Procedure to Setup DCS Zones

1. DCS Zones used to eliminate robot light screens

The robot DLD light screen and inside operator light screen can be replaced with DCS Zones. The zone
that replaces the robot light screen is named Zone 1. The inside operator light screen restricts the robot
envelope at all times from entering the operator area and is named Zone 2.

Figure 1: DCS Zones

1.1 Simulation

Simulation provides an LS file with the initial zone definitions and end effector volume models. This LS
file is named DCS_ZONE.LS and will be provided with the robot files. If a DCS Frame is required it will
also be provided in the LS file, for each zone.

1.2 Setting up the end effector model

Models other than the robot base model can be used for the robot end effector. Using an end effector
model will prevent any part of the end effector from entering the restricted zone through any motion.

To create or modify a user model, select USER MODEL from the top DCS menu.
Normally a robot will only require one user model User Model No. 1. Enter into No. 1 detail from the
user model list.

Selecting the user model brings up the model links selection screen. A user model can consist of several
different linkages. It is preferred to use as few linkage elements as possible, however to reduce wasted
volume multiple elements can be used.
Selecting Link 1 will bring up the link setup screen. Here is where the shape for the link is defined.

 Enter an appropriate name for the model, such as R01 EOAT.

 Enable the model link
 Leave the default link No. 99 (robot faceplate)
 The Link Type is ignored when the Link No. is 99. Leave it at the default.
 Leave the Tool Frame at 0
 The preferred shape is the line_seg, which consists of two points and a radius. Enter the data
from the simulation LS file for the end effector model.
The line segment shape consists of two points and a radius. Point 1 and point 2 create spheres which
are connected by line segments to achieve the model. This is illustrated below:

Figure 2: Line_seg Shape Model

1.3 Setting up the robot side and tool side DCS zones

Robot DCS Zones are configured from the robot’s DCS menu, under the System menu. Initial values to
enter are provided by simulation in an LS file.

1.3.1 Zone Guidelines

 Figure 3: DCS Zone guidelines

Figure 4: DCS Zone guidelines

Zone 1 (Robot side zone)

Zone 1 replaces the robot light screen. It should be positioned using the same rules as placing the robot
light screen. There should be 36” between the normal robot path and the operator in the shared space.
The zone depth should extend a minimum of 1000mm. The zone width should span the tool base and to
the fence on each side.

Zone 1 should be safe OUTSIDE and the zone needs to cover the robots shared space with the operator.

Zone 1 is set to a NOT STOP type, it will report status to the PLC and not automatically estop.

Simulation provides the initial zone setup information in an LS file (dcs_zone.LS).

For a robot that uses Zone 1 on one station and then needs a robot side zone for a second station, Zone
3 will be used.

Zone 2 (Tool side zone / Restricted Envelope Zone)

Zone 2 replaces the inside operator light screen and functions to restrict the robot from ever entering
the operator space. The zone should be positioned 10” from the operator screen. The depth should be
a minimum of 1000mm.

Zone 2 should be safe OUTSIDE and the zone needs to prevent the robot from reaching the operator
light screen.

Zone 2 is set to a NOT STOP type; it will report status to the PLC and not automatically estop..

Simulation provides the initial zone setup information in an LS file (dcs_zone.LS).

For a robot that uses Zone 2 on one station and then needs a tool side zone for a second station, Zone 4
will be used.

1.3.2 Setup of the DCS Zones

To setup Zone 1 (Robot side zone), follow the following procedure:

 Enable TP
 [ENTER] on Cartesian position from the DCS menu
 [ENTER] into desired zone number
 Answer [YES] to question DO YOU WANT TO CHANGE SETTINGS
 Enter Comment describing the zone (“STA010 RBT SIDE”)
 Select from [CHOICE] to ENABLE the zone
 Select from [CHOICE] the Method Diagonal (OUT)
 Leave group (1) at default
 If the sim LS data has a DCS user frame select it, otherwise leave it default (0).
 Leave Target Model 1 at (-1) for the robot model.
  For Target 2 enter (1), which is the User Model for the EOAT.
 Select X, Y, Z Point 1 and Point 2 that represent the shared robot operator space from
the LS file (dcs_zone.LS).
 If necessary, the robot current position can be used to assist in determining/adjusting
these values.
 Select Stop Type NOT STOP from [CHOICE], this allows the PLC to control the stop.
 Do not select a disabling input, it is not required
 Move to the next zone, or if finished:
o [PREV] to top DCS page
o Press [APPLY], enter Pos/Speed password, wait until ready.
o Press [OK]
o Cycle Power for changes to take effect
o PLC must acknowledge changed signature by toggling the Configuration
Changed Reset bit before the robot will run in Auto.

To setup Zone 2 follow the following procedure:

 Enable TP
 [ENTER] on Cartesian position from the DCS menu
 [ENTER] into desired zone number (2 for first station)
 Answer [YES] to question DO YOU WANT TO CHANGE SETTINGS
 Enter Comment
 Select from [CHOICE] to ENABLE the zone
 Select from [CHOICE] the Method Diagonal (OUT)
  Leave group (1) at default
 Enter User Model -1 for Robot AND Model 1 for your end effector user model.
 If the LS file has a user frame enter it
 Select X, Y, Z Point 1 and Point 2 that represent the shared robot operator space fro the
LS file (dcs_zone.LS).
 The robot current position can be used to assist in determining these values. Move the
robot toward the station and use the current position values to find the proper shared
space values.
 Select Stop Type NOT STOP from [CHOICE], this allows the PLC to control the stop.
 Do not select a disabling input, it is not required
 Move to the next zone, or if finished:
o [PREV] to top DCS page
o Press [APPLY], enter Pos/Speed password, wait until ready.
o Press [OK]
o Cycle Power for changes to take effect
o PLC must acknowledge changed signature by toggling the Configuration
Changed Reset bit

1.4 Mapping the zone clear signal to the PLC

The zone status needs to be mapped in the Safe IO connect area so the safety PLC knows if the robot is
in the zone.
The safety PLC map for the robot includes DCSStatus1, DCSStatus2, DCSStatus3, and DCSStatus4. To
map the DCS zone status to these bits, map CSO[13] – CSO[16] to the corresponding zone CPC[1] –
CPC[4] :

CSO[13] – CPC[1] : DCSStatus1

CSO[14] – CPC[2] : DCSStatus2

CSO[15] – CPC[3] : DCSStatus3

CSO[16] – CPC[4] : DCSStatus4

CSO is CIP Safety Output, CPC is Cartesian Position Check.

Always map all the zones to the PLC status bits. If a zone is not used it should still be mapped as a
placeholder.

1.5 Stop Prediction

Robot stop position prediction enables the robot to shut down its servo motors before it has reached
the limit of the safe zone, predicting when it needs to stop so that the robot does not exceed the zone
where it stops.

As the same effect can be achieved by setting the zone appropriately, as light curtains have been placed
keeping the stopping distance in mind, use of this feature is not recommended.
Use of this feature is not needed in this application and can cause confusing results.

Ensure that all the Stop Prediction options are DISABLED under the Stop Position Prediction item 11 on
the main DCS menu.