Discover how precise codes and sequences of movements open up unlimited possibilities in industry and logistics
Robot Programming as a Foundation
At NexaRob, we place great emphasis on robot programming - a process that allows us to fully utilize the potential of advanced hardware. Even the most innovative technologies from trusted suppliers will not pass the test without precise, well-written code. Appropriately designed sequences of movements and algorithms determine whether the robot will efficiently perform repetitive tasks (e.g., assembly, packaging) or even adapt independently to new conditions in the process.
How does NexaRob support you?
- Full flexibility - We cooperate with a global network of robot suppliers and use various environments (such as ABB RAPID, FANUC Karel, KUKA KRL, Kawasaki AS, Universal Robots URScript, Mitsubishi Melfa Basic, Festo FTL, Toshiba SCOL, Comau PDL2, Stäubli VAL3, and others) to adapt to the requirements of a specific industry.
- Individual approach - We help in defining control logic, selecting safety factors, and organizing robot work in such a way that they form an integrated whole with existing lines.
- Increased efficiency - Good software means faster cycles, fewer errors, and less downtime. The tangible benefits are visible in the form of reduced production time and improved product quality.
Why is programming so important? For years, we have observed an increase in customer requirements - more and more product variants, smaller batches, and increasing pressure on deadlines. It is the programmer who gives the machine "intelligence" - defines the movement pattern, reaction to signals from sensors or vision systems, as well as emergency procedures to protect both employees and the equipment itself.
Learn about the stages and types of support that NexaRob offers for industrial robot programming.
From Consultation to Multilingual Environments
Professional programming is not only writing code, but a whole process - from initial familiarization with the project goal to optimization and user training. As an integrator, NexaRob provides the necessary know-how at every stage, cooperating with a global network of robotic technology suppliers. Our services can be divided into several areas:
Consultation and Requirements Analysis
- Understanding the process: We analyze what the robot should achieve and within what time frame (assembly, packaging, welding, testing, etc.).
- Environment selection: We determine which language will be optimal (e.g., ABB RAPID or KUKA KRL), taking into account the existing infrastructure and staff skills.
Creating Algorithms and Sequences
- Defining control logic: We design the movement sequence, sensor signal handling, communication with the PLC system, or speed management.
- Offline programming: If necessary, we use simulators to test trajectories before running them on a physical robot.
Implementation in the Selected Language
- Universality: We adapt to many platforms - from FANUC Karel and Kawasaki AS, through Universal Robots URScript, to Comau PDL2 and Stäubli VAL3.
- Parameterization: We create flexible code templates, so that changing the product (e.g., a new shape, different size) requires minimal editing.
Testing and Optimization
- FAT and SAT: Before official implementation, we conduct acceptance tests in conditions similar to real ones (Factory Acceptance Test), and then at the target station (Site Acceptance Test).
- Motion corrections: If the robot takes too much time to change position or there is a risk of collision, we make corrections to ensure safety and efficiency.
Training and Documentation
- Team preparation: We show how to modify or develop the code so that the company is not dependent solely on external service providers.
- Manuals and comments in the code: We create clear, well-documented code, which facilitates any changes and maintenance.
NexaRob is an integrator and business partner that provides technologies from trusted manufacturers and combines them with an expert approach to programming. As a result, you get a stable, flexible robotic system capable of handling various tasks - from simple manipulations to advanced operations requiring interaction with the visual environment, IoT or other machines. In the following sections, you will find detailed information about programming modes, integrations and languages that we work with.
Discover the various ways to create code for robots and choose the solution that best suits your facility.
Main Modes and Programming Methods: Online, Offline, Teach Pendant, and More
Robot programming can be done in several ways - from directly editing code on the robot's panel to using advanced simulation tools that operate outside the production environment. At NexaRob, we help you choose the right method to suit your team's needs and skills, so that the process of writing and implementing code is fast, safe, and flexible. Below are the main modes:
Teach Pendant (Online Programming)
- Direct control: The operator uses a panel (pendant) connected to the robot to manually set the trajectory point by point and save sequences of movements.
- Quick adjustments on the line: Ideal when there is a need to make minor changes "on the fly" without interrupting production for an extended period.
- Limitations: More time-consuming for complex processes; more difficult with a large number of points or advanced algorithms.
Offline Programming (Simulation Software)
- Working on a computer: The code and trajectories are created in a virtual environment before being transferred to the robot. This allows you to test different motion scenarios, analyze cycle times, or detect potential collisions.
- Time saving: The line can continue to operate while engineers prepare a new version of the code outside the production hall. After uploading it to the robot, only a short correction is needed and it can start working.
Online Programming remote (Network Control)
- Remote access: NexaRob engineers or your team can make changes to the robot from another location, provided that the network infrastructure is properly secured.
- Expert support: This makes it possible to quickly obtain assistance from external specialists, for example, in the event of unusual errors or a need for urgent motion optimization.
Hybrid Approach
- Combining methods: Often, a Teach Pendant is used to quickly set up basic points, and offline software is used for advanced optimization or the implementation of vision algorithms.
- Gradual Improvement: Once written, the code can be continuously improved by testing different variants in a simulator, and the corrections can be uploaded to the robot online.
Macros and Programming Automation
- Motion libraries: We create universal code fragments (macros) that can be reused multiple times in different tasks.
- Templates for new products: If the production range changes frequently, we support the preparation of templates - easily parameterized according to the dimensions or shapes of parts.
Programming methods should be flexible - so that the team can react to changes in products, trends or line expansion. Often, several different modes are used in one factory, depending on the degree of advancement of a given process. In the following sections, we will discuss specific programming languages (e.g., ABB RAPID, FANUC Karel, KUKA KRL) and the possibilities of connecting robots with vision systems and intelligent grippers.
Discover the platforms in which NexaRob creates flexible and efficient code tailored to the specifics of your process.
Overview of Languages and Development Environments for Robots.
Each manufacturer of industrial robots provides its own language and environment for programming - from simple, intuitive solutions to advanced systems supporting vision algorithms or IoT integrations. Below you will find a brief description of the most commonly used languages that we support at NexaRob, along with links to dedicated pages where we describe them in more detail.
Features: A language similar to Pascal, a large number of library procedures for handling I/O and network communication.
Application: Often used in the automotive and logistics industries. Enables extensive expansion through external plugins (so-called handling tool, paint tool, etc.).
Features: Structure similar to high-level languages, easy creation of procedures and global variables.
Application: Machine industry, large-scale production with the requirement of stable, continuous processes for manipulating heavy parts.
Features: A scripting language that is understandable even for less experienced programmers. UR robots are known for their safety and ease of implementation.
Application: Collaborative robots (cobots) in the assembly of small components, manual operations and sectors where interaction with people is needed.
Features: Intuitive language that integrates well with Mitsubishi PLC controllers.
Application: In places where linking robots with industrial automation of the same brand is key (e.g., a narrow specialization of the line).
Features: Specific to Toshiba Machine, supports SCARA and articulated robots.
Application: Assembly lines for small components, pick & place processes at high speeds.
Features: Derived from applications in the automotive industry, it has a rich library of macros for welding and handling heavy elements.
Application: Projects where Comau robots are integrated with high-throughput production lines.
Features: Characterized by its clear structure and high precision of movements, especially in 4- and 6-axis robots.
Application: Processes requiring a high degree of hygiene (food industry, pharmaceutical industry) and areas where reliable 24/7 operation is required.
Features: Typical language for Yaskawa/Motoman robots, based on motion instructions, variables and simple logical structures.
Application: Welding, palletizing, machine handling and production lines requiring stable continuous cycle operation.
Features: A scripting language for Denso robots, convenient for creating motion sequences, process logic and communication with external devices.
Application: Precision assembly, electronics, laboratories and high-accuracy pick & place applications.
Features: Clear programming language for Epson robots, well suited for SCARA robots and fast positioning applications.
Application: Assembly of small components, dispensing, testing, packaging and processes requiring short cycle times.
Features: An environment that combines robot programming, PLC controllers, vision and motion axes in a single automation platform.
Application: Integrated production lines where robotics works with motion control, sensors and safety systems.
Features: Programming language for Reis robots, adapted to industrial manipulation applications and special processes.
Application: Welding, machining, handling large parts and automated workstations in heavy industry.
Features: Hyundai robot language, enabling programming of movements, process logic and cooperation with peripheral devices.
Application: Automotive, palletizing, welding, machine tending and applications requiring high repeatability.
Features: A popular language for creating web applications, operator panels, API servers, and system integration.
Application: Production dashboards, HMI applications, communication with MES/ERP systems, and handling data from industrial devices.
Features: A graphical PLC programming language based on diagrams resembling relay circuits.
Application: Machine control, production sequences, safety, logic of technological lines, and integration with robots.
Why so many platforms? At NexaRob, we provide technologies from trusted vendors, and we still see that different industries prefer different designs and languages. Mastering multiple environments allows us to quickly adapt software to a specific line or project - without the need to change robot suppliers, and also seamlessly integrate different brands into one system. As a result, each company receives a solution tailored to its needs, while also being ready for future market challenges.
Discover how to enhance robot programming with image analysis and flexible manipulators that increase automation capabilities.
Vision Systems and Integration with Adaptive Grippers
In order for industrial robots to react to changing environments - such as different shapes, positions, and types of parts - vision systems (so-called vision systems) and adaptive grippers play a key role. At NexaRob, we help in the selection and programming of these solutions so that the robot can reliably identify and precisely manipulate objects.
Vision Systems
- 2D/3D image analysis: Allows the robot to detect the position and orientation of parts on a conveyor or pallet. It can also distinguish between product types or check for completeness and quality.
- Integration with robot code: We create procedures in which data from the camera is processed into coordinates in the robot's coordinate system (articulated, SCARA, Delta, etc.). This ensures that movement and gripping are adapted to the current situation.
- Quality control on the fly: In industries requiring high precision (e.g., electronics, pharmaceuticals), vision systems automatically detect defects and initiate rejection or correction, without operator intervention.
Adaptive Grippers
- Variable shapes and sizes: An adaptive gripper adapts to objects of different sizes or textures, allowing a single machine to handle a wide range of products.
- Adjustable clamping force: Thanks to programming in the robot language, it is possible to control the gripping force, which reduces the risk of damage to delicate elements or slipping of heavier parts.
- Quick tool changes: Depending on the technology, the robot can automatically change grippers (so-called tool changer) to perform various operations during a single production cycle.
Programming and Calibration
- Setting camera parameters: Most often, we perform calibration so that the vision system correctly maps the actual position of objects in the robot's coordinates.
- Creating motion paths: Depending on the data from the camera or adaptive sensors, the robot code selects the optimal way to pick up and place an element.
- Control loops: We can add instructions that, upon detecting an irregularity (e.g., a missing item in the field of view), repeat the sequence or display a message to the operator.
Practical Applications
- Food Industry: Recognizing irregular shapes of vegetables or fruits, placing them on a conveyor belt with precise orientation, and defect detection.
- Electronics: Assembly of microcircuits of various sizes, automatic scanning of codes, and detection of defects in PCBs.
- Logistics and e-commerce: Sorting shipments of various sizes, placing packages in designated locations, and checking barcodes.
Combining robot programming with vision systems and adaptive grippers frees machines from static, repetitive tasks, directing them towards flexible and intelligent automation. At NexaRob, we provide technologies from trusted suppliers and write software that gives robots the ability to "see" and adapt to diverse challenges.
See how advanced robotic scripts solve difficult tasks in industrial environments.
Soldering, Welding, Quality Control
Many customers, when considering robot programming, ask: "Can more complex processes be handled, such as soldering precision components or welding along strictly defined trajectories?" The answer is yes, provided that the software - together with appropriate peripheral devices - is properly designed and implemented. Below are some examples of difficult applications in which NexaRob has demonstrated skillful use of advanced programming functions.
Soldering Precision Components
Challenge: Delicate components with small tolerances require maintaining the correct angle, temperature, and contact time of the soldering tip.
Solution: We create sequences (e.g., in ABB RAPID or KUKA KRL) that include a temperature control loop for the soldering iron and a force sensor. The robot can also distinguish between different product variants thanks to its connection with a vision system.
Multi-Point Welding in the Automotive Industry
Challenge: Precise welding seams, coordination with other robots on the line, various parts (car bodies, components) in varying shapes.
Solution: Programming in FANUC Karel or Kawasaki AS allows you to create libraries of welding parameters for different thicknesses and materials. Cooperation with arc sensors and weld deviation guarantees uniformity and high quality of joints.
Quality Control Using Machine Learning Algorithms
Challenge: Automatic recognition of surface defects or assembly errors, without manual operator supervision.
Solution: The robot code (e.g., URScript in the case of Universal Robots) communicates with an external AI module that processes the image from the camera and returns information about any irregularities. The robot can then reject the part, notify the MES system, or send it for rework.
Palletizing and Depalletizing with Dynamic Package Recognition
Challenge: Different sizes and weights of cartons, no uniform layout pattern, constant changes in orders.
Solution: Code in Stäubli VAL3 or Comau PDL2 controls the adaptive gripper and communication with the vision system. The robot retrieves data on the position and size of subsequent packages, independently deciding on the arrangement on the pallet to maintain maximum stability.
Cooperation of Robots and AGV/AMR Systems
Challenge: Synchronization of robot movement (e.g., picking up finished products) with an autonomous vehicle delivering materials.
Solution: Appropriate scripts (e.g., in Mitsubishi Melfa Basic) communicate with the AMR fleet over a local network. The robot "knows" when the AMR vehicle arrives and what operations to perform in sequence to avoid unnecessary downtime.
The application of advanced robot programming extends far beyond simple transfer or assembly. Thanks to integration with vision systems, temperature control, data analysis from sensors, and artificial intelligence, even complex processes become fully automatable. As an integrator, NexaRob ensures that each application is carefully considered and adapted to the client's conditions - regardless of whether it involves soldering microcomponents, heavy welding, or advanced quality control.
How to improve already written scripts and quickly respond to unforeseen errors?
Troubleshooting in Practice
Even the best-designed robot program may require corrections or upgrades during the operation of a production line. Sometimes, it is necessary to shorten the cycle time; in other cases, it is necessary to adapt to a new product range or change parameters related to safety. At NexaRob, we offer comprehensive support in optimizing and debugging code so that your robots always operate at the highest level of performance.
Cycle Time and Motion Analysis
- Trajectory Recording: We use tools that monitor the path and speed of individual axes to identify moments of inactivity or unnecessary downtime.
- Parameter Adjustment: Based on the collected data, we introduce corrections to speed, acceleration, or the sequence of operations so that the robot works more smoothly and faster while maintaining safety.
Error and Exception Management
- Conditional Instructions: We add code fragments that allow the robot to handle emergency situations (e.g., missing part, collision in an undefined area) without having to stop the entire line.
- Logs and Diagnostics: By recording detailed system messages, we can quickly determine when an error occurred and what caused it.
Adaptation to New Tasks
- Modifying Existing Sequences: When the product range changes or a new packaging format appears, there is no need to create code from scratch. Often, minor adjustments to the logic and reference points are sufficient.
- Project Expansion If we add a new robot or gripper to the line, we introduce common procedures and resource sharing in the code (e.g., safety modules, network communication).
Offline Tests and Simulations
- Making changes outside of production: Thanks to simulation environments (e.g., RobotStudio), tools like FANUC ROBOGUIDE, we can test the effects of code modifications before deploying them to actual hardware.
- Test scenarios: We create different simulation variants (e.g., slower pace, higher load, missing part) to predict how the robot will behave in unforeseen situations.
Remote and Service Support
- Online updates: If the infrastructure allows, we can remotely upload new versions of the code, minimizing downtime.
- Expert consultations: NexaRob engineers are ready to help interpret logs, analyze errors, and propose solutions in difficult cases.
Thanks to the integration with IoT, robots become an active element of a broader ecosystem in which every process is monitored and optimized in real time. This makes it possible to reduce costs, respond more quickly to problems, and continuously improve production or logistics methods. In short, IoT enhances the advantages of automation, making it even more efficient and competitive.
Dispel your doubts and contact our team of robot programming experts.
Frequently Asked Questions
Below, we present the questions that our customers most often ask in the context of robot programming and optimization. If you cannot find an answer to your own questions here, please contact NexaRob - we will be happy to discuss the details and provide advice on your project.
Not necessarily. Depending on your needs, you can use NexaRob's services or we can train your operators to make basic modifications themselves.
Usually not. Often, only minor changes in existing sequences or adding a new module supporting, for example, a different gripper or product type are sufficient.
For one robot and a standard setup, this can take from a few hours to a few days, depending on the degree of automation, accuracy requirements, and the number of motion points.
We always recommend performing a basic risk analysis after making changes (e.g., unloaded test, at low speed). If in doubt, we will support you in verifying and updating safety procedures.
No. We provide solutions from many suppliers, and our engineers have experience with ABB RAPID, FANUC Karel, KUKA KRL, Kawasaki AS, and many other languages.
During the project, we always determine which data is critical and must be transmitted in real time, and which can be aggregated and sent less frequently. Thanks to this transmission management strategy, we avoid unnecessary bandwidth congestion.
Yes. We offer remote and on-site support, log analysis, and offline simulations to effectively find the source of problems and fix them.
We have experience in configuring and programming robots that work with various vision systems, sensors, or smart grippers, to enable the robot to react to current conditions.
We invite you to use the contact form on our website or send a direct email/call. We will arrange an initial meeting during which we will discuss the project scope, goals, and terms of cooperation.
Do you have more questions?
Contact NexaRob - we will be happy to provide a personalized offer for robot programming and optimization, tailored to the challenges of your market and the nature of your production. Together, we will ensure that your robots work effectively, flexibly, and safely.
Automate Your Business with NexaRob - Contact Us!
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