Handling
Parts and materials are moved between stations, conveyors and fixtures.
Robot and PLC have to
master the same sequence
Prepare movements and interfaces offline and fine-tune them on the real cell.
A working robot program alone is not enough for a stable cell sequence. Handovers, releases and process steps have to fit together with the PLC, peripherals and operation.
IQstruct Engineering programs robots for handling, palletising, assembly and screwdriving. Offline programming, simulation, interface coordination and commissioning are part of the offer. We work with ABB, KUKA and FANUC as well as Universal Robots for cobot applications; welding and bonding extend the possible range of processes.
Start now at no cost
In a free first conversation we clarify which robot brand is in use, how the cell is connected to the controller and what can be checked against a model beforehand.
Applications
Welding and bonding extend the possible range of processes.
Palletising and depalletising
Layer patterns, gripper changes and handovers are coordinated with the plant.
Assembly
Joining operations are connected with the process steps and peripherals of the cell.
Screwdriving
Screwdriving processes are integrated into the cell sequence with releases and feedback.
Engineering environments and manufacturers
We work with ABB, KUKA and FANUC as well as Universal Robots for collaborative applications.
For offline programming we use ABB RobotStudio, FANUC ROBOGUIDE as well as KUKA.Sim, KUKA.WorkVisual and KUKA iiQWorks. Which environment fits depends on the robot generation, the controller and the task.
In the model, robots, grippers, workpieces and surroundings are positioned, tool and user coordinate systems defined and paths planned. Reach, movement envelopes and possible collisions are checked at the level of detail of the model before the real cell is available.
Virtual commissioning can then test robot and PLC programs together against the plant model. On the real cell, calibration, final path adjustments and tests with the real mechanics follow.
In the cell
Robot, PLC and peripherals work to one cycle
Programs prepared offline are calibrated on the real cell and coordinated with handovers and releases.
Approach in the project
Ai1
Discuss process requirements
Process description, plant layout and interfaces are clarified with your team.
Ai2
Program the controllers
PLC and robot programs are developed as one coordinated automation concept.
Ai3
Virtual commissioning
The real programs control the model through a bidirectional coupling; the phase ends with an accepted software version.
Ai4
Commission the real plant
The tested software version goes to the real plant and is fine-tuned there.
What robot and PLC exchange
Which functions sit in the PLC and which in the robot controller depends on the plant architecture and the customer specification.
Readiness and releases
Start, stop and release signals determine when the robot may work.
Program and variant selection
The PLC selects the right program for the part and the variant.
Gripper and process states
Gripper commands, positions and feedback keep robot and plant in the same state.
Fault and diagnostics
Fault information reaches the operators before the sequence falters.
Handover
The handover comprises more than motion programs
The agreed program version, the associated simulation environment and technical documents allow the solution to be developed further.
Interfaces, special features and tests are documented with test and inspection reports. This shows which version was handed over, even when changes are made later.
Frequently asked questions
We are glad to answer your detailed questions in a personal conversation.
Does a cobot make a safety concept unnecessary?
A cobot does not replace a safety concept. Specific protective functions and responsibility for acceptance are defined for the application.
What remains for on-site commissioning?
Mechanical tolerances, real gripper behaviour and process forces are assessed on the real cell. Offline programming shortens this work, but it remains part of the project.
Do you commit to a particular cycle time?
We state a cycle time result as soon as the process, the safety requirements, the mechanics and the real boundary conditions are known.
Do you also implement safety zones?
We take agreed safety zones into account and implement them. The dividing line with functional safety is defined in the project.
Further industry solutions
Every industry has its particularities. That calls for a reliable partner who knows the requirements and delivers suitable solutions.
- AutomotiveThe cycle time of a line is settled before it is built, and the buyer asks for proof that it is reached.
- IntralogisticsConveyors, storage and retrieval machines and vehicles come from several manufacturers and speak different protocols.
- PackagingA format change takes minutes, and the visual inspection runs along at machine cycle.
First conversation
Arrange a free first conversation
Describe your task. We agree a date and discuss the possible project scope.
Ai1
You request an appointment
Ai2
We discuss your requirements
Ai3
You receive a quotation for the agreed scope
Tobias KuckBusiness Development ManagerTakes up new projects, coordinates offers and accompanies the cooperation from the first enquiry.
Free first conversation
Describe your task in the contact form. We come back with a proposed date.
Arrange a first conversationBooking calendar
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Not quite what you need?
Discover further suitable services.
PLC programming, HMI and SCADA
Connect sequence control, operation and diagnostics in one coordinated automation concept.
Functional safety
Implement specified protective functions in control software and test their response on the plant.
Virtual commissioning
Test PLC and robot programs on the digital plant model before real commissioning begins.