PLC robot controller for any user-defined custom articulated robot (robot arm)

    Are there any PLC-based generic robot controllers and end-to-end software suite that can be used to control a custom articulated robot (i.e. robot arm with 6 or more axes)?

    I'm aware of ROS open source software. But there is a steep learning curve that I'm still on.

    I'm looking for an off-the-shelf PLC solution that has all the functions and control algorithms already developed for applying to any user-defined 6 or 7 axis robot arm that uses standard servomotors and drives.

    Typically, industrial robot companies like Kuka have their own hardware and software integrated. I want to integrate an off-the-shelf controller and software with my hardware i.e. robot arm.

    So, basically, I'm looking for a ROS type system but more developed and more "plug and play".

    there are plenty of PLCs out there that can do complex motion, support safety, fast processing, various communication options, can support many axes of any size etc. There are also mobile HMI units that would lend themselves as tech pendants. it should be not hard to make the PLC get streamed data from ROS to control the axes.

    did you do any cost analysis? the controls side hardware (motors, servo drives, cables, PLC and PLC software) for 6 or 7 axis will easily cost as much as complete and ready to use robot system. so right there any cost saving is out of window and we did not even begin to think of mechanical side. have you checked the prices of robot gearboxes?

    and then we are still talking about a lot of hours of integrating it all (mechanical, electrical, software...). with open source, someone has done some work but you ultimately need to know how to finish it and turn it into a product and that means advanced skill and lots of hours to make something that can move.

    next comes reality in terms of the performance - what kind of positional accuracy, path accuracy, speed etc. do you expect? what do you know about inertia, vibrations and elasticity? what about longevity? why do you think that someone who is just learning, can buy generic of the shelf parts and make something that not only works but compares or competes with top class design that was meticulously refined by a huge team of engineers over many decades?

    i do have some doubts but do not mean to discourage you - please proceed with your plan and make something that will bring affordable industrial robots to everyone's budget.

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    Siemens have something for KUKA robots and B&R for ABB.

    I have only seen sales presentation, but it should work in way, that you teach positions and write logic directly in PLC. Not sure if it send data directly to servo, or if there is program running on robot.

    And I also have seen Siemens + Yaskawa (custom programmed), where on robot side there was program running in loop and asking PLC for next position, which were stored in PLC, also with logic.

    Hi panic mode good to see you again.

    This is for a work project, not a hobby project. The physical constraints of the application necessitated development of a custom mechanical design for a robot arm. That's the mechanical team's responsibility. My responsibility is control and software. That's why I am looking for a generic PLC based robot controller and software that might have some built-in templates for doing 6dof articulated robot inverse kinematics, dynamics and control algorithms. So that I don't have to start from scratch.

    As I mentioned in my OP, I'm still ramping up on ROS.

    Quote from panic mode

    it should be not hard to make the PLC get streamed data from ROS to control the axes.

    Do you mean, model the robot in ROS and use ROS algorithms and stream the servo control signals from ROS to the PLC?


    Quote from panic mode

    and then we are still talking about a lot of hours of integrating it all (mechanical, electrical, software...). with open source, someone has done some work but you ultimately need to know how to finish it and turn it into a product and that means advanced skill and lots of hours to make something that can move.


    next comes reality in terms of the performance - what kind of positional accuracy, path accuracy, speed etc. do you expect? what do you know about inertia, vibrations and elasticity? what about longevity? why do you think that someone who is just learning, can buy generic of the shelf parts and make something that not only works but compares or competes with top class design that was meticulously refined by a huge team of engineers over many decades?

    All fair points, and I have been educating the mechanical team (who don't have any experience with the huge amount of integration that goes into a robot) on the time and effort it will take.

    Our manipulator arm will certainly not meet or compete with top class design.

    Quote

    top class design that was meticulously refined by a huge team of engineers over many decades?

    That is exactly what I have been repeating to everyone, just so their expectations are calibrated.

    Quote from Patrik Paukov

    Siemens have something for KUKA robots and B&R for ABB.

    I have only seen sales presentation, but it should work in way, that you teach positions and write logic directly in PLC. Not sure if it send data directly to servo, or if there is program running on robot.

    And I also have seen Siemens + Yaskawa (custom programmed), where on robot side there was program running in loop and asking PLC for next position, which were stored in PLC, also with logic.

    Thank you, I will look into Siemens. How about Schneider or Rockwell?

    Siemens 840D is, I've been told, the "gold standard" for creating custom kinematics. But it's $$$ and requires some real expertise to use.

    I believe Rockwell has something similar, I've seen Rockwell PLCs used as servo controllers for robot arms, but only in joint mode, not interpolated. I assume Rockwell has some sort of kinematic modelling available, but I don't know any details.

    The kinematic model for any custom robot is going to have to be itself custom, by definition. There's no "algorithms" for this, but Siemens and Rockwell have toolkits for it. The $$$ question is going to be, how much can those toolkits do for you, and how much kinematic math do you have to do yourself, the hard way?

    The trial version of RoboDK might not be a bad place to start, just to get a feel for the complexity of the problem:https://robodk.com/doc/en/General…nism-Robot.html

    Trio Motion has a whole family of control modules, drives, and software for this sort of thing, and it its likely more affordable than rockwell or siemens. I seem to remember a salesman telling me you can control your own custom robot with their stuff.

    There are a few other "motion control" companies out there they may have something that works for you. KEB is one that comes to mind.

    Codesys have robot solution named axis group. The communication between PLC and roobot are eatherCAT .It means PLC control the drive directly.

    And Siemens also have one solution named Simatic Kinematics Integrator (SKI). This solution must ues T CPU in this solution.

    Both two solution are based on PLC base. And they support from 3 axis to 7 axis.

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