Rollomatic Connectivity Guide

Overview

Rollomatic machines (GrindSmart, ShapeSmart, LaserSmart, NanoGrind tool grinding machines) can be connected to MachineMetrics in more than one way:

FOCAS to the FANUC control provides machine status, alarms, and basic program information from the control.
OPC-UA to Rollomatic RConnect on the Windows HMI (port 8999) provides production counts, wheel pack and robot-related data, and a broad set of monitoring tags from the HMI.

You do not need both connections. You can use FOCAS only, OPC-UA (RConnect) only, or both, depending on what data you want in MachineMetrics. Using both is recommended when you want the fullest picture: control-side data from FOCAS plus HMI production and wheel data from RConnect.

Network Requirements

Run network drops for the connection types you plan to use:

FANUC control (FOCAS): If you use FOCAS, connect to the FANUC Ethernet port (port label CD38A). See the FOCAS (FANUC) Connectivity Guide for full setup instructions.

Windows HMI (OPC-UA / RConnect): If you use RConnect OPC-UA, connect to the Windows HMI PC. The HMI will need either a static IP address configured or DHCP enabled (see Windows HMI Network Setup below).

If you use both FOCAS and OPC-UA, you need both of the above network paths (typically two Ethernet cables to the machine).

Connecting the FANUC Control (Machine Status Data)

The FANUC control on a Rollomatic machine can be connected using the standard FOCAS protocol. This provides:

Machine execution state (running / stopped)
Alarm data
Basic program information

note

If you connect FOCAS only, you get control-side status and alarms but not RConnect’s production counts or wheel pack tags on that connection. If you connect OPC-UA only, you get RConnect’s data model (including production and wheel-related tags) without a separate FOCAS machine in MachineMetrics. For both datasets in one deployment, add both connection types (often as two machines or two paths, per your MachineMetrics setup).

Refer to the FOCAS (FANUC) Connectivity Guide for full setup instructions.

Connecting via OPC-UA (Production & Wheel Pack Data)

To capture production counts, active wheel pack information, and the other RConnect tags described in this guide, connect to the Rollomatic Windows HMI over OPC-UA. You can use this path without FOCAS if OPC-UA alone meets your needs.

warning

The OPC-UA server (RConnect) is a purchasable option from Rollomatic. It must be purchased and enabled before MachineMetrics can connect. Contact Rollomatic to purchase the RConnect OPC-UA option if it is not already installed on the machine.

Once the OPC-UA option is active:

The OPC-UA server runs on the Windows HMI PC.
Port: 8999
Connection string format: opc.tcp://<HMI-IP-ADDRESS>:8999

Refer to the OPC-UA Connectivity Guide for instructions on adding an OPC-UA machine in MachineMetrics and entering the adapter script.

Sample Rollomatic OPC-UA Adapter Script

version: 2
read-mode: polling
opcua-condition-key: system

# OPC-UA Tags - Input Section
tags:
  # Machine Program Information
  programname:
    path: ns=2;s=VGSuite/Program/ProgramName
  jobidentifier:
    path: ns=2;s=Rollomatic/Production/ActiveProgram/JobIdentifier

  # Machine Status and Operation Mode
  machineStatus_tmp:
    path: ns=2;s=Rollomatic/Production/MachineStatus
  operationmode:
    path: ns=2;s=Rollomatic/Monitoring/MachineTool/OperationMode
  loadingmode:
    path: ns=2;s=Rollomatic/Monitoring/MachineTool/LoadingMode
  iswarmup:
    path: ns=2;s=Rollomatic/Monitoring/MachineTool/IsWarmUp
  sleepmode:
    path: ns=2;s=Rollomatic/Monitoring/MachineTool/SleepMode

  # Channel and Control Settings
  channelmode:
    path: ns=2;s=Rollomatic/Monitoring/Channel 1/ChannelMode
  channelstate:
    path: ns=2;s=Rollomatic/Monitoring/Channel 1/ChannelState
  singlestep:
    path: ns=2;s=Rollomatic/Monitoring/Channel 1/ChannelModifiers/SingleStep
  optionalstop:
    path: ns=2;s=Rollomatic/Monitoring/Channel 1/ChannelModifiers/OptionalStop
  dryrun:
    path: ns=2;s=Rollomatic/Monitoring/Channel 1/ChannelModifiers/DryRun

  # Production and Part Counting
  partsproducedinlifetime:
    path: ns=2;s=Rollomatic/Production/Statistics/PartsProducedInLifetime
  jobManagerProducedPieces:
    path: ns=2;s=Rollomatic/Production/ProductionPlan/JobManagerProducedPieces
  runsCompleted:
    path: ns=2;s=Rollomatic/Production/ProductionPlan/Job 1/RunsCompleted
  cycleTime:
    path: ns=2;s=Rollomatic/Production/ProductionPlan/Job 1/CycleTime
  runningCycleTime:
    path: ns=2;s=Rollomatic/Production/ProductionPlan/Job 1/RunningCycleTime

  # Spindle Monitoring
  is-rotating:
    path: ns=2;s=Rollomatic/Monitoring/Main Spindle/IsRotating
  override:
    path: ns=2;s=Rollomatic/Monitoring/Main Spindle/Override
  currentload:
    path: ns=2;s=Rollomatic/Monitoring/Main Spindle/CurrentLoad
  controlledSpeed:
    path: ns=2;s=Rollomatic/Monitoring/Main Spindle/ControlledSpeed
  cycleMaxLoad:
    path: ns=2;s=Rollomatic/Monitoring/Main Spindle/CycleMaxLoad
  spindleOverride:
    path: ns=2;s=Rollomatic/Monitoring/Main Spindle/Override

  # Feed and Override Controls
  feedoverride:
    path: ns=2;s=Rollomatic/Monitoring/Channel 1/FeedOverride
  rapidoverride:
    path: ns=2;s=Rollomatic/Monitoring/Channel 1/RapidOverride

  # Stack Light Indicators
  greensignalon_raw:
    path: ns=2;s=Rollomatic/Monitoring/Stacklight/Green/SignalOn
  yellowsignalon_raw:
    path: ns=2;s=Rollomatic/Monitoring/Stacklight/Yellow/SignalOn
  redsignalon_raw:
    path: ns=2;s=Rollomatic/Monitoring/Stacklight/Red/SignalOn

  # Axis Position Monitoring
  distanceX:
    path: ns=2;s=Rollomatic/Monitoring/Axes/X/Distance
  distanceY:
    path: ns=2;s=Rollomatic/Monitoring/Axes/Y/Distance
  distanceZ:
    path: ns=2;s=Rollomatic/Monitoring/Axes/Z/Distance

  # Temperature Monitoring
  xTemp:
    path: ns=2;s=Rollomatic/Monitoring/Axes/X/Temperature
  yTemp:
    path: ns=2;s=Rollomatic/Monitoring/Axes/Y/Temperature
  zTemp:
    path: ns=2;s=Rollomatic/Monitoring/Axes/Z/Temperature
  aTemp:
    path: ns=2;s=Rollomatic/Monitoring/Axes/A/Temperature
  bTemp:
    path: ns=2;s=Rollomatic/Monitoring/Axes/B/Temperature
  cTemp:
    path: ns=2;s=Rollomatic/Monitoring/Axes/C/Temperature
  uTemp:
    path: ns=2;s=Rollomatic/Monitoring/Axes/U/Temperature
  wTemp:
    path: ns=2;s=Rollomatic/Monitoring/Axes/W/Temperature
  xwTemp:
    path: ns=2;s=Rollomatic/Monitoring/Axes/XW/Temperature
  cwTemp:
    path: ns=2;s=Rollomatic/Monitoring/Axes/CW/Temperature

  # Robot and Tool Management
  piecestodo:
    path: ns=2;s=Rollomatic/Robot/PiecesToDo
  activeTool:
    path: ns=2;s=Rollomatic/Equipment/ActiveTool/Name

  # Tool Configuration
  blankLength:
    path: ns=2;s=Rollomatic/Robot/Configuration/Blank/Length
  shankDiameter:
    path: ns=2;s=Rollomatic/Robot/Configuration/Blank/ShankDiameter
  toolDiameter:
    path: ns=2;s=Rollomatic/Robot/Configuration/Blank/ToolDiameter

  # Cassette Configuration
  cassetteCount:
    path: ns=2;s=Rollomatic/Robot/Configuration/MachineSetup/CassetteCount
  holeUCount:
    path: ns=2;s=Rollomatic/Robot/Configuration/Cassette/HoleUCount
  holeWCount:
    path: ns=2;s=Rollomatic/Robot/Configuration/Cassette/HoleWCount

  # Load Tool Positions
  loadToolCassetteIndex:
    path: ns=2;s=Rollomatic/Robot/LoadToolPosition/CassetteIndex
  loadToolHoleU:
    path: ns=2;s=Rollomatic/Robot/LoadToolPosition/HoleU
  loadToolHoleW:
    path: ns=2;s=Rollomatic/Robot/LoadToolPosition/HoleW

  # Unload Positions
  unloadBlankCassetteIndex:
    path: ns=2;s=Rollomatic/Robot/UnloadBlankPosition/CassetteIndex
  unloadBlankHoleU:
    path: ns=2;s=Rollomatic/Robot/UnloadBlankPosition/HoleU
  unloadBlankHoleW:
    path: ns=2;s=Rollomatic/Robot/UnloadBlankPosition/HoleW

  # Energy and Performance
  energyConsumption:
    path: ns=2;s=Rollomatic/Monitoring/EnergyConsumption/ActiveEnergyConsumption
  powerOnDuration:
    path: ns=2;s=Rollomatic/Monitoring/MachineTool/PowerOnDuration

  # Alerts and Messages
  errorcode:
    path: ns=2;s=Rollomatic/Notification/Messages/AlertEvent/ErrorCode
  cncalarmtype:
    path: ns=2;s=Rollomatic/Notification/Messages/AlertEvent/CncAlarmType
  alerts:
    path: ns=2;s=Rollomatic/Notification/Messages/Alerts
  message:
    path: ns=2;s=Rollomatic/Notification/Messages/CompletedMessageEvent/Message
  identifier:
    path: ns=2;s=Rollomatic/Notification/Messages/CompletedMessageEvent/Identifier
  completeAlarmsWarning:
    path: ns=2;s=Rollomatic/Notification/Messages/CompletedMessages

  # Production Program State
  currentState:
    path: ns=2;s=Rollomatic/Production/ActiveProgram/State/CurrentState
  numberInList:
    path: ns=2;s=Rollomatic/Production/ProductionPlan/Job 1/NumberInList
  endOfProduction:
    path: ns=2;s=Rollomatic/Production/ProductionPlan/Job 1/EndOfProduction
  pieceOutOfGripper:
    path: ns=2;s=Rollomatic/Robot/Configuration/LoadUnload/PieceOutOfGripper

  # Additional tags from original script
  partsProducedInLifetime:
    path: ns=2;s=Rollomatic/Production/Statistics/PartsProducedInLifetime
  # Additional condition monitoring tags for testing
  energyConsumptionPhysical:
    path: ns=2;s=Rollomatic/Monitoring/EnergyConsumption/ActiveEnergyConsumption
  voltage:
    path: ns=2;s=Rollomatic/Monitoring/EnergyConsumption/Voltage
  coolantTempSensor:
    path: ns=2;s=Rollomatic/Monitoring/Temperatures/Coolant
  grindingZoneTempSensor:
    path: ns=2;s=Rollomatic/Monitoring/Temperatures/GrindingZone
  outsideAboveMachineTempSensor:
    path: ns=2;s=Rollomatic/Monitoring/Temperatures/OutsideAbove
  outsideBelowTempSensor:
    path: ns=2;s=Rollomatic/Monitoring/Temperatures/OutsideBelow
# Variables - Transformation Section
variables:
  # Standard MachineMetrics execution states
  execution:
    - source: machineStatus_tmp
    - state:
      - ACTIVE: this == 1 #1.000
      - STOPPED: this == 3
      - READY: true

  # Part count from job manager (full parts)
  mm-count:
    - source: jobManagerProducedPieces
    - value-increase
    - expression: floor(this / 2)
    - count

  # Half part count tracking
  half-mm-count:
    - source: jobManagerProducedPieces
    - expression: this
    - value-increase
    - count

  # Robot loading mode mapping
  robot-loading-mode:
    - source: loadingmode
    - state:
      - MANUAL: this == 1
      - SINGLE: this == 2
      - FULL: this == 3

  # Spindle rotation status
  isrotating:
    - source: is-rotating
    - state:
      - ON: this == true
      - OFF: true

  # Channel mode mapping
  mode:
    - source: channelmode
    - state:
      - AUTO: this == 0
      - MDI: this == 1
      - JOG: this == 2 or this == 3
      - TEACH: this == 4
      - REMOTE: this == 5
      - REF: this == 6
      - OTHER: this == 7

  # Operation mode mapping
  operation-mode:
    - source: operationmode
    - state:
      - Manual: this == 0
      - Automatic: this == 1
      - Setup: this == 2
      - Auto with manual intervention: this == 3
      - Service: this == 4
      - Other: this == 5

  # Machine status detailed mapping
  machineStatus:
    - source: machineStatus_tmp
    - state:
      - Settings: this == 0
      - Production: this == 1
      - Shutdown: this == 2
      - Alarm: this == 3
      - Warmup: this == 4
      - WarningStop: this == 5
      - DryRun: this == 6
      - Emergency: this == 7

  # Optional stop state
  optional-stop:
    - source: optionalstop
    - state:
      - ON: this == true
      - OFF: true

  # Single block mode
  singleblock:
    - source: singlestep
    - state:
      - ON: this == true
      - OFF: true

  # Dry run mode
  dry-run:
    - source: dryrun
    - state:
      - ON: this == true
      - OFF: true

  # Stack light status mapping
  greensignalon:
    - source: greensignalon_raw
    - state:
      - ON: this == true
      - OFF: true

  yellowsignalon:
    - source: yellowsignalon_raw
    - state:
      - ON: this == true
      - OFF: true

  redsignalon:
    - source: redsignalon_raw
    - state:
      - ON: this == true
      - OFF: true

# Output Section - Data Items
data-items:
  - alerts
  # Critical minimum requirements
  - mm-count
  - half-mm-count
  - programname
  - execution
  - jobidentifier
  - robot-loading-mode
  - mode
  - operation-mode
  - optional-stop
  - singleblock
  - dry-run
  - greensignalon
  - yellowsignalon
  - redsignalon
  - partsproducedinlifetime
  - piecestodo
  - errorcode
  - controlledSpeed
  - cycleMaxLoad
  - spindleOverride
  - cncalarmtype
  - runsCompleted
  - partsProducedInLifetime
  - numberInList
  - runningCycleTime
  - currentState
  - blankLength
  - shankDiameter
  - toolDiameter
  - cassetteCount
  - holeUCount
  - holeWCount
  - loadToolCassetteIndex
  - loadToolHoleU
  - loadToolHoleW
  - pieceOutOfGripper
  - unloadBlankCassetteIndex
  - unloadBlankHoleU
  - unloadBlankHoleW
  - distanceX
  - distanceY
  - distanceZ
  - feedoverride
  - iswarmup
  - cycleTime
  - endOfProduction
  - jobManagerProducedPieces
  - channelstate
  - rapidoverride
  - isrotating
  - override
  - powerOnDuration
  - currentload
  - machineStatus
  - activeTool
  - xTemp
  - yTemp
  - zTemp
  - aTemp
  - bTemp
  - cTemp
  - uTemp
  - wTemp
  - xwTemp
  - cwTemp
  - energyConsumption
  - energyConsumptionPhysical
  - voltage
  - coolantTempSensor
  - grindingZoneTempSensor
  - outsideAboveMachineTempSensor
  - outsideBelowTempSensor
  - machineStatus_tmp

# Conditions - System Fault Monitoring
conditions:
  system3:
    code: ${errorcode}
    message: ${message}
    value:
      FAULT: machineStatus_tmp == 3

Windows HMI Network Setup

If you are using OPC-UA / RConnect, the Windows HMI PC must have a network IP address accessible from the MachineMetrics edge device.

Option A — Static IP

On the Windows HMI:

Open Control Panel → Network and Sharing Center → Change adapter settings.
Right-click the network adapter → Properties.
Select Internet Protocol Version 4 (TCP/IPv4) → Properties.
Select Use the following IP address and enter a static IP, subnet mask, and gateway appropriate for your network.

Option B — DHCP

Follow the same steps as above, then:

Select Obtain an IP address automatically.
Note the assigned IP address for entry into MachineMetrics.

Once the HMI has a network IP, refer to the OPC-UA Connectivity Guide to complete the machine setup in MachineMetrics using port 8999.

Overview​

Network Requirements​

Connecting the FANUC Control (Machine Status Data)​

Connecting via OPC-UA (Production & Wheel Pack Data)​

Sample Rollomatic OPC-UA Adapter Script​

Windows HMI Network Setup​

Option A — Static IP​

Option B — DHCP​

Related Pages​