DMC first integrated with the Allen Bradley PLC using Anybus protocol to communicate digital and analog signals for the operation. We then instructed the robots to perform operations with simple Boolean commands. The robots can also be commanded to move to specific positions from the HMI panel, such as a maintenance position and a safe position. The PLC then receives back boolean data as well as integer statuses, alarms, and other data. The basic points, logic, and control programming were near completion before arriving for on-site commissioning.

Upon arriving at the customer facility, DMC downloaded the programming and configurations to the robots, updated the revolution counters and points, and was performing manual dry cycling on the first robot by the start of the second day. 

The cycle time was required to be within four seconds for the full operation. After about two days of refinement, DMC and the customer’s in-house programmer were able to get the cycle time to within four seconds, allowing for a small margin for error.

DMC also configured ABB World Zones to ensure that the robot was clear for the system to move. We utilized safety resetting, error reporting to the PLC, and performed programming so that the robot could perform basic operations without requiring a teach pendant.

Finally, DMC spent the last few days on-site training the customer's programmers on the ABB platforms. This including minor touchups to points, I/O configurations, and how to set up systems from scratch. The customer also learned from DMC how to use RobotStudio to perform updates to the robot programming offline. Training was provided to update revolution counters and recalibrate the robot in the event of a catastrophic collision or other loss of calibration.

Learn more about DMC's Robotic Automation and Integration services.