Discover how precise code and movement sequences open up extensive possibilities in industry and logistics
Robot Programming as a Foundation
At NexaRob, we place strong emphasis on robot programming, the process that makes it possible to fully utilize the potential of advanced equipment. Even the most innovative technologies from trusted suppliers cannot perform effectively without precise, well-written code. Properly designed motion sequences and algorithms determine whether a robot will efficiently perform repetitive tasks, such as assembly or packaging, or even adapt independently to new process conditions.
How Does NexaRob Support You?
- Full flexibility - We work 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 match the requirements of a specific industry.
- Individual approach - We help define control logic, select safety factors, and organize robot operation so that it forms an integrated whole with existing production lines.
- Productivity increase - Good software means faster cycles, fewer errors, and less downtime. The tangible benefits can be seen in shorter production times and improved product quality.
Why is programming so important? For years, we have observed growing customer requirements, including more product variants, smaller batches, and increasing deadline pressure. It is the programmer who gives the machine its intelligence by defining movement patterns, responses to signals from sensors or vision systems, and emergency procedures designed to protect both employees and the equipment itself.
Explore the Stages and Types of Support NexaRob Offers for Industrial Robot Programming
From Consulting to Multilingual Environments
Professional programming is not just writing code, but an entire process, from initial understanding of the project objective through optimization and user training. As an integrator, NexaRob provides the necessary know-how at every stage, working with a global network of robotics technology suppliers. Our services can be divided into several areas:
Consultation and Requirements Analysis
- Understanding the process: We examine what the robot is expected to achieve and within what time frame, such as assembly, packaging, welding, or testing.
- Environment Selection: We determine which language will be optimal, such as ABB RAPID or KUKA KRL, taking into account existing infrastructure and staff competencies.
Creating Algorithms and Sequences
- Defining Control Logic: We design the movement sequence, sensor-signal handling, communication with the PLC system, and speed management.
- Offline programming: When necessary, we use simulators to test trajectories before running them on the physical robot.
Implementation in the Selected Language
- Versatility: 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 changing a product, for example to a new shape or size, requires minimal editing.
Testing and Optimization
- FAT and SAT: Before official deployment, we conduct acceptance tests under conditions close to real operation in a Factory Acceptance Test, followed by testing at the target workstation in a Site Acceptance Test.
- Motion corrections: If the robot spends too much time changing position or there is a collision risk, we make adjustments to improve safety and efficiency.
Training and Documentation
- Team preparation: We show how to modify or develop code so that the company is not dependent solely on external service providers.
- Manuals and Comments in Code: We create clear, well-documented code, making future changes and maintenance easier.
NexaRob is an integrator and business partner that supplies technologies from trusted manufacturers and combines them with an expert approach to programming. As a result, you receive a stable, flexible robotic system capable of handling diverse tasks, from simple manipulation to advanced operations requiring interaction with vision environments, IoT, or other machines. The following sections provide detailed information about programming modes, integrations, and the languages we work with.
Explore different ways to create robot code and choose the solution that best fits your plant
Main Programming Modes and Methods: Online, Offline, Teach Pendant, and More
Robot programming can be performed in several ways, from direct code editing on the robot panel to advanced simulation tools operating outside the production environment. At NexaRob, we help choose the right method for the team's needs and competencies so code development and deployment are fast, safe, and flexible. The main modes are outlined below:
Teach Pendant (Online Programming)
- Direct control: The operator uses a panel, or teach pendant, connected to the robot to manually set the trajectory point by point and save movement sequences.
- Quick Corrections on the Line: Ideal when small changes need to be introduced "on the fly" without interrupting production for an extended period.
- Limitations: More time-consuming for complex processes and more difficult when there are many points or advanced algorithms.
Offline Programming (Simulation Software)
- Working on a computer: Code and trajectories are created in a virtual environment before being transferred to the robot. This makes it possible to test different motion scenarios, analyze cycle times and detect potential collisions.
- Time savings: The line can continue operating while engineers prepare a new version of the code away from the production floor. Once uploaded to the robot, only a brief adjustment is needed before work can resume.
Remote Online Programming, Network-Based Control
- Remote access: NexaRob engineers or your team can make changes to the robot from another location, provided the network infrastructure is properly secured.
- Expert support: This model makes it possible to quickly obtain help from external specialists, for example in the event of unusual errors or an urgent need to optimize motion.
Hybrid Approach
- Combining methods: A Teach Pendant is often used to quickly set base points, while offline software is used for advanced optimization or implementing vision algorithms.
- Continuous improvement: Once written, code can be improved incrementally by testing different variants in a simulator and uploading updates to the robot online.
Macros and Programming Automation
- Motion libraries: We create reusable code fragments, or macros, that can be used repeatedly in different tasks.
- Templates for new products: If the product range changes frequently, we support the preparation of templates that can be easily parameterized according to component dimensions or shapes.
Programming methods should be flexible so that the team can respond to product changes, trends, or line expansion. A single factory often uses several different modes depending on the sophistication of a process. In the following sections, we discuss specific programming languages such as ABB RAPID, FANUC Karel, and KUKA KRL, as well as ways to combine robots with vision systems and intelligent grippers.
Explore the platforms where NexaRob creates flexible and efficient code tailored to the specifics of your process
Overview of Programming Languages and Environments for Robots
Every industrial robot manufacturer provides its own programming language and environment, ranging from simple, intuitive solutions to advanced systems supporting vision algorithms or IoT integrations. Below you will find a brief overview of the most commonly used languages supported by NexaRob, together with links to dedicated pages where we describe them in more detail.
Features: A Pascal-like language with a substantial number of library procedures for I/O handling and network communication.
Application: Often used in the automotive and logistics industries. It offers extensive expansion capabilities through external plug-ins, such as handling tools and paint tools.
Features: A structure resembling high-level programming languages, with easy creation of procedures and global variables.
Application: Machinery industry and large-scale production requiring stable, continuous processes for handling heavy components.
Features: A scripting language that is understandable even to less advanced programmers. UR robots are known for their safety and ease of implementation.
Application: Collaborative robots, or cobots, for assembling small components, manual tasks, and sectors where interaction with people is required.
Features: An intuitive language that integrates well with Mitsubishi PLC controllers.
Application: In applications where close integration between robots and industrial automation from the same brand is essential, for example on highly specialized lines.
Features: Specific to Toshiba Machine, supports SCARA and articulated robots.
Application: Assembly lines for small components and high-speed pick and place processes.
Features: It originates from automotive applications and includes an extensive library of macros for welding and handling heavy components.
Application: Projects in which Comau robots are integrated with high-throughput production lines.
Features: It features a clear structure and high movement precision, especially in 4-axis and 6-axis robots.
Application: Processes requiring high hygiene standards, such as food and pharmaceutical production, and areas where reliable 24/7 operation is required.
Features: A language typical of Yaskawa/Motoman robots, based on motion instructions, variables, and simple logical structures.
Application: Welding, palletizing, machine tending, and production lines requiring stable continuous-cycle operation.
Features: A scripting language for Denso robots, convenient for creating movement sequences, process logic, and communication with external devices.
Application: Precision assembly, electronics, laboratories and high-accuracy pick & place applications.
Features: A clear programming language for Epson robots, well suited to SCARA robots and fast-positioning applications.
Application: Assembly of small components, dispensing, testing, packaging, and processes requiring short cycle times.
Features: An environment combining robot, PLC, vision, and motion-axis programming within a single automation platform.
Application: Integrated production lines where robotics works together with motion control, sensors, and safety systems.
Features: Reis robot programming language, tailored to industrial handling applications and special processes.
Application: Welding, processing, handling large parts, and robotic workstations in heavier industries.
Features: Hyundai's robot language, enabling programming of motion, process logic, and cooperation with peripheral devices.
Application: Automotive, palletizing, welding, machine tending, and applications requiring high repeatability.
Features: A popular language for developing web applications, operator panels, API servers, and system integrations.
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, production line logic, and integration with robots.
Why so many platforms? At NexaRob, we provide technologies from trusted suppliers and consistently see that different industries prefer different robot designs and programming languages. Mastering multiple environments allows us to quickly adapt software to a specific line or project without requiring a change of robot supplier, while also integrating different brands smoothly within one system. This gives each company a solution tailored to its needs and ready for future market challenges.
Discover how to enhance robot programming with image analysis and flexible manipulators that expand automation capabilities
Vision Systems and Integration with Adaptive Grippers
For industrial robots to respond to changing surroundings, such as different shapes, positions, and types of parts, vision systems and adaptive grippers play a key role. At NexaRob, we help select and program 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 product types or check completeness and quality.
- Integration with Robot Code: We create procedures in which camera data is converted into coordinates in the robot's reference system, whether articulated, SCARA, Delta or another kinematic type. This allows movement and gripping to adapt to the current situation.
- On-the-fly quality control: In industries requiring high precision (e.g. electronics, pharmaceuticals), vision systems automatically detect defects and initiate rejection or correction without operator involvement.
Adaptive Grippers
- Variable shapes and sizes: An adaptive gripper adjusts to objects of different sizes and textures, allowing a single machine to handle a wide range of items.
- Adjustable Contact Force: Programming in the robot's language can be used to control gripping force, reducing the risk of damaging delicate components or heavier parts slipping out.
- Fast tool change: Depending on the technology, a robot can automatically change grippers using a tool changer to perform different tasks during a single production cycle.
Programming and Calibration
- Camera Parameter Configuration: We most often perform calibration so that the vision system correctly maps the actual position of objects into robot coordinates.
- Creating Motion Paths: Depending on data from the camera or adaptive sensors, the robot code selects the optimal method for gripping and placing the component.
- Control Loops: We can add instructions that repeat the sequence or display a message to the operator when an irregularity is detected, such as a missing component in the field of view.
Practical Applications
- Food industry: Recognizing irregular shapes of vegetables or fruit, placing them on a conveyor in a precise orientation, and checking for missing items.
- Electronics: Assembly of microchips of different sizes, automatic code scanning, and PCB defect detection.
- Logistics and e-commerce: Sorting parcels of various dimensions, placing packages in designated locations, and checking barcodes.
Combining robot programming with vision systems and adaptive grippers moves machines beyond static, repetitive tasks toward flexible and intelligent automation. At NexaRob, we deliver technologies from trusted suppliers and develop 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 and Quality Control
Many customers 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 the appropriate peripheral devices, is properly designed and implemented. Below are several examples of demanding applications in which NexaRob has demonstrated skillful use of advanced programming functions.
Soldering Precision Components
Challenge: Delicate components with tight tolerances, requiring the correct angle, temperature, and tip contact time.
Solution: We create sequences, for example in ABB RAPID or KUKA KRL, that include a soldering-iron temperature control loop and a contact-force sensor. The robot can also distinguish between different product variants through integration with a vision system.
Multi-Point Welding in the Automotive Industry
Challenge: Precise weld seams, coordination with other robots on the line, and different parts such as car bodies and components in changing shapes.
Solution: Programming in FANUC Karel or Kawasaki AS makes it possible to create libraries of welding parameters for different thicknesses and materials. Integration with arc and seam-deviation sensors helps ensure consistent, high-quality joints.
Quality Control Using Machine Learning Algorithms
Challenge: Automatic detection of surface defects or assembly errors without manual operator supervision.
Solution: Robot code, such as URScript for Universal Robots, communicates with an external AI module that processes camera images and returns information about possible 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 carton sizes and weights, no uniform stacking pattern, and constant changes in orders.
Solution: Code in Stäubli VAL3 or Comau PDL2 controls the adaptive gripper and communication with the vision system. The robot receives data about the position and dimensions of successive packages and independently decides how to arrange them on the pallet to maintain maximum stability.
Cooperation Between Robots and AGV/AMR Systems
Challenge: Synchronizing robot motion, for example when collecting finished products, with an autonomous vehicle delivering materials.
Solution: Appropriate scripts, for example in Mitsubishi MELFA Basic, communicate with the AMR fleet over the local network. The robot knows when an AMR vehicle arrives and which operations to perform in sequence to avoid unnecessary downtime.
The use of advanced robot programming goes far beyond simple handling or assembly. Thanks to integration with vision systems, temperature control, sensor data analysis, and artificial intelligence, even complex processes can become fully automated. As an integrator, NexaRob ensures that every application is carefully designed and adapted to the customer's conditions, whether it involves soldering microcomponents, heavy-duty welding, or advanced quality control.
How can already written scripts be improved and unexpected errors handled quickly?
Practical Troubleshooting
Even the best-designed robot program may require corrections or modernization during production-line operation. Sometimes cycle time needs to be reduced; in other cases, the system must adapt to a new product range or safety parameters need to change. At NexaRob, we offer comprehensive support in code optimization and debugging so your robots can continue operating at a high level of efficiency.
Cycle Time and Motion Analysis
- Recording trajectories: We use tools that monitor the path and movement speed of individual axes to identify idle periods or unnecessary downtime.
- Parameter Adjustment: Based on collected data, we adjust speed, acceleration or operation sequence so the robot works more smoothly and quickly while maintaining safety.
Error and Exception Management
- Conditional statements: We add code fragments that allow the robot to handle emergency situations, such as a missing part or a collision outside a designated zone, without the need 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 is introduced, there is no need to create code from scratch. Minor adjustments to the logic and reference points are often sufficient.
- Project Expansion: If a new robot or gripper is added to the line, we introduce shared procedures and resource sharing in the code, for example safety modules and network communication.
Offline Testing and Simulations
- Introducing Changes Outside Production: Using simulation environments such as RobotStudio, KUKA.OfficeLite and FANUC ROBOGUIDE, we can verify the effects of code modifications before releasing them to actual hardware.
- Test scenarios: We create different simulation variants (e.g. slower speed, greater load, missing part) to predict robot behavior in unexpected situations.
Remote Support and Service
- Online updates: If the infrastructure allows it, we can remotely upload new code versions, reducing downtime to a minimum.
- Expert consultations: NexaRob engineers are ready to help interpret logs, analyze errors and propose solutions in difficult cases.
Through IoT integration, robots become an active part of a broader ecosystem in which every process is monitored and optimized in real time. This enables cost reduction, faster responses to problems, and continuous improvement of production or logistics methods. In short, IoT amplifies the benefits of automation, making it even more efficient and competitive.
Clear up your doubts and contact our team of robot programming experts
Frequently Asked Questions
Below we present the questions our customers most frequently ask about robot programming and optimization. If you do not find an answer to your own question here, contact NexaRob. We will be happy to discuss the details and advise you on your project.
Not necessarily. Depending on your needs, you can use NexaRob services, or we can train your operators so they can make basic modifications independently.
Usually not. Small changes to existing sequences or the addition of a new module handling, for example, a different gripper or product type are often sufficient.
For a single robot and a standard setup, this can take from several hours to several days, depending on the level of automation, accuracy requirements and number of motion points.
We always recommend performing a basic risk analysis after changes are introduced, such as a no-load test at low speed. If there are doubts, we support verification and updating of occupational safety procedures.
No. We provide solutions from multiple suppliers, and our engineers have experience with ABB RAPID, FANUC Karel, KUKA KRL, Kawasaki AS, and many other languages.
During a project, we always determine which data is critical and must be transmitted in real time and which data can be aggregated and sent less frequently. This transmission management strategy helps us avoid unnecessary network load.
Yes. We offer remote and on-site support, log analysis, and offline simulations to effectively identify and resolve the source of problems.
We have experience configuring and programming robots to work with various vision systems, sensors, and smart grippers, enabling the robot to respond to current conditions.
Use the contact form on our website or contact us directly by email or phone. We will arrange an initial conversation to discuss the project scope, objectives, and cooperation conditions.
Do you have more questions?
Contact NexaRob. We will be happy to present a personalized proposal for robot programming and optimization, tailored to the challenges of your market and the nature of your production. Together, we can help your robots operate effectively, flexibly, and safely.