2.5 RapidPlan Controller Profinet Interface User Guide

1 Overview
2 Hardware Requirement
3 Profinet I/O Data Mapping
- 3.1 General rules of I/O mapping
4 RTR controller I/O module slot assignment
5 Export ID’s
6 Getting started with Profinet communication on RapidPlan
7 Typical Move command timing sequence
- 7.1 Move
- 7.2 Combined Move with Smoothing enabled
- 7.3 Combined Move with HoldMove
8 Programming Notes
9 Known issues
10 Typical communication latencies
11 GSD file

Overview

As a preliminary feature, Profinet is supported in RapidPlan 2.5. Please contact Realtime Robotics for technical support.

Hardware Requirement

RTR controller V1: Intel I210 NIC or newer PCI-e add-on card is required.
RTR Runtime Controller.

Profinet I/O Data Mapping

To download an offline copy of the I/O data mapping, click the icon below and save:

General rules of I/O mapping

Input: from RTR controller to PLC.
Output: from PLC to RTR controller.
all byte and bit offsets are 0-based.
if not defined on bit level, bytes are unsigned integers(0-255).
integers and DINT's are signed and Cyclic values unless specified otherwise.
all bit level requests are edge triggered unless specified as cyclic.
default values should always be 0 unless specified otherwise.
if there's a command conflict due to shared data fields between 2 commands, e.g., SetAlternateLocation with specified config, and a move to pose/config, both commands will be rejected and a command error code will be given.
max. # of presets per robot: 255;
max. # of object states: 255;
max. # of stateful objects: 32
max. # of targets per project: 16777215 (0xFFFFFF);
max # of move segments per Combined Move: 10
Time-based trigger functionality from the Move command is excluded from the I/O map because the PLC can track the Move status and create its own time-based triggers.

RTR controller I/O module slot assignment

Profinet device Module-Slot assignment

A HW Configuration example of a 2-robot RapidPlan project

Input: from RTR controller to PLC.
Output: from PLC to RTR controller.

slot 1 is always reserved for 16 byte RTR controller input
slot 2 is always reserved for 16 byte RTR controller output
slot 3 is always reserved for 32 byte object states input
slot 4 is always reserved for 32 byte object states output
slot 5 is always reserved for 48 byte DSM input
slot 6 is always reserved for 48 byte DSM output
slot 7 is always reserved for 64 byte robot 1 input
slot 8 is always reserved for 64 byte robot 1 output
and so on for robot 2, to robot 16, for the slots thereafter. For each robot, it always starts with 64 bytes of input and then 64 bytes of output.
slot 1 to slot 6 are always fixed(not editable) and required.
from slot 7 and beyond, there can be no gaps. For example, a user can't have robot 1, and robot 5 for a 2-robot cell. It must be robot 1 and robot 2. The robot ID numbers are generated by appliance as part of the export lookup table and the same rule is followed.

Export ID’s

In order to address RapidPlan objects efficiently in a Profinet interface, symbolic names must be replaced by numerical values. Therefore, a lookup table is generated by Appliance and can be download from the Control Panel. Anytime a RapidPlan project is changed during runtime, or targets are updated/added/removed, the lookup table must be re-exported and PLC programs must be updated accordingly.

project ID: an integer generate by RapidPlan
robots: 0-15
stateful object ID: 0-31
robot preset ID: 0-255(0xFF) - may be the same under different robots
frame ID and target ID: 0-16777215(0xFFFFFF) - globally unique
object states ID: 0-255 - may be the same under different object ID
Any time a project is loaded in Control Panel, or targets are added or deleted or renamed, the user is responsible to re-download the updated ID file from CP.
Up to 2 external axes are supported by the PNIO data map. There’s no specific look up value for each external axis. External axis#1 is always the axis with lower actuator index number.

An example:

project: 1
robots:
  Robot1: 0
  Robot2: 1
  Robot3: 2
  Robot4: 3
  Robot5: 4
presets:
  Robot1:
    default: 0
  Robot2:
    Preset1_no_eoat: 0
    Preset2_torch: 1
    Preset3_weld: 2
  Robot3:
    Preset1: 0
  Robot4:
    Preset1: 0
  Robot5:
    Preset1: 0
    Preset10: 1
    Preset11: 2
    Preset12: 3
    Preset13: 4
    Preset14: 5
    Preset15: 6
    Preset16: 7
    Preset17: 8
    Preset2: 9
    Preset3: 10
    Preset4: 11
    Preset5: 12
    Preset6: 13
    Preset7: 14
    Preset8: 15
    Preset9: 16
targets:
  Robot1:
    default:
      r1a1: 0
      r1a2: 1
      r1a3: 2
      r1a45: 3
      r1alt: 4
      r1home: 5
      r1t1: 6
      r1t2: 7
      r1t3: 8
      r1t4: 9
      r1t5: 10
      r1t6: 11
      r1up: 12
  Robot2:
    Preset3_weld:
      r2a1: 13
      r2a2: 14
      r2a3: 15
      r2a4: 16
      r2alt: 17
      r2home: 18
      r2t1: 19
      r2t2: 20
      r2t3: 21
      r2t4: 22
      r2up: 23
  Robot3:
    Preset1:
      r3t1: 24
      r3t10: 25
      r3t100: 26
      r3t11: 27
      r3t12: 28
      r3t13: 29
      r3t14: 30
      r3t15: 31
      r3t16: 32
      r3t17: 33
      r3t18: 34
      r3t19: 35
      r3t2: 36
      r3t20: 37
      r3t21: 38
      r3t22: 39
      r3t23: 40
      r3t24: 41
      r3t25: 42
      r3t26: 43
      r3t27: 44
      r3t28: 45
      r3t29: 46
      r3t3: 47
      r3t30: 48
      r3t31: 49
      r3t32: 50
      r3t33: 51
      r3t34: 52
      r3t35: 53
      r3t36: 54
      r3t37: 55
      r3t38: 56
      r3t39: 57
      r3t4: 58
      r3t40: 59
      r3t41: 60
      r3t42: 61
      r3t43: 62
      r3t44: 63
      r3t45: 64
      r3t46: 65
      r3t47: 66
      r3t48: 67
      r3t49: 68
      r3t5: 69
      r3t50: 70
      r3t51: 71
      r3t52: 72
      r3t53: 73
      r3t54: 74
      r3t55: 75
      r3t56: 76
      r3t57: 77
      r3t58: 78
      r3t59: 79
      r3t6: 80
      r3t60: 81
      r3t61: 82
      r3t62: 83
      r3t63: 84
      r3t64: 85
      r3t65: 86
      r3t66: 87
      r3t67: 88
      r3t68: 89
      r3t69: 90
      r3t7: 91
      r3t70: 92
      r3t71: 93
      r3t72: 94
      r3t73: 95
      r3t74: 96
      r3t75: 97
      r3t76: 98
      r3t77: 99
      r3t78: 100
      r3t79: 101
      r3t8: 102
      r3t80: 103
      r3t81: 104
      r3t82: 105
      r3t83: 106
      r3t84: 107
      r3t85: 108
      r3t86: 109
      r3t87: 110
      r3t88: 111
      r3t89: 112
      r3t9: 113
      r3t90: 114
      r3t91: 115
      r3t92: 116
      r3t93: 117
      r3t94: 118
      r3t95: 119
      r3t96: 120
      r3t97: 121
      r3t98: 122
      r3t99: 123
      r3up: 124
  Robot4:
    Preset1:
      r4home: 125
      r4t1: 126
      r4t10: 127
      r4t11: 128
      r4t12: 129
      r4t13: 130
      r4t14: 131
      r4t15: 132
      r4t16: 133
      r4t17: 134
      r4t18: 135
      r4t19: 136
      r4t2: 137
      r4t20: 138
      r4t21: 139
      r4t22: 140
      r4t23: 141
      r4t24: 142
      r4t25: 143
      r4t26: 144
      r4t27: 145
      r4t28: 146
      r4t29: 147
      r4t3: 148
      r4t30: 149
      r4t31: 150
      r4t32: 151
      r4t33: 152
      r4t34: 153
      r4t35: 154
      r4t36: 155
      r4t37: 156
      r4t38: 157
      r4t39: 158
      r4t4: 159
      r4t40: 160
      r4t41: 161
      r4t42: 162
      r4t43: 163
      r4t44: 164
      r4t45: 165
      r4t46: 166
      r4t47: 167
      r4t48: 168
      r4t49: 169
      r4t5: 170
      r4t50: 171
      r4t6: 172
      r4t7: 173
      r4t8: 174
      r4t9: 175
      r4up: 176
frames:
  Robot1:
    r1_default_tcp: 3
    r1_tcp: 4
  Robot2:
    r2_default_tcp: 5
    r2_no_eoat_tcp: 6
    r2_torch_tcp: 7
    r2_weld_tcp: 8
  World:
    Origin: 0
    Robot3TCP: 1
    origin_frame: 2
    r4tcp: 9
objects:
  torch_latch: 0
  vertical_beam: 1
  weld_gun_latch: 2
  Box1: 3
  Box2: 4
  Box3: 5
  Box4: 6
  Cylinder1: 7
  gun_moving: 8
  gun_static: 9
  jig: 10
  rail_with_shims: 11
  sliding_platform: 12
  tool_changer_base: 13
  torch_robot: 14
  weld_gun_robot: 15
  workcell_empty: 16
states:
  torch_latch:
    Suppressed: 0
    present: 1
  vertical_beam:
    Suppressed: 0
    present: 1
  weld_gun_latch:
    Suppressed: 0
    present: 1
dsm:
  static_frames:
    Origin: 0
    Robot3TCP: 1
    origin_frame: 2
    r4tcp: 9

Getting started with Profinet communication on RapidPlan

Ethernet interface used by Profinet must be named fieldbus.

To rename an ethernet interface(e.g., enp2s0) in Ubuntu:

sudo ip link set enp2s0 down
sudo ip link set enp2s0 name fieldbus
sudo ip link set fieldbus up

2. Environment variable must be set - this should be done automatically when a megadeb is installed.

If not done automatically:

sudo systemctl set-environment RAPIDPLAN_PROFINET_ENABLE=true

3. Profinet must be enabled from Control Panel - Settings - Network.

If the Profinet Enabled toggle is turned on, appliance must be restarted for the function to start working.

sudo systemctl restart rtr_appliance_app.service

Profinet can be enabled without a loaded project. However, in order to export ID lookup table, a project must be loaded.

4. If Profinet is enabled for the first time, a Profinet device name must be assigned using TIA Portal. Once assigned, the device name is persistent.

5. IP address is assigned by the PLC after Profinet device name is assigned.

Typical Move command timing sequence

Move

Combined Move with Smoothing enabled

Combined Move with HoldMove

Programming Notes

A Siemens PLC library and an application example is available upon request.
To reset fault mode, the OperationMode output needs to be manually reset, before the reset output is set.
Some API commands only work in Config mode, while others only work in Operation mode. Mode interlock logic is recommended.
The transition of InMotion status may not be available for certain moves or move segments, under the following conditions:
- InMotion bit may not be available for queued moves due to smoothing.
- InMotion bit may not be available for move segments if smoothing is enabled.
The transition of InPosition status may not be available for certain moves, under the following conditions:
- InPosition bit may not be available for queued moves due to smoothing.
- InPosition bit may be delayed when HoldMove or AlternateLocation is set.

Known issues

Triggers are not supported as part of a move command.
When appliance restarts, the Ubuntu OS routing table is added with a duplicate default gateway pointing to the IP address assigned by the PLC. This is causing loss of internet access until the duplicate default gateway in the Ubuntu routing table is manually cleared. This is related to Ubuntu OS. Workaround: after Profinet is running, issue sudo ip route del default to restore internet access from the RTR controller.
Occasionally the PLC triggers a Profinet watchdog error. This is due to the Ubuntu Desktop OS is not optimized for real-time communication. OS thread priority should be fine tuned. Workaround: increase the number of retries in the Profinet device IO settings in TIA Portal, while keeping the same 2mS update time.
The Profinet driver is tested on RTR controllers(V1 and runtime) only.
DSM boxes, objects, and frames are tracked in the Profinet look up ID table. When items are created or removed, their Profinet IO mappings are handled as such, the handler retrieves the new id of the entity, and publishes it with Profinet. However, this does not cover cases where an external command source elicits a change in the DSM that’s unknown to a PLC.

Typical communication latencies

The charts below measure the time delay between a move command sent by a PLC and the ACK signal received by a PLC, with PNIO update time = 2mS.