Automation Canada - Robotic Integration Issue - 19

PLC INTEGRATED ROBOTS:
THE CASE FOR A SINGULAR CONTROL
ARCHITECTURE
ABSTRACT

Robots have become an integral part of the manufacturing floor, whether it is the automotive,
electronics or consumer packaged goods industry. During the last five decades, the automotive
sector has had a solid working base of robots, but robots are relatively new to the consumer
packaged goods industry. When considering the CPG space, manufacturers are embracing the use of
robots at a highly accelerated rate. This paper focuses on how robotics can be a friend on the floor and
how manufacturers can really own their robotics systems.

PLC CONTROLLED ROBOTS?

Traditionally, Programmable Logic Controllers (PLC) are used as supervisory controls for
approximately 90 percent of manufacturing systems. These PLCs control conveyors, filling systems,
sealing and forming systems and most of the equipment in the plant.
Even in a typical robotics system, the PLC controls the entire operation of the cell. However, robot
operations and path planning are done on a different controls platform that is proprietary to the robot
manufacturer. As with any proprietary system, robots require specially trained professionals to
program, control and interface them with the PLC for major operational commands. These specially
trained technicians are in high demand but short supply, especially when needed unexpectedly for
emergency repairs or adjustments. Even qualified robot technicians are usually familiar with only one
or two - of many - brands of robots, and not necessarily the ones that you have. This specialization
contributes to the technical skills scarcity and related delays and downtime. In most cases,
manufacturers rely on their systems integration house or the robot manufacturer for troubleshooting, service and support. This reliance on outside
resources is the reason robot " ownership " has been a myth.
In comparison to the scarcity and specialization of robot experts, PLC experts are much more accessible because the programming concepts and
foundations remain the same no matter what brand of PLC is being used. Insofar as most machinery in a plant runs on a PLC, there are naturally more
PLC experts than robot experts. Also, PLC programming is commonly taught in technical schools, while robot programming is not. To solve this
problem, manufacturers and industrial and process engineers sought a way for robots to be programmed and controlled entirely through a PLC.
Their work led to the development and implementation of the PLC-integrated robot control concept, also known as a Singular Controls Architecture.

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