Plug & Play Design Eliminates Integration Barriers in Robotic Systems

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.

Cattron addressed this challenge with the XBMCU Multi-Interface Machine Control Unit, a compact device that 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 controls 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 takes the form of 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 leading provider of safe and reliable RF communication technology. This, in combination with the advanced design of the XBMCU, signifies a progression in wireless control solutions for industrial automation.

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 an extremely simple hardware interface. Serial communication setup 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, CANopen 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 a paramount concern in robotic applications. 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 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. By facilitating communication between robotic arms and peripheral equipment with simplified connectivity, the XBMCU streamlines cell implementation and reduces maintenance requirements.
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 enables customers 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.

Manufactured in America with global support capabilities, the XBMCU offers robotics implementers a reliable, secure and efficient path to enhanced automation without the traditional integration complexity that can delay implementation.

Rebecca Weber is a product manager for Cattron.