18. Custom protocol slave commands

18.1. Overview

18.2. Industrial Bus Protocol Integration for Robot Motion Control

To facilitate PLC-based robot motion control through various industrial bus protocols (CC-Link IEF Basic, Profinet, Ethernet/IP, and EtherCAT), the integrated mini control cabinet has been equipped with FRH-PCIeN-EC/EIP/CC/PN-RJ-V10 cards, FRJ-PCIeN-EIP/CC/PN-RJ-V10 cards, and FRJ-PCIeN-EC-RJ-V10 cards.

18.3. Environment Configuration

The required card models and software versions are as follows:

Protocol Type	Board Model	Robot Software Version
CC-Link IEF Basic	FRJ-PCIeN-EIP/CC/PN-RJ-V10 Board	V3.8.4 and above
CC-Link IEF Basic	FRJ-PCIeN-EC-RJ-V10 Board	V3.9.5 and above
Profinet	FRJ-PCIeN-EIP/CC/PN-RJ-V10 Board	V3.8.4 and above
Profinet	FRJ-PCIeN-EC-RJ-V10 Board	V3.9.5 and above
Ethernet/IP	FRJ-PCIeN-EIP/CC/PN-RJ-V10 Board	V3.8.4 and above
Ethernet/IP	FRJ-PCIeN-EC-RJ-V10 Board	V3.9.5 and above
EtherCAT	FRJ-PCIeN-EC-RJ-V10 Board	V3.9.5 and above

18.3.1. FRH-PCIeN-EC/EIP/CC/PN-RJ-V10 board hardware environment setup

1. Install the FRH-PCIeN-EC/EIP/CC/PN-RJ-V10 board into the integrated mini control box as shown.

Figure 17.2-1 FRH-PCIeN-EC/EIP/CC/PN-RJ-V10 board installation

Figure 17.2-2 FRH-PCIeN-EC/EIP/CC/PN-RJ-V10 board network port

2. The robot control box and PLC wiring is shown below.

Figure 17.2-3 Control Box & Mitsubishi PLC Wiring Diagrams

Figure 17.2-4 Control Box & Siemens PLC Wiring Diagrams

Figure 17.2-5 Control Box & Omron PLC Wiring Diagrams

Figure 17.2-6 Control Box & Omron PLC Wiring Diagrams

Note

1: Robot control box (board input network port); 2: Switch; 3: PC; 4: Mitsubishi PLC (CC-Link IEF Basic network port); 5: Siemens PLC (Profinet network port); 6: Omron PLC (Ethernet/IP network port); 7: Omron PLC (EtherCAT network port);

Important

When the protocol is switched to EtherCAT bus, the board’s network port needs to be distinguished as EtherCAT_IN and EtherCAT_OUT. At this time, the PLC’s EtherCAT network port is directly connected to the board’s EtherCAT_IN through a network cable.

18.3.2. FRJ-PCIeN Board Hardware Setup

1. Install the board into the integrated mini control box as shown.

Figure 17.2-7 FRJ-PCIeN Board Ethernet Port

2. Wiring between robot control box and PLC is shown below.

Figure 17.2-8 Control Box & Mitsubishi PLC Wiring Diagram

Figure 17.2-9 Control Box & Siemens PLC Wiring Diagram

Figure 17.2-10 Control Box & Inovance PLC Wiring Diagram

Note

1: Robot control box (board Ethernet port); 2: Switch; 3: Laptop PC; 4: Mitsubishi PLC (CC-Link IEF Basic port); 5: Siemens PLC (Profinet port); 6: Inovance PLC (Ethernet/IP port);

18.3.2.1. FRJ-PCIeN-EIP/CC/PN-RJ-V10 Board Firmware Upgrade

When switching protocols on the board, a firmware upgrade is required. During the firmware upgrade, the IP address of the board and the IP address of the laptop PC must be configured on the same network segment. Then, open the “Gateway Tool Set” software -> select the PC network card device to be connected -> click the “Start” button in the lower right corner -> click the “Search” button in the upper right corner to search for the board device.

Figure 17.2-11 Connecting Board Device

Click “Upgrade” (bottom left)

• Select board device

• Click “…” (top right) to choose protocol firmware

• Click “Upgrade” and wait for completion

Figure 17.2-12 Board Protocol Switching

Note

IP address changes after protocol switching as shown below.

Table 17.2-1 Board IP Addresses

Protocol	IP Address
CC-Link IEF Basic	192.168.0.113
Ethernet/IP	192.168.0.112
Profinet	192.168.0.2

When configured for CC-Link IEF Basic, controller changes board IP to “192.168.0.113”.

When configured for Ethernet/IP, controller changes board IP to “192.168.0.112”.

When switching to Profinet, if slave device name matches master, master will automatically configure slave IP.

18.3.2.2. FRJ-PCIeN-EC-RJ-V10 Board Firmware Upgrade

Enter the robot interface via the URL 192.169.58.2, then click “Initial Settings” -> “Peripherals” -> “Board Communication” to obtain the firmware version number of the FRJ-PCIeN-EC-RJ-V10 board. Select the bin file to be upgraded, click Upload, wait for the firmware upgrade to complete, and then restart the control box.

Figure 17.2-13 Board Firmware Upgrade

Note

To upgrade the firmware of the FRJ-PCIeN-EC-RJ-V10 board, the running open protocol must be unloaded first.

18.3.3. Software environment setup

1. Browser IP input 192.168.58.2, account for admin, password for 123, click ‘Login’, enter the robot control box Web interface.

Figure 17.2-14 Web Login Interface

2. Click System Settings -> About Interface, click the Software Upgrade button, select the software.tar.gz file, and upload the upgrade package.

Figure 17.2-15 Upgrade software

Note

QX control box web version needs 3.8.0 and above, LA control box web version needs 3.8.0 and above.

3. Click the extension button in the upper right corner and switch from ‘Local Mode’ to ‘Remote Mode’.

Figure 17.2-16 Switch remote mode

4. Select the controller slave protocol and whether the auto-start function is required, then click the “Set” button. Note: To switch between different protocols, you need to click the “Uninstall” button first before configuring other protocols.

Figure 17.2-17 Configure the communication protocol

Note

Switching different protocols requires restarting the control box before configuring the protocols.

18.3.4. PLC Environment construction

The test environment built to implement the slave commands for each protocol is shown in the table below, which includes the PLC model, firmware version and test software used in each protocol.

Protocol	Brand	Type	Firmware	Software
Profinet	Siemens	CPU 1515-2 PN	6ES75152AM020AB0	TIA Portal V17
CC-Link IEF Basic	Mitsubishi	FX5S-30TR/DS	30MR/ES V1.3	GX Works3 V1.097B
Ethernet/IP	Omron	MX102-1100	V1.3	Sysmac Studio V1.50
EtherCAT	Omron	MX102-1100	V1.3	Sysmac Studio V1.50

18.3.4.1. Siemens Profinet

1. GSD file (XML file) importing

Open Siemens programming software TIA Portal V17, create a new PLC project, select ‘Devices and Networks’, and select ‘Hardware Catalogue’ on the right side to add PLC module by double clicking 6ES7 515-2AM02-0AB0 to add PLC module.

In the TIA PORTAL software, select Options-> Manage Generic Station Description File (GSD) in the menu bar to install or remove a GSD file that has already been installed.

As an example, to install the Herschel GSD file, select ‘Manage Generic Station Description File (GSD)’ as above, and the ‘Manage Generic Station Description File’ window will appear.

Select the folder where you want to install the GSD file from the ‘Source Path’, select one or more files to install from the list of displayed GSD files, and click the ‘Install’ button. Click the Install button as shown in the following figure.

After successful installation, you can find the device with the installed GSD file in the hardware catalogue, other field devices, as shown in the figure below.

2. Executable programme

Open the project ‘QNXtest’.

Compiler: Double-click on the left side of the project tree to enter ‘Devices and Networks’, right-click on the ‘PLC_1’ module, select Compile from the drop-down menu, and then select ‘Hardware and Software (Changes Only)’ from the stand-alone menu. Hardware and Software (Changes Only)’. After the compilation is completed, it will prompt ‘Compilation complete’ at the bottom of the software view.

Download the programme to the device: Double click on the left side of the project tree to enter the ‘Device and Network’, right click on the ‘PLC_1’ module, and select ‘Download to Device’ from the drop-down menu. ‘Download to Device’, “Hardware and Software (change only)”.

Search and download devices: After the pop-up window, configure the PG/PC interface type as shown in the following figure, click Start Search, select the device that needs to download the programme, and click Download.

18.3.4.2. Mitsubishi CC-Link IEF Basic

1. CC-Link IEF Basic Setup

Enable CC-Link IEF Basic: Select ‘Ethernet Port’ in the left menu bar, set the ip address of PLC and make sure it is in the same network segment as the address of Huexun card. Click ‘CC-Link IEF Basic’ and select ‘Use’.

CC-Link IEF Basic Network Configuration Settings: Also in CC-Link IEF Basic Settings, select ‘Network Configuration Settings’, and choose Hueyoson CIFX Digital I/O module. Drag and drop the module to the bottom left of the view to complete the hardware configuration.

CC-Link IEF Basic Refresh Settings: Also in CC-Link IEF Basic Settings, click Refresh Settings to customise the transmission settings: 256 bytes receive, 256 bytes transmit.

2. Program Download

After opening the test programme, click ‘Online’->‘Write to Programmable Controller’ to enter the download interface.

After opening the download interface, click ‘Parameter+Programme’ on the top left, then click ‘Execute’ on the bottom right corner to download, wait for the download to complete.

18.3.4.3. Inovance EtherCAT Configuration

1. XML File Import

Open Inovance AutoShop programming software and create a new PLC project. Select “EtherCAT Devices” from the right toolbox:

Right-click after selecting “EtherCAT Devices” to open the “Import Device XML” dialog. Locate the folder containing the card’s XML file. After successful import, the card name will appear under “EtherCAT Devices”. Close and reopen the project to complete the import process.

2. Variable Mapping

Double-click the variable table in the left toolbar. Create: - 256-byte input array (Soft element address: D0) - 256-byte output array (Soft element address: D200)

Under “EtherCAT” in the left toolbar, double-click “Xone-PCIe-ECATs”. In the dialog, click “I/O Mapping”, then bind variable addresses by selecting from the variable table. Repeat sequentially for other addresses.

3. Program Download

Open the test program and change PLC IP from default “192.168.1.88” to “192.168.0.88”:

Click “Modify IP/Device Name” and update both IP and gateway to “192.168.0.88”:

Confirm modification by clicking “Yes” in the popup dialog when clicking “Modify IP”.

After successful communication, download the PLC program.

18.3.5. HMI setting (CC-Link IEF Basic emulation)

1. After logging into the HMI interface, enable ‘Enable Task’ to establish the communication connection between PLC and controller.

2. Click ‘01_MC_EnableRobot’ interface and then click ‘EnableRobot’ to enable the robot, and click ‘Reset’ to reset if there is any error during the process.

3. Click ‘02_MC_ToolData’ to enter the tool information interface, enter the parameters on the left and click WriteToolData to write the tool information; on the right, click ReadToolData to read the existing tool information.

4. Click ‘03_MC_FrameData’ to enter the interface of workpiece information. On the left side, after inputting parameters, click WriteFrameData to write workpiece information; on the right side, click ReadFrameData to read existing workpiece information.

5. Click ‘04_MC_LoadData’ to enter the load information interface, enter the parameters on the left and click WriteLoadData to write load information; on the right, click ReadLoadData to read the existing load information.

6. Click ‘05_MC_RobotReferenceDynamics’ to enter the interface of Maximum Velocity and Maximum Acceleration of Robot, enter the parameters on the left side and then click WriteRobotRefD to write the information of Maximum Velocity and Maximum Acceleration; click ReadRobotRefD on the right side to read the information of Maximum Velocity and Maximum Acceleration. On the right side, click ReadRobotRefD to read the max speed and max acceleration information.

7. Click ‘06_MC_Robot DefaultDynamics’ to enter the interface of robot default speed and default acceleration, enter the parameters on the left side and click WriteRobotDefD to write the default speed and default acceleration information; on the right side, click ReadRobotDefD to read the default speed and default acceleration information. on the left side, and then click WriteRobotDefD to write the default speed and default acceleration information; on the right side, click ReadRobotDefD to read the information.

8. Click ‘07_MC_RobotSwLimits’ to enter the coordinate limit interface. On the left side, input the maximum limit and minimum limit parameter values and click WriteRobotSwLimits to write the limit parameter information; on the right side, click ReadRobotSwLimits to read the existing limit parameter information. parameter information.

9. Click ‘08_MC_ReadActualPosition’ to enter the read actual position interface, click ReadPosition to read the existing position information.

10. Click ‘09_MC_MoveLinearAbsolute’ to enter the Linear Motion interface, input the coordinate parameter and click MoveLinearAbsolute to make the robot move linearly at the target position.

11. Click ‘10_MC_MoveAxesAbsolute’ to enter the interface of axis coordinate movement, input the coordinate parameter and click MoveAxesAbsolute to make the robot move to the target position with the input axis coordinate as the end point.

12. Click ‘11_MC_MoveDirectAbsolute’ to enter the direct motion interface, input the coordinate parameter and click MoveDirectAbsolute to make the robot move directly to the target position with the input parameter as the end point.

13. Click ‘12_MC_Groups’ to enter the direct motion interface, in which, clicking GroupInterrupt can interrupt the movement of the robot in the process of movement, and clicking GroupContinue can make the robot continue to move to the target position. Click GroupStop to stop (end) the ongoing position movement. If an alarm or error is triggered during the process, click GroupReset to reset the robot to the error.

14. Click ‘13_MC_PositionConversion’ to enter the position conversion interface, XtoJ1 can be converted from Cartesian position to joint angle, and J1toX can be converted from joint angle to Cartesian position.

15. Click ‘14_MC_GroupJog’ to enter the interface of robot jogging, after the configuration is finished, drop down the axes to select the axis you need to jog, and then select the rotation direction of the axis. Click JogMove to move. MC_ChangeSpeedOverride on the right side can adjust the moving speed of the robot arm.

18.3.6. HMI setting (Profinet emulation)

1. After opening the programme, click on ‘HMI_1[ktp700 Basic PN]’ in the project tree, and then click on ‘Online’→‘Simulation’→‘Start’ in the menu bar. Click ‘Online’→‘Simulation’→‘Start’ in the menu bar. Wait for the software to compile and simulate.

2. The function after emulation is the same as the content of the Velcro screen (CC-Link IEF Basic). You can refer to the above content to set up.

18.4. Robot Slave Mode Operation Manual

18.4.1. Loading Slave Mode

Step 1: Open the WebApp, navigate to Initial Setup -> Peripherals -> Board Communication -> Manual Configuration.

Figure 17.3-1 Board Communication Manual Configuration

First, configure the IP address of the FRJ-PCIeN board. If left blank, the board will use the default IP: 192.168.0.100 for startup configuration. Currently, IP configuration only applies to EIP and CC-Link IEF Basic protocols. For PN protocol, the IP is assigned by the PLC master station scanning slave devices.

Note

After changing the IP address on the page, you need to load the slave mode for the changes to take effect.

Select the required mapping functions for DI, DO, and AO (see Appendix 1). The parameters are defined as follows:

• DI (Robot Control): The robot slave accepts external input signals and executes the mapped functions.

• DO (Robot Status Output): The robot slave feeds back status signals to the master station.

• AO (Robot Status Feedback): The robot slave feeds back status data to the master station. AO0~AO15 are signed integers (int16), and AO16~AO31 are single-precision floating-point numbers (float).

Step 2: Click the “Configure” button to generate the open protocol Lua file.

Figure 17.3-2 Device Operation and Status

Note

The open protocol Lua file supports download and can be imported in the auto-configuration interface.

Example generated program:

local id = 3
local ctrlDI = {0, 0, 0, 0, 0, 0}
local funcDI = {0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0}
local DOState = {0, 0, 0, 0, 0, 0, 0, 0}
local AOState = {0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0}
-- Launch the board communication process
LoadFieldBusSlave()
sleep_ms(8000)
while(1) do
   -- Set the DO status
   CtrlBoxDO, CtrlBoxCO, CtrlBoxDI, CtrlBoxCI, errState, motionState, moveToOriginState, robotStartDoneState, modeChangeState, programStartStopState, emergencyState, reduceState, collision, enablestate, safetyStop0, safetyStop1, pauseState, interfereState = GetRobotFuncDOState()
   DOState[1] = CtrlBoxDO
   DOState[2] = CtrlBoxCO
   DOState[3] = CtrlBoxDI
   DOState[4] = CtrlBoxCI
   local ctrlWord0 = 0
   ctrlWord0 = SetBitWithIndex(ctrlWord0, 0, errState)
   ctrlWord0 = SetBitWithIndex(ctrlWord0, 1, motionState)
   ctrlWord0 = SetBitWithIndex(ctrlWord0, 2, moveToOriginState)
   ctrlWord0 = SetBitWithIndex(ctrlWord0, 3, robotStartDoneState)
   ctrlWord0 = SetBitWithIndex(ctrlWord0, 4, modeChangeState)
   ctrlWord0 = SetBitWithIndex(ctrlWord0, 5, programStartStopState)
   ctrlWord0 = SetBitWithIndex(ctrlWord0, 6, emergencyState)
   ctrlWord0 = SetBitWithIndex(ctrlWord0, 7, reduceState)
   DOState[5] = ctrlWord0
   local ctrlWord1 = 0
   ctrlWord1 = SetBitWithIndex(ctrlWord1, 0, collision)
   ctrlWord1 = SetBitWithIndex(ctrlWord1, 1, enablestate)
   ctrlWord1 = SetBitWithIndex(ctrlWord1, 2, safetyStop0)
   ctrlWord1 = SetBitWithIndex(ctrlWord1, 3, safetyStop1)
   ctrlWord1 = SetBitWithIndex(ctrlWord1, 4, pauseState)
   ctrlWord1 = SetBitWithIndex(ctrlWord1, 5, interfereState)
   DOState[6] = ctrlWord1
   SetFieldBusDOState(DOState)

   -- Set the AO status
   mainErrCode, subErrCode, TCPSpeed, axisPos1, axisPos2, axisPos3, axisPos4, axisPos5, axisPos6, jointVelFeedback1, jointVelFeedback2, jointVelFeedback3, jointVelFeedback4, jointVelFeedback5, jointVelFeedback6, jointCurFeedback1, jointCurFeedback2, jointCurFeedback3,jointCurFeedback4,jointCurFeedback5,jointCurFeedback6, jointTorqueFeedback1, jointTorqueFeedback2,jointTorqueFeedback3,jointTorqueFeedback4, jointTorqueFeedback5, jointTorqueFeedback6, cartPosx, cartPosy, cartPosz, cartPosrx, cartPosry, cartPosrz = GetRobotFuncAOState()
   AOState[1] = mainErrCode
   AOState[2] = subErrCode
   AOState[17] = axisPos1
   AOState[18] = axisPos2
   AOState[19] = axisPos3
   AOState[20] = axisPos4
   AOState[21] = axisPos5
   AOState[22] = axisPos6
   AOState[23] = cartPosx
   AOState[24] = cartPosy
   AOState[25] = cartPosz
   AOState[26] = cartPosrx
   AOState[27] = cartPosry
   AOState[28] = cartPosrz
   SetFieldBusAOState(AOState)
   sleep_ms(10)

   -- Set the DI status
   -- Configure the DI function and update it in real-time
   ctrlDI[1],ctrlDI[2],ctrlDI[3],ctrlDI[4],ctrlDI[5],ctrlDI[6] = GetFieldBusDIState()
   funcDI[1] = ctrlDI[1]
   funcDI[2] = ctrlDI[2]
   funcDI[3] = GetBitWithIndex(ctrlDI[3], 0)
   funcDI[4] = GetBitWithIndex(ctrlDI[3], 1)
   funcDI[5] = GetBitWithIndex(ctrlDI[3], 2)
   funcDI[6] = GetBitWithIndex(ctrlDI[3], 3)
   funcDI[7] = GetBitWithIndex(ctrlDI[3], 4)
   funcDI[8] = GetBitWithIndex(ctrlDI[3], 5)
   funcDI[9] = GetBitWithIndex(ctrlDI[3], 6)
   funcDI[10] = GetBitWithIndex(ctrlDI[3], 7)
   funcDI[11] = GetBitWithIndex(ctrlDI[4], 0)
   funcDI[12] = GetBitWithIndex(ctrlDI[4], 1)
   funcDI[13] = GetBitWithIndex(ctrlDI[4], 2)
   funcDI[14] = GetBitWithIndex(ctrlDI[4], 3)
   funcDI[15] = GetBitWithIndex(ctrlDI[4], 4)
   funcDI[16] = GetBitWithIndex(ctrlDI[4], 5)
   SetRobotFuncDIState(funcDI)
   local stopFlag = GetOpenLUAStopFlag(id)
   if(stopFlag ~= 0) then
      UnloadFieldBusSlave()
      break
   end
   sleep_ms(10)
end

Step 3: Click the “Load” button to load the robot slave mode.

Figure 17.3-3 Loading Slave Mode

Note

After successfully loading the robot slave mode, the auto-start function is supported. To use remote mode, unload the slave mode first.

Step 4: Click the status bar button on the right to monitor DI, DO, AI, and AO interaction information. The parameters are as follows:

• CtrlDO: Input signal value from the master device controlling the robot control box DO.

• DI: Input signal value from the external master control.

• DO: Output signal value fed back by the robot slave.

• AI: Input value from the external master. AI0~AI15 are int16 type, and AI16~AI31 are float type.

• AO: Output value from the robot slave. AO0~AO15 are int16 type, and AO16~AO31 are float type.

Figure 17.3-4 DI, DO, AI, AO Interaction Information

Step 5:After loading is complete, you can use the Teach Program -> Communication Command -> Board Card to generate Lua commands for the board. This allows you to:

1. Set Slave DO (Digital Output) and AO (Analog Output).

2. Read Slave DI (Digital Input) and AI (Analog Input).

3. Wait for Slave DI and AI signals.

Figure 17.3-5 Board Lua Commands

Appendix 1: Slave Mode Address Mapping Table

18.5. Board Communication Cycle Configuration

18.5.1. FRJ-PCIeN-EIP/CC/PN-RJ-V10 Board

The communication cycle of the board can be configured via the host computer. Currently, only PN protocol firmware is provided, with future compatibility for EIP, CC-Link IE Basic, and EtherCAT protocols.

1. Directly connect the PC (Windows 11 system) network port to the board’s network port. Open Device Assistant v1.1.0, double-click “Ethernet,” and click the “Refresh” button in the upper left corner to scan for currently connected board devices.

2. In the firmware update interface, upload the new version of PN firmware and click the “Update” button. A prompt reading “Upgrade Successful” will appear in the lower left corner when printed.

3. Enter the desired communication cycle (supports 1~100ms) and click the “Set” button. A prompt reading “Cycle Setting Successful” will appear in the lower left corner when printed.

18.5.2. FRJ-PCIeN-EC-RJ-V10 Board

Enter the robot interface via the URL 192.169.58.2, then click “Initial Settings” -> “Peripherals” -> “Board Communication” to obtain the board communication cycle. Enter the required communication cycle (1~100 ms), click the “Configure” button, wait for the configuration to complete, and then restart the control box.

Note

To configure the communication cycle of the FRJ-PCIeN-EC-RJ-V10 board, the running open protocol must be unloaded first.

18.6. Appendice

18.6.1. Instruction List

Command code	Command description
0x1000	Robot enablement
0x1001	Reset all error
0x1002	Robot stops moving
0x1003	Read actual position
0x1004	Set robot speed
0x1005	Resume robot motion
0x1006	Robot pauses motion
0x1007	Calculate the Cartesian position from the joint position
0x1008	Calculate joint position from Cartesian position
0x2000	Write tool information
0x2001	Read tool information
0x2002	Write workpiece information
0x2003	Read workpiece information
0x2004	Write load information
0x2005	Read load information
0x2006	Write reference dynamic information
0x2007	Read reference dynamic information
0x2008	Write default dynamic information
0x2009	Read default dynamic information
0x2010	Write soft limit information
0x2011	Read soft limit information
0x3000	MoveAxes (based on joint angle)
0x3001	MoveLinear
0x3002	MoveDirect (based on Cartesian coordinate system)
0x3003	jog motion
0x3004	jog stop