GCCS-2

Global Common Control Software Design

LMS # 33544
Document Version 6.0

Module 16: Starting Up a Cell

 DOCUMENT MANAGEMENT INFORMATION

Sponsoring Group:

Manufacturing Engineer: Noel Miller

ME Engineering Group: GM Vehicle Systems-Automation Standards
Manufacturing Engineer Phone: 810-602-9768

Template Version 1.0

Document Revisions:
Date Revision By Revision History
Updated DeviceNet addressing section and
8-26-13 5.0 J. Hocking
graphics.
Synchronized to G16 with Powertrain and
7-9-15 6.0 J. Hocking
EtherNet I/O

This training is based on the Global Common Software Design Standards, GCCS-1.
Please refer to the GCCS-1 manual found on the “GM intranet” or
www.gmsupplypower.com. The GCCS-1 manual is comprehensive and will have the
latest information. This training manual is used as an instructional guide.
 Copyright Information
Copyright General Motors Company, 2015, Detroit, Michigan. All rights reserved under
U.S., International, and Universal Copyright Conventions. Published in the United
States of America. These materials may be used only with related printed materials.
In no event will the General Motors Company be responsible or liable for
incidental or consequential damages resulting from the use or application of the
materials in this manual.
The examples, diagrams, and charts in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular safety situation, the General Motors Company expressly disclaims all
express and implied warranties relating to the materials in this manual, including
all examples, diagrams, and charts.
Reproduction of the contents of this manual, in whole or in part, without written
permission of the General Motors Company, is prohibited.

© 2015 General Motors Company. All Rights Reserved – Rev. 4.1

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 Table of Contents
16. Starting Up a Cell ................................................................. 16-1
16.1. Objectives:............................................................................................. 16-1
16.2. Cell Validation Requirements .............................................................. 16-2
16.3. Configure and Validate DeviceNet Networks...................................... 16-2
16.3.1. Create Network Files .................................................................... 16-2
16.3.2. Setup DNB .................................................................................... 16-3
16.3.3. Setup Network Devices................................................................. 16-3
16.3.4. Connecting to the DeviceNet Network .......................................... 16-3
16.3.5. Configure Network ........................................................................ 16-3
16.3.6. Debug ........................................................................................... 16-3
16.4. Validate the Safety System (Perimeter Guards, Estops, etc.) ........... 16-4
16.4.1. Perimeter Guards ......................................................................... 16-4
16.4.2. Estops (Emergency Stops) ........................................................... 16-4
16.4.3. Gate Boxes ................................................................................... 16-4
16.4.4. Light Curtains................................................................................ 16-5
16.5. Using the Scroll List in Manual Mode ................................................. 16-5
16.5.1. Verify Station Sequence Steps ..................................................... 16-5
16.5.2. Manually Initiate Motion ................................................................ 16-5
16.5.3. Verify Group / Ungroup Functionality ............................................ 16-6
16.5.4. Initiate Robot to Pounce and Back ................................................ 16-6
16.5.5. Verify Remote Actions .................................................................. 16-6
16.5.6. Verify Return to Load / Unload...................................................... 16-6
16.6. Software Checklist ................................................................................ 16-6
16.6.1. Search / Replace TBD Bits ........................................................... 16-6
16.6.2. Motion Action ‘Clears’ ................................................................... 16-6
16.6.3. Mapping Routine Configurations................................................... 16-6
16.6.4. Interlocks ...................................................................................... 16-6
16.6.5. Exercise 1: Search and Replace ‘TBD’ Bits in Logic. .................... 16-7
16.7. Review ................................................................................................... 16-8

© 2015 General Motors Company. All Rights Reserved – Rev. 6.0

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16. Starting Up a Cell
16.1. Objectives:
1. The student will be able to start a cell.
2. The student will be able to validate cell functionality.
3. The student will be able to validate the safety system.

Rev. 6.0 © 2015 General Motors Company. All Rights Reserved 16-1
16.2. Cell Validation Requirements
The following is a list of items that must be validated when starting up a tooling cell.
1. Ethernet System Configuration
2. Load firmware in all firmware upgradable devices
3. DNet Communications (Standard & Safe)
4. Safety System check – EStop, Perimeter, MPS
5. Robot path segment and Interference zone check.
6. Full Cell Reset (Master On – Gates Reset)
7. Manual Tool Operation from Scroll list on HMI
8. Interlocks to other cells + Transfer System
9. Validate Producer/Consumer
10. Auto Mode
A. Tryout Mode
B. With Parts
11. Interlocks to Upper Level (PMC, Tput, Ascii Echo)
12. Through-put evaluation of cell/system – modify operation for required cycle
time improvements
13. Validate tooling alarms

16.3. Configure and Validate DeviceNet Networks

16.3.1. Create Network Files

Use RSNetworx to scan DeviceNet network devices and configure the DNB scan
list in the DeviceNet scanner.
• The I/O of each device must be properly mapped in the DNB configuration
according to GCCS-1 standards. Device I/O is mapped to scanner I/O image at
DINT [Node number x 2].
• For additional help, reference: Project Module 13.4 Creating a RSNetworks .DNT
Configuration File.

16-2 © 2015 General Motors Company. All Rights Reserved Rev. 6.0
 16.3.2. Setup DNB
The default node address of the DNB is set to 63 from the factory. GCCS-1 now
uses node 0 for all DeviceNet scanner modules (DNB) in Logix racks and node 1 for
all (SDN) scanner modules in CompactLogix systems.

16.3.3. Setup Network Devices

Like the DNB, the node address of new hardware devices is typically set to 63 at the
factory. Set the node address and communication baud rate on all network
hardware devices. Devices typically have a mechanism like a rotary switch or
dipswitch to set the address and the baud rate.

16.3.4. Connecting to the DeviceNet Network

Access to the DeviceNet network can be either direct or indirect.
• The direct method involves connecting the programming device (i.e. laptop)
directly to the network.
o Requires the use of an adapter (e.g. 1784-PCD card for a laptop)
o Access is limited to the network the laptop is connected to.
• The indirect method (i.e. Ethernet)
o Preferred connection method: The workstation or laptop can be readily
connected to the cell Ethernet network for access to the PLC and all
interconnected DeviceNet networks.
o Use another network to ‘bridge’ to the DeviceNet network.
• Direct and Indirect connection methods require configuration of a network driver
using RSLinx. Reference Project Module 2.4; Configuring RSLinx.

16.3.5. Configure Network

Open the network file created in Exercise Section 4.5. Set the ‘Online Path’ by
accessing the Network properties. The ‘Online Path’ will contain the driver created in
the previous section and the DNB number (the slot in which it resides in the
controller chassis). Go online. Once online, the network configuration stored in the
network file can be downloaded to the DNB.

16.3.6. Debug
Validate that all nodes are present in the network browse. After all nodes are
properly configured, add them to the scan list and map the nodes. Complete this
same process for each DeviceNet DNB Scanner in the MCP. After the configuration

Rev. 6.0 © 2015 General Motors Company. All Rights Reserved 16-3
 process is complete, use a diagnostic tool, such as the NetAlert meter, to validate
that the DeviceNet network is functioning properly.

16.4. Validate the Safety System (Perimeter Guards, Estops,

etc.)

16.4.1. Perimeter Guards

The Perimeter Guard can be used for light curtains or safety mats. Regardless of the
sensing device used, two redundant ‘clear’ channels are connected to a safe I/O
module within the enclosure. Confirm the module status indicators for these inputs
change state during Perimeter Guard violation. Confirm the Perimeter Guard Reset
PBLT remains off until the reset PB is pressed.

16.4.2. Estops (Emergency Stops)

Estops appear on runstands, Gateboxes, HMIs, etc. In each case, two sets of NC
contacts from the Estop switch are used to create an Estop PB OK channel A and
channel B. Confirm the change of state of the module status indicators for these
inputs during Estop activation.
Channel A & B inputs are also mapped to the safety input data structure in the
controller as tags ‘XXX.I.NoEStopChA’ and ‘XXX.I.NoEStopChB’. These tags are
used in the Estop instruction in the various safety program routines for each
channel. Confirm that the output of this instruction drops when Estop is pressed and
is reactivated when reset.

16.4.3. Gate Boxes

The Safety Task must be locked with a signature for the MPS system to function
properly. After locking the safety task with a signature, use the Gatebox Functional
Specification from GCCH-1 to check the operation of each gatebox in relation to the
robots and tooling.

16-4 © 2015 General Motors Company. All Rights Reserved Rev. 6.0
 16.4.4. Light Curtains
Light curtain and / or safety mat safety circuits can also be found in station fixture
boxes and inter-cell light curtain boxes. Safety Device #1 channel A and B are wired
to the same safety module inputs as discussed in Module 8.4.2. Fixture boxes may
offer the option for up to three more sets of safety devices: Safety Device #2, Safety
Device #3, and Safety Device #4. Confirm the change of state of the module status
indicators for these inputs during light curtain violation.
Inputs are also mapped to the safety data structure using the same basic tag names
- ‘XXX.I.LCYClearCh1’ and ‘XXX.I.LCYClearCh2’: where ‘XXX’ correlates to the
enclosure subscript (e.g. F1 – Fixture Box 1, LE1 – Entrance Light Curtain 1, LX2 –
Exit Light Curtain 2, etc.). ‘Y’ correlates to the safety device number (e.g. Light
Curtain #1, Safety Mat #2, etc.). Like the Perimeter Guard safety devices, these tags
are used in RIN instructions.

16.5. Using the Scroll List in Manual Mode

In the Manual Mode, verify all manual functions using the scroll list.

16.5.1. Verify Station Sequence Steps

Verify the scroll list line items match the sequence steps of each station.

16.5.2. Manually Initiate Motion

Manually move the scroll list cursor to each line and initiate motion with the ‘Do’
pushbutton. Press the ‘Undo’ pushbutton to verify opposite motion action, if
applicable. Enable the ‘Auto Cursor’ function. Verify the scroll list cursor
automatically indexes to the next line item after the current motion completes.

Rev. 6.0 © 2015 General Motors Company. All Rights Reserved 16-5
 16.5.3. Verify Group / Ungroup Functionality
Confirm that any scroll list line items that are ‘grouped’ can be expanded to the
correct number of line items and condensed again. With the group expanded,
manually initiate each line item.
16.5.4. Initiate Robot to Pounce and Back
Manually initiate any scroll list motion actions that send robots to the ‘Pounce’
position. Verify the ‘Undo’ pushbutton will initiate motion to return the robot from
‘Pounce’ to ‘Home’.
16.5.5. Verify Remote Actions
Verify scroll list line items for remote actions that initiate motion in remote cells, if
applicable.
16.5.6. Verify Return to Load / Unload
Confirm the return to load / unload position requests function as expected in each
station.
16.6. Software Checklist

16.6.1. Search / Replace TBD Bits

Search the logic for any remaining ‘TBD’ bits created during the software generation
process and replace with the proper logic.

16.6.2. Motion Action ‘Clears’

Confirm ‘crash’ conditions are addressed where station tooling interacts with other
tooling and / or robot actions. Update the prompting logic to match clear conditions.

16.6.3. Mapping Routine Configurations

Confirm all input and output devices are properly mapped in the appropriate Main
and Safety Task programs.

16.6.4. Interlocks
Confirm the configuration of station-to-station and cell-to-cell interlocks, if applicable.
For cell-to-cell communication, verify that the controller heartbeat is monitored at
each end and that alarm messages are present to announce communication
interruptions.

16-6 © 2015 General Motors Company. All Rights Reserved Rev. 6.0
 16.6.5. Exercise 1: Search and Replace ‘TBD’ Bits in Logic.
Exercise is Optional if time permits.
1. Open ComTask16Exercises program in RSLogix 5000.
2. Open Cross Reference.
3. Verify the following settings:
4. Type = tag
5. Scope = controller has controller icon
6. Show = Show All
7. Name = TBD
8. Select Refresh to update cross reference or click Enter.
9. Double-click any cross reference line to navigate to the TBD bit use in the
logic.
10. Do what the @TODO rung comment tells you to do.
Note: TBD bits will require application-specific logic edits. Some examples are as
follows:
o Add conditions to Action Auto or Clear Rungs
o Add prompts for contacts in the clear rung to the action prompt rung
o Add routines to match your application where placeholders are given
11. Repeat this process until all TBD bits are replaced or removed.
END OF EXERCISE 1

Rev. 6.0 © 2015 General Motors Company. All Rights Reserved 16-7
16.7. Review
1. How is a cell started?
2. How is the safety system validated?
3. How is the functionality of the cell validated?

16-8 © 2015 General Motors Company. All Rights Reserved Rev. 6.0