Today, robot-based automation solutions must efficiently combine flexibility, productivity, quality and simplicity. In addition, four "megatrends" are changing business processes and driving automation in new sectors of the economy: the individualization of customer needs, the shortage of skilled workers, digitalization and increasing uncertainty due to unforeseeable events.

However, the robot cell must be planned before it can be used. One challenge here is that all components of a system - including the robot controller and PLC - must be coordinated with each other. Robot and PLC programmers usually work in different locations and communicate by e-mail or telephone. In short, they meet for the first time when the machines and systems are to be put into operation. This often results in rework because the coordination was not clear enough and the robot controller and PLC do not harmonize. The result: commissioning is delayed and costs increase.

Virtual commissioning for greater planning reliability

With the powerful RobotStudio simulation and offline programming software and interfaces to other simulation platforms, ABB enables the virtual commissioning of automated production systems. Users can test and validate the interaction between the robot controller and PLC even before the system is set up - for example, when the robot cells created and tested in RobotStudio are connected to a virtual or real PLC and thus simulated realistically. The design, development and testing of a system can be carried out in parallel. The programmers and technicians can virtually check directly in the office whether the system, its interfaces, the machines and the assigned processes are running smoothly. This means that hardly any adjustments need to be made during installation, and planners can work with a whole new level of certainty that everything is working. Errors are detected before commissioning and production can begin more quickly.

By using RobotStudio, users achieve optimized utilization and use of the robot cell. At the same time, the software paves the way for digitalization. RobotStudio is based on the so-called Virtual Controller, an exact copy of the original software for controlling the robot. The Virtual Controller provides data and configurations of the robot as in real production. This creates an exact replica of the factory in virtual space. The additional integration of a physics engine to simulate friction, weight and holding forces enables a high-precision simulation before the robot starts work at the production site. Application examples include the realistic simulation of external cable packages (DressPacks) on the robot or the exact simulation of robot braking distances.

Virtual and augmented reality - the commissioning of the future

Thanks to a virtual image of the production systems in RobotStudio, users can put them into operation smoothly and thus save considerable time and costs. RobotStudio also allows the entire factory, including robots, to be mapped in a digital twin. This digital one-to-one copy of the production line enables the user to program and test changes during operation, for example if geometries are to be changed or completely new components are to be manufactured on the system. The virtual programming environment thus ensures that the system can be adapted quickly and flexibly without having to stop real production.

RobotStudio also makes it possible to immerse yourself in the robot cell using VR glasses. Virtual reality simplifies detailed observation or fine-tuning right from the planning phase. The Robot Studio AR Viewer is particularly suitable for companies that want to get started with robot-supported automation, as well as for those who have not yet had the time or resources to initiate the planning of a corresponding system. A visualization on a smartphone or tablet quickly and easily shows how robots can be integrated into existing processes and systems - even in action. The simulated model can be used to identify potential problems in advance or explore further optimizations.

User-friendliness through simple programming

Simple programming opens the door to robotics for many users - from small and medium-sized enterprises (SMEs) to large companies. ABB therefore strives to make programming as intuitive as possible - from cobots to classic industrial robots. Among other things, this is accelerating expansion into high-growth segments such as electronics, healthcare, consumer goods, logistics and the food and beverage industry, some of which have not yet been automated to any great extent.

ABB's "Wizard Easy Programming" software, for example, makes it possible to program robots without any special programming know-how or knowledge of rapid code creation. It is based on graphical blocks that represent actions such as moving to a position, picking up an object and repeating movements. This makes it quick and intuitive to create a series of simple processes for the robot to carry out. All the user has to do is drag and drop the relevant function blocks onto the ABB FlexPendant display.