In classic industrial robotics, automation tasks are approached from a planning perspective, including the use of professional simulation and planning tools. © Yaskawa

Niche suppliers, for example in small robotics with simple handling applications, naturally offer programming solutions that are particularly simple for their product, its typical range of applications and the typical user group. Robot manufacturers with a full product range, such as Yaskawa, cover a wider spectrum and support not just one, but a correspondingly wide range of programming solutions.

Who programs robot applications?

Experienced robot programmers and system integrators value broad functionality and efficiency during commissioning and therefore prefer the classic robot teach pendant. The user interface may not always be as graphical and intuitive, but here robot positions can be taught and optimized very precisely, logic and parameters can be called up quickly in menus and function keys, and command parameters can be set up quickly in a line-oriented syntax. Advanced programming options at high-level language and tools for deep integration and customization of interfaces, protocols and functions are highly appreciated. For the subsequent operator, apps for easy operation and visualization can be set up either on an operating PC or on the touchscreen of the hand-held pendant station.

In plant engineering, there are often many PLC programmers, but only a few robot programmers, so there is a requirement to program the robot directly via PLC function blocks in your familiar PLC IEC programming environment (Siemens, Beckhoff, Rockwell, Yaskawa). This is possible with MotoLogix, an IEC-compliant PLC interface. From their experience with the graphically oriented PC and smartphone world, operators without a programming background increasingly find line-based programming "old school" and cumbersome and prefer the much more intuitive manual control of the robot or a smart counterpart.

Integrating robot programming into the digital process chain

If CAD data for the workpieces is available, CAD/CAM tools can be used to automatically generate robot paths using software and transfer them to the robot. Typical applications for this are milling, deburring, painting and additive processes such as WAAM or 3D printing. If planning tools such as offline simulation are used from the outset and virtual commissioning is to be supported with a digital twin of the robot, large parts of the robot program are generated in the virtual world and then loaded into the real robot. Suitable software tools at various performance levels (robot, cell, line or at a higher factory level) are offered by the robot manufacturers themselves or by third-party providers, whereby the robots and virtual controllers of leading robot manufacturers such as Yaskawa are available in the libraries of such tools.

The robot programs itself

If the position, location or number of workpieces is constantly changing, positions cannot be taught in advance. This is where sensor technology is used to guide the robot, such as 2D, laser-supported 3D image processing or force sensors. Thanks to intelligent pattern recognition and AI, image processing is increasingly able to handle parts that the robot has not seen before (pick & place, reaching into the box). Application examples for path processes include the automatic finding and guiding of welded or glued seams.

MotoLogix, an IEC-compliant PLC interface, enables the robot to be programmed directly via PLC function blocks and seamlessly integrated into the familiar PLC IEC programming environment. © Yaskawa

Cross-manufacturer programming environments and tools are often easy to use and offer the advantage of a uniform programming environment across many robot models from different manufacturers. However, compared to the robot manufacturer's standard solutions, they must be purchased and, if necessary, installed separately, so that the investment must be justified in terms of reduced programming time or flexibility compared to the robot manufacturer's on-board resources.

So every task has its optimal programming method, and none of the methods listed is so difficult that it cannot be learned within a few days of training. There are around 3 million industrial robots in operation around the world, and over 400,000 new ones are added every year. Every single one of them has been successfully programmed so far. And anyone involved in programming robots, whether newcomer or professional, will confirm that robot programming - with the right method - can also be fun.
Dr. Michael Klos, General Manager Business Development, Yaskawa Robotics Division

Yaskawa, www.yaskawa.eu.com