In today’s fast-paced mobile equipment landscape, efficiency and reliability are key to maximizing productivity and return on investment. One of the most impactful advancements in this regard is the ability to automatically start and stop generators supplying power to mobile and rental equipment. This capability optimizes job site performance and significantly increases operational efficiency, leading to a higher rate of return on investment.

Importance of Reliable Communication

Reliable communication between the controller and the generator is crucial for generators to function effectively, especially those that are mechanically or electronically governed. Any lapse in communication can lead to downtime, reducing productivity and increasing costs. Ensuring seamless interaction between the control systems and the generators is paramount for maintaining a consistent power supply and operational efficiency.

Durability in Harsh Environments

Generators often operate in challenging environments, exposed to harsh weather conditions such as rain, snow, dust, and extreme temperatures. Controllers used to power these solutions must be exceptionally durable and designed to withstand these elements. Robust construction and advanced engineering ensure that these control systems can perform reliably, no matter the environmental conditions.

Efficient Controllers for OEMs

By integrating advanced controllers into mobile generators, Original Equipment Manufacturers (OEMs) can monitor and manage generator performance from virtually anywhere. This integration offers several significant benefits:

Better Management of Start/Stop Times: Control solutions enable precise management of when generators start and stop, optimizing their use and reducing unnecessary run times.

Fuel Consumption Adjustment: Efficiently managing fuel consumption is critical for cost savings. Advanced control systems can adjust fuel usage based on real-time data and operational needs.

Issue Diagnosis: Early detection and diagnosis of potential issues can prevent costly breakdowns. By adding telemetry devices with remote monitoring capabilities, controllers allow for real-time diagnostics, helping to identify and address problems before they escalate.

Reducing Downtime and Increasing Efficiency

One of the most significant advantages of integrating control solutions into mobile generators is the reduction of downtime. With real-time adjustments, these systems ensure that generators are always operating at their best. This reliability translates into less downtime for mobile equipment, enhancing overall job site productivity.

The ability to manage generators brings a new level of efficiency and reliability to job sites. OEMs can achieve significant cost savings and operational improvements by ensuring robust communication, durability in harsh environments, and comprehensive remote monitoring. These advancements enhance performance and provide a competitive edge in today’s demanding industrial landscape.


 

DynaGen™ PRO600

DynaGen™ TG410

DynaGen™ TG350

DynaGen™ Retro Kit

 

Messenger BLE

Messenger Lite

VisiTek™ 600

remoteIQ telemetry family
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.

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.”

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.

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.

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.

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.

 

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

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.

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].