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Eliminating Integration Barriers in Robotic Systems with XBMCU
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Robotic systems have revolutionized manufacturing across industries, yet a persistent challenge remains: optimizing integration processes and simplifying system maintenance. For system integrators, facility managers, OEMs, and maintenance teams, the complexity of connecting robotic systems with existing control architectures often creates costly delays and implementation challenges.

At Cattron™, we’ve addressed this challenge with the XBMCU Multi-Interface Machine Control Unit. This compact device fundamentally transforms how robotic systems integrate into industrial environments by supporting wireless control and monitoring through safe, encrypted RF communication combined with diverse serial protocol support.

The Integration Challenge in Robotics 

For control engineers and machine builders implementing robotic solutions, historical challenges include the time and expense of traditional cabling required to bring valuable data and critical controls to end users. These dated methods not only cost time and money upfront to set up but require much more maintenance long-term, resulting in system downtime and additional costs to sustain operation.

“Application requirements are dictated by the machinery in use, existing communication systems, and industrial standards,” explains Mark Densley, sales leader at Cattron. “The XBMCU’s flexibility allows it to support industrial automation no matter the technology in place, benefiting both OEMs and end users with a singular product solution.”

Advanced Wireless Technology for Robotics 

The XBMCU’s wireless functionality is provided by Cattron’s black channel, encrypted RF protocol. The unit serves as a gateway for machine data and control to safely travel over the air for a truly wireless solution with range support up to one kilometer.

This capability is particularly valuable for robotic applications, as the XBMCU takes data from the machine via traditional I/O or a customer PLC, converts it using a custom RF message structure with encryption, and broadcasts it to a variety of Cattron transmitters or another XBMCU in what is known as a machine-to-machine solution.

Cattron is a market leader in providing safe and reliable RF communication, and in combination with the advanced design of the XBMCU, represents the next era of wireless control for industrial automation integration. Specifically, the XBMCU’s machine-to-machine configuration acts as a bridge providing machine data and control in real-time, eliminating human response delays and taking the optimization of machine control and maintenance to an entirely different level.

Simplified Serial Integration

The XBMCU champions complex operations with a straightforward hardware interface. Setting up serial communication is as easy as connecting a PLC to the D-coded M12 connector. For safe protocols such as CANopen Safety, CIP Safety, and PROFIsafe, customers only need to add a power supply, and their machine is ready to go.

The unit supports a comprehensive range of protocols, including:

  • Ethernet IP with future CIP Safety support
  • PROFINET with PROFIsafe (currently under certification)
  • Dual CANbus interfaces supporting J1939, CAN FD, CANope,n and CANopen Safety

This protocol flexibility enables the XBMCU to serve as a universal bridge between different robotic components, reducing system complexity and integration time.

Facilitating Robotic Safety Applications

Safety is paramount in robotic applications, and the XBMCU also delivers here. The core of the XBMCU product is designed and certified PL-d per the ISO 13849 standards. Beyond the hardware, the XBMCU has achieved several certifications with lab-tested and approved PROFINET and Ethernet/IP, and is in the process of TUV certification for PROFIsafe and CIP Safety.

The XBMCU works seamlessly with Cattron’s Safe-D-Stop™ wireless emergency stop system, enabling operators to carry portable e-stops with them as they work alongside robotic systems. This capability transforms the traditional stationary e-stop approach into a mobile safety solution that follows the operator, addressing a critical need in dynamic robotic work environments.

Machine-to-Machine Communication for Robotics

The XBMCU facilitates data-rich, bi-directional machine-to-machine communication that enhances robotic system performance. This connectivity enables:

  • Seamless coordination between multiple robots
  • Integration with existing PLC systems via serial protocols
  • Real-time data exchange between robotic end-effectors and control systems
  • Remote monitoring and control capabilities

This machine-to-machine configuration acts as a bridge, providing machine data and control in real-time, eliminating human response delays and taking robotic system optimization to a new level. The result is robotic systems that operate as cohesive units rather than isolated machines, maximizing efficiency and throughput.

 

Technical Specifications for Robotics Applications

The XBMCU’s technical capabilities make it ideal for demanding robotic applications:

  • Eight digital inputs configurable for Category 3 PL-d
  • Six 3A digital outputs configurable for Category 3 PL-d
  • Wide range 9-36 VDC supply
  • IP66-rated aluminum enclosure for harsh environments
  • Lab-certified PROFINET communications with Class C Conformance
  • Black channel wireless interface for secure communications
  • Data logging capabilities for performance analysis

Practical Applications in Robotics

The XBMCU demonstrates significant value in several robotics applications:

AGV/AMR Control: The unit enables wireless control of autonomous vehicles through safe, encrypted RF communication with range support up to one kilometer, maintaining consistent connections even in challenging industrial environments.

Robotic Cell Automation: The XBMCU streamlines cell implementation and reduces maintenance requirements by facilitating communication between robotic arms and peripheral equipment with simplified connectivity.

Collaborative Robot Safety: The integration with Cattron’s Safe-D-Stop wireless e-stops enables enhanced safety protocols around collaborative robots, allowing operators to immediately halt operations from anywhere in the workspace.

Remote Operation: For hazardous environments or remote operations, the XBMCU enables operators to control robotic systems from safe distances using Cattron’s wireless transmitters.

Machine Tending: The unit simplifies the integration of robotic machine tending applications by reducing the complexity of connecting robots to the machines they service.

Transforming Robotics Implementation 

The XBMCU is the wireless solution customers can rely on to improve their system operation and efficiency without compromising safety. The plug-and-play approach with simple M12 connectivity allows systems to be operational within minutes, dramatically improving implementation timelines and reducing engineering overhead.

For robotics integrators and end-users alike, this represents a paradigm shift in how automation solutions are deployed, maintained, and scaled. The XBMCU’s ability to work as an independent PLC while supporting multiple communication protocols makes it a versatile solution for virtually any robotic application.

The XBMCU offers robotics implementers a reliable, secure, and efficient path to enhanced automation without the traditional integration complexity that can delay implementation. For more information about implementing the XBMCU in robotic applications, contact us at [email protected].

New XBMCU Multi-Interface Machine Control Unit

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Radio Remote Control Xbmcu LeftOur new XBMCU Multi-Interface Machine Control Unit represents a significant advancement in industrial automation technology, offering seamless integration into PLC systems through multiple serial protocols.

The XBMCU is a compact, multi-interface receiver and machine control unit designed for mobile machines, industrial automation, robotics, and machine-to-machine control. The unit works compatibly with Cattron’s Safe-D-Stop wireless emergency stop, most CattronControl radio remote transmitters, and the latest generation of Remtron wireless devices.

According to the company, what sets the XBMCU apart is its robust capability to support machine-to-machine functionality in both directions, handling high data volumes. The unit features dual CANbus interfaces supporting J1939, CAN FD, CANopen, and CANopen Safety protocols, along with lab-certified PROFINET communications for reliable, real-time data handling with Class C Conformance.

For North American customers, the XBMCU will soon support Ethernet IP protocols certified by ODVA, with plans to incorporate CIP safety, making it a comprehensive solution for systems integrators who previously required multiple products from different manufacturers.

The XBMCU is housed in a rugged IP66-rated aluminum enclosure, making it suitable for the most demanding industrial environments. It features a wide range of 9-36 VDC supply, eight digital inputs that can be combined for Category 3 PL-d configurations, and six 3A digital outputs that can be similarly configured for enhanced safety.

The unit incorporates a black channel wireless interface for secure communications. The XBMCU also supports globally recognized safe industrial protocols, such as PROFIsafe (currently under certification), CIP safety, and CANopen Safety, to ensure reliable protection for personnel and machinery in automation environments. The unit supports IEC 61131 programming via the CattronLink programming tool, allowing for configuration via the CattronLink app or over wireless or Ethernet connections, eliminating the need for complex setup procedures.

The XBMCU is ideal for multiple industrial applications, including:

  • Industrial automation systems and robotics
  • Autonomous guided vehicles
  • Logistics control and monitoring
  • Industrial manufacturing equipment
  • Palletizing and packaging equipment
  • Decentralized control systems

The XBMCU is manufactured at Cattron’s Warren, Ohio, facility, offering customers the advantage of American-made quality and local technical support.

Agricultural Robot with Wireless Emergency Stop
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indus gemini e-stop from tyro

Self-driving Robotti

AGROINTELLI from Denmark is a development company for sustainable farming. It devises advanced products and new technological applications that reduce risk and effort for modern agricultural farmers. One of these products is the agricultural robot: Robotti.

This robot can sow, spray, and even weed autonomously. With its GPS connection and exact data, it gives valuable information to the farmer.

Tablet or smartphone

The control is done via an app on a phone or tablet. This machine ensures greater efficiency in the field and thus saves the farmer money and time.

Safety first

Safety has been very important in the development of the Robotti. An emergency stop has been added, allowing the driver to stop the robot remotely in case of an emergency situation. The choice was made for the Indus emergency stop by Tyro Remotes, which reacts within 0.5 seconds and is impact and shock resistant. The Indus remote control is supplied together with the Gemini receiver and meets the strict safety requirements of Performance Level c (PLc).

Concrete Products Remote Control

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A global player in radio remote controls, these wireless remote control systems suit mobile, construction, and material handling equipment and, with IP65 to IP68 ratings, resist shock, impact, dust, moisture, and water. The 2S generation spans Cetus, Fornax, Musca, and Pyxis transmitters plus Aquarius, Auriga, and Scorpius receivers.

Tyro Pyxis 2S

The Tyro 2S line supports a range of frequencies, including 915 MHz for North America. Universal compatibility ensures series devices can be used seamlessly throughout different regions to control a variety of diesel engines and electric or hydraulic motors, providing reliable connectivity across a broad swath of equipment types.

Customers can personalize their transmitters with specific icons and symbols that match their equipment’s control interfaces, enhancing safety and ease of use. Tyro 2S systems offer advanced features such as one-button pairing, allowing operators to quickly pair a new transmitter with the receiver, minimizing downtime. This is particularly beneficial in mobile applications where equipment may be frequently moved or lost.

Additionally, the systems support multiple transmitters per receiver and vice versa, providing multiple users with flexibility and redundancy in their operations.

The Tyro 2S systems have an LCD screen that displays real-time feedback from the connected equipment. This feature is particularly valuable in applications like concrete pumps, stone crushers, and other heavy machinery where monitoring parameters such as oil temperature, fuel level, and operational speeds are crucial.

The integration with CAN bus systems allows for seamless communication between the remote control and the machinery, enhancing operational efficiency and safety.

Machine-to-machine programming is also an option.

Order your system now!

The Importance of Black Channel Communication in Radio Remote Control
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Radio remote controls are an integral part of modern manufacturing plants and operations. They allow operators to manage machinery and equipment from a safe distance while reducing the need for direct human interaction with potentially hazardous machines. Radio remote controls also enable precise equipment control, leading to improved efficiency and less risk of operator error. With additional protection like Black Channel Communication, radio remote controls become even more secure and reliable.

Overview of Black Channel Communications

Black Channel Communication is a communication technology used to ensure the reliability of transmitted signals within control systems, particularly in manufacturing plants. This communication strategy involves the use of a functional safety protocol that operates on a separate, dedicated channel (the “black channel”) to verify the integrity of transmitted signals.

How Black Channel Communications Works  

Black Channel Communication revolutionizes how signals are transmitted in control systems by utilizing a dedicated, functional safety protocol that operates independently of noncritical communication channels. This safety protocol inspects the integrity of signals sent across the ‘black channel’. Functioning independently ensures that even if the noncritical channel is compromised or experiences interference, the safety protocol remains unscathed, thus providing a failsafe mechanism.

How the Black Channel Enhances Safety  

Another aspect of Black Channel Communication is the safety mechanisms to verify outgoing and incoming data sequencing. The sequencing mechanisms ensure that the correct data is processed in a very particular order. This technology is especially beneficial in high-stakes environments like manufacturing plants, where the slightest error or interruption can have far-reaching consequences. Its application is vital in systems where safety is paramount, as it can detect and react to any interference or corruption of the data.

Implementing Black Channel Communication can improve safety and efficiency metrics, especially in large manufacturing plants. For example, consider a plant experiencing occasional signal interference within its control systems, leading to sporadic operational glitches and potential safety hazards. With Black Channel Communication integrated into its radio remote control systems, the functional safety protocol can monitor the integrity of critical data, immediately detecting errors and taking necessary, safe approaches to correcting the problem. As a result, the instances of operational glitches will drop, thereby enhancing overall safety. Additionally, the newfound reliability of the plant’s control systems improves production efficiency by minimizing downtime.

Partner for Safe and Reliable Radio Remote Controls

Black Channel Communication is a technology that strengthens safety and efficiency within manufacturing plants and beyond. Ensuring the integrity of signals transmitted via radio remote control eliminates the risk of interference or corruption that can lead to operational glitches and potential safety hazards.

We selected radio remote controls enhanced with black channel communication to provide a robust solution for protecting control signals from unauthorized access or tampering. Products include Remtron and Safe-D-Stop.