us/articles/21007991693079-Remote-Mode-Issues-with-Tip-Change-Box