What Are The Key Steps To Integrate Superisys RFID with Omron NXJ PLC Using Ethernet/IP Gateway?

Integrating Superisys RFID systems with Omron NXJ series PLCs via an Ethernet/IP gateway offers a powerful solution for real-time data exchange and process automation in industrial environments. This article explores the detailed steps, hardware architecture, and software configurations necessary to achieve seamless communication between these devices, ensuring high reliability and performance.

Understanding the Technology

What Is Ethernet/IP and Why Is It Important?

Ethernet/IP is an open industrial communication protocol developed in the 1990s by ControlNet International and ODVA. It is based on the Common Industrial Protocol (CIP) and operates over standard Ethernet hardware. This protocol is widely adopted by manufacturers such as Rockwell Automation and Omron due to its:

• High-speed data transmission

• Standardized message formats

• Flexibility in connecting a variety of industrial devices

Ethernet/IP facilitates real-time communication between controllers, sensors, and other industrial equipment, enabling smart factory automation.

Overview of Superisys IACM-P4 Gateway

The Superisys IACM-P4 gateway is a rugged, industrial-grade RFID controller that supports multiple industrial protocols including Profinet, EtherCAT, and Ethernet/IP. Key features include:

• Dual M12 power connectors for redundancy

• Multiple RFID reader ports (up to 4)

• IP67-rated enclosure for dust and water protection

• 100 Mbps Ethernet transmission

• Support for UHF and HF RFID readers

This gateway acts as a bridge connecting Superisys RFID readers with Omron PLCs, managing data flow and command execution.

Hardware Architecture

Components and Connections

• Omron NXJ PLC: Controls and communicates with the RFID gateway.

• Superisys IACM-P4 Gateway: Interfaces with both the PLC and RFID readers.

• RFID Readers: Connected to the gateway; read and write RFID tags.

• RFID Tags: Store unique identification (UID) and user data (USER memory).

RFID Tag Memory Structure

• UID Memory: Read-only, 8 bytes unique identifier for each tag.

• USER Memory: Read/write area used for application data.

Software Configuration Steps

1. Installing and Setting Up the Gateway in Sysmac Studio

• Create a new project for the NX1P2 PLC.

• Open "EtherNet/IP Connection Settings" and add the IACM-P4 gateway EDS file.

• Use the Gateway Assistant software to locate the device on the network.

• Configure the gateway's IP address (e.g., 192.168.250.10) and subnet mask.

• Save and reboot the gateway to apply settings.

2. Adding the Gateway to the PLC Project

• In Sysmac Studio, add the IACM-P4 device under Ethernet/IP port settings.

• Assign the device's IP address.

• Set up connection groups for communication.

3. Defining I/O Memory Mapping

• Declare global byte arrays for gateway input/output memory in the PLC program (e.g., 128 bytes each).

• Map these variables to the gateway’s memory addresses (e.g., 100 for input, 150 for output).

• Create tag groups in Sysmac Studio linking these variables.

4. Deploy and Test Communication

• Download the configuration to the PLC.

• Verify the “LINK/ACT” LED on the gateway blinks, confirming communication.

• Test data transfer between PLC and gateway.

Using Sysmac Studio RFID Function Blocks

INOUTRFIDDataMove Function Block

Manages data transfer between the PLC memory and up to four RFID reader ports. Inputs include gateway input/output arrays and port enable flags.

RFIDDemo Function Block

Controls reading and writing operations on RFID tags:

• Inputs:

• Start addresses for reading/writing USER memory.

• Data arrays for write operations.

• Commands to trigger read/write.

• Outputs:

• Status flags for success or failure.

• Tag detection signals.

Example Workflow for Tag Operation

1. RFID reader detects a tag (triggering xTP signal).

2. Automatically reads the UID.

3. PLC commands read/write of USER memory via RFIDDemo.

4. Status signals confirm operation results.

Error Codes and Troubleshooting

Superisys systems provide error codes indicating:

• Communication errors

• Command execution failures

• Function block internal errors

Proper interpretation facilitates quick diagnosis and resolution.

Advantages of This Integration

• Supports multiple RFID readers independently.

• High data transfer speed (100 Mbps).

• IP67 enclosure protects hardware in harsh environments.

• Dual Ethernet ports for flexible network topology.

• Electrical protections against reverse polarity, surges, and overcurrent.

Summary

Integrating Superisys RFID readers with Omron NXJ PLCs using the Ethernet/IP gateway ensures efficient, high-speed industrial communication. By following structured hardware setup and software configuration in Sysmac Studio, industrial automation systems can achieve reliable RFID data management, vital for smart manufacturing and Industry 4.0.