I've never run into what you are describing, all of the signals I know of are pre-declared. Can you provide an example?
I found the problem now I do cross connection, the problem was that I was doing these tests on an old backup on RS 2019 and when I opened the safe configuration it was not synchronized with the controller as soon as I clicked write configuration to controller, I found the signals in the signal view
how now can I manage this signal? the cross conncection make sure that when for example the signal fdo_ok_zone_02 is at 1 also the signal di_inside_area is at 1.
in the program i can do in this way:
IF di_inside_area then
setdo do_unlock_gripper
ENDIF
But in MANUAL MODE the operetor can force the signal do_unlock_gripper also if the robot is not in the safety area.
How can i prevent this?