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].

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.

Mobile Equipment

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Unleashing Efficiency and Safety for Your Operations  

When it comes to system design and integration for mobile equipment, we are the industry leader. We take a comprehensive approach, partnering with the Engine OEM and the Machine OEM to enhance productivity, maximize uptime, and prioritize safety.

Our integrated solutions cater to the needs of both the machine OEM and the end user. For instance, we offer durable plug-and-play subsystems, including engine control panels with variable speed capabilities, wireless machine control, and cloud-based remote monitoring and diagnostics. Our CANbus-based hardware seamlessly ties it all together with optimized wire harnesses, sensors, and HMI products.

No matter your mobile equipment application, we’ve got you covered. We start by thoroughly understanding your requirements, specifications, and scope of work. Next, our team of experienced application engineers, project managers, and product experts will collaborate with you throughout the development process.

Mobile Equipment Applications

TRAILER MOUNTED EQUIPMENT

Airport ground support

Cable reels

Concrete line pumps

Generators

Industrial cleaning

Light towers and signs

Road maintenance

Water pumps

Wood chippers

WORK TRUCKS

Aerial work platforms

Bulk feed trailers

Car transport

Concrete mixers

Concrete volumetric mixers

Digger derricks

Fire apparatus

Hook lifts

Knuckle boom cranes

Service truck cranes

Tow recovery

Trailer axle steering

Vacuum trucks

CONSTRUCTION EQUIPMENT

Excavators

Mobile conveyors

Paving equipment

Rock crushers and screeners

Wheel loaders

MINI CONSTRUCTION & FORESTRY

Forwarders

Harvesters

Horizontal boring

Skid steer loaders

Stump grinders

Trenching

mobile wood chipper cutting logs

AGRICULTURE

Bale wrappers

Frost protection

Harvesters

Mobile conveyors

Mulchers

Planters

Seed tenders

Sprayers

Turf placement

 

MINING

Conveyors

Drills

Feeder breakers

General dewatering

Generators

LHDs and Light towers

Network/Communications

Rock breakers

Roof bolters

Shotcrete sprayer

Wheel dozers

Service vehicle equipped with Tyro remote control
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Arcxis, located in Belgium, specializes in fitting out commercial vehicles. For one of their customers, they have fitted out a service vehicle that uses a remote control by Tyro Remotes.

The commercial vehicle is fully equipped to provide maintenance and servicing for semi-trailers and trailers on the road should they run into problems. This vehicle is equipped with hose reels for compressed air, gas, and oxygen so that welding or other necessary repairs can also be carried out on the road.

The Pyxis 8F remote control in combination with the Aquarius 10F receiver is specifically configured for the 24V cable reel. The cable reel with 20 meters of cable and 13-pin plug is used to control the lighting on, e.g., a trailer. With the remote control in your hand, you can stand behind the trailer to easily and efficiently test the lighting.

What are some hazardous ATEX Ratings

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Dependable electronics are an absolute necessity in hazardous environments. However, the combination of combustible gases or dust with an arc or a spark from these products can potentially cause devastating fires or explosions. Whether you are at the chemical plant, on your oil platform or offshore drilling rig, in your mill, or somewhere equally as dangerous, all of your equipment is likely carrying a hazardous rating like Class I Div 2, Class I Div 1, IECEx/ATEX Zone 1 or Zone 2. But what does that mean exactly and how does this affect what lighting you should buy? Read on for more clarity on hazardous environments and ratings.

What is a hazardous location?

Hazardous locations are in more places than you think and it’s important to be aware of them if you are purchasing electronic equipment including LED lighting. Even your local gas/petrol station is considered a hazardous location because of the potential for an explosion. If, for example, a spark or lit cigarette collides with a drop or puddle of gasoline – FIRE! Your gas station needs hazardous-rated lighting.

According to UL (a US-based global certification laboratory), a hazardous location is “where explosion or fire hazards exist due to the presence of flammable gases, flammable or combustible liquid-produced vapors, combustible dust, or ignitable fibers or flyings.”

This could mean anything from the obvious like a drilling rig or chemical plant where highly flammable substances are mined or processed. Or it could mean the less obvious like a mill or sugar processing facility where the minute particles in the air have the potential to create a spark in the right conditions. Each facility is rated differently, based on their potential for explosion, which we’ll dive deeper into below.

What are some of the hazardous UL Ratings?

UL ratings are seen and adhered to most often in North America but do apply to countries in South America, Asia, and the Middle East. When looking at a hazardous UL rating, you’ll find the Class first and then the Division.

Dialight most often sees and certifies Class I, II, and III. The main difference between the three is the presence of flammable gases/vapors; combustible or conductive dust; or fibers like wood chips and cotton (see the chart below). The lower the Class the higher the hazard.

The Division (1 or 2) is what defines the likelihood of there being hazardous substances in enough ignitable concentrations in the atmosphere (i.e. what is the likelihood that there is enough gas or dust in a given situation that it would ignite or explode and what is the circumstance for that). If your facility is Div 1, it means that the particles or gases/vapors created at your facility are always potentially going to ignite and severe caution is needed to prevent a spark (think chemical processing). Div 2 means that an explosion or fire could only happen in the event of some breakdown or system failure but that extreme caution should still be observed to prevent catastrophe (ex. A platform in an oil refinery may be a CI D2 environment as the decks tend to be outdoors and far enough away from the source of the flammable gas. It would only become hazardous if an abnormal condition occurred like a valve failure or similar accident.)

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What are some hazardous ATEX Ratings?

IECEx/ATEX ratings are seen most often in Europe, Australia, and parts of Africa, Asia, and the Middle East. They are relatively similar to UL ratings in that the lower the Zone the higher the probability is for fire or explosion based on the materials present and their concentration in the atmosphere. Both UL and ATEX classify certain substances in groups. Check out our ATEX reference chart below.

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