YAI YDG Barrier Interface

Part#(s):

• 186910-1: Interface Assembly, Barrier Door, EtherNet/IP  (OBSOLETE)
• 186910-2: Interface Assembly, Barrier Door, EtherNet/IP
• 186910-3: Interface Assembly, Barrier Door, EtherNet/IP, Banner Light Curtains
• 186910-4: Interface Assembly, Barrier Door, EtherNet/IP, Sick Light Curtains

Used within the following barrier assemblies:

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Overview:

The YAI YDG-Barrier / Door Guard Interface (PN#186910-*) is a modular enclosure that mounts within a Yaskawa manufactured Barrier Door and provides an EtherNet/IP connection and safety wiring from this subsystem back to the YRC1000 robot controller.  This allows for a modular build, testing of components, and reduced wiring between the subsystems.  The barrier door interface is ready to accept various light curtain connections and brands, depending on the part numbers selected. 

Components:

The interface consists of several major hardware components:

1. VFD: this variable frequency drive controls the motor for up and down motion of the barrier door.  It is I/O controller and takes 480VAC for power.  I/O is wired the EtherNet/IP-to-Discrete IO-Module which is discussed in more detail in bullet point #3.
2. Main Housing: This sheet metal housing provided mounting, enclosure, and protection for the components in this solution.(This is everything in dark grey)  This entire interface or enclosure is later inserted into one of the Barrier Assembly part numbers listed earlier.
3. EtherNet/IP-to-Discrete IO-Module: This commercially available device is assigned 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.
4. M12 Accessory Board (5-Port): This printed circuit board contains several internal and external connection points for cabling, on-board fusing, & fuse status indicators.
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.

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 16 IO points that can be configured for either inputs or outputs and are designated by the labels “IO*”. In this application, these IO points are all configured as input or output per the below in the chart. 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 setup via the SimpleConnect application. Further details on the contents of that program can be found in the linked article listed under “Associated Software Details” listed at the top of this page.

IO-Mapping:

Robot Inputs (Barrier Door EtherNet/IP module outputs):

The following table details the robot inputs generated at the barrier door interface enclosure and set to the robot controller. The table shows four possible barrier doors 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.

Robot Outputs (Barrier/EtherNet/IP module inputs):

The following table details the robot outputs generated at the robot controller and sent to the barrier door interface enclosure’s EtherNet/IP module. The table shows four barrier doors that can be connected and the associated Universal and External Output addresses.

LED Indicators:

The module has three LEDs that annunciate 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 places in the Barrier Door interface:

The program placed within the Barrier Door 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 on 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.
• Barrier Door specific additions to the template:
  • This device has NO customization or non-direct signal I/O routing. All I/O is mapped 1:1.
  • Robot generated outputs intended for the barrier door are passed to the controlling VFD with no additional logic other than the robot must be connected via EtherNet/IP in order for the output to be issued.  (These signals are “cut off” by relay contacts controlled by in-position sensors allowing quick reaction time at the hardware level.  No change from DX200 design.)

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