Discover FTL, a dedicated specialized language developed by Festo that allows the full capabilities of the brand's robots and automation systems to be utilized
Programming Festo Industrial Robots in FTL
FTL (Festo Technology Language) is a language created for Festo automation solutions, distinguished by precise motion control and easy integration with additional equipment, including grippers, feeders, and sensors. Thanks to its modular structure and extensive instruction set, FTL offers the flexibility required in modern production lines, from simple pick and place operations to complex assembly or inspection processes. NexaRob uses FTL wherever precision, speed, and easy adaptation to changing market needs are required.
Why FTL?
- Precise Motion Control: FTL enables detailed trajectories to be defined with custom acceleration and deceleration parameters, helping with tasks that require exceptional delicacy and smoothness.
- Compatibility with Festo devices: The language supports a wide range of Festo components and accessories, making it easy to create advanced applications within one consistent environment.
- Rapid adaptation capability: FTL allows code to be divided into modules and functions, making changes to individual motion parameters or adding new functionality significantly easier and less time-consuming.
How Can NexaRob Help?
- Needs analysis: Together with the client, we define the expected scope of automation to assess whether FTL and selected Festo solutions are the best fit for a given production line.
- Code Creation and Optimization: We create applications in FTL, test them in a simulation environment, and then fine-tune them at the workstation to provide high performance and stability.
- Service and training: We offer dedicated operator training, assistance with hardware integration, and servicing during use so your team can efficiently maintain and develop the Festo system.
Learn what distinguishes the FTL language and in which sectors Festo robots and devices are especially valued
Key Functions and Application Examples in FTL
Although many languages and systems exist in automation, FTL stands out through its alignment with Festo device architecture and a rich set of built-in functions. Below we present the most important features of FTL and examples of industries in which Festo robots and solutions achieve high efficiency:
Advanced Motion Instructions
FTL offers classic point-to-point commands as well as linear and arc trajectories, with the ability to define custom speed and acceleration profiles.
Application: Precise assembly of small electronic components, welding lightweight structures, or handling packaging in the food industry.
Advanced Communication and Integration
The language supports communication with sensors for force, torque and temperature, cameras and PLC controllers, enabling dynamic correction of robot movements.
Application: A production line in which robots and Festo devices must exchange data in real time, for example for quality control or cycle optimization.
Flexible Code Structure
The ability to divide a project into modules and functions makes software maintenance and further development easier. Operators can quickly change parameters (e.g. speed, gripping force) without redesigning the entire codebase.
Application: Industries with highly variable product ranges (e.g. food, cosmetics), where rapid adaptation to a new product is essential.
Focus on Safety
FTL includes built-in mechanisms for collision detection and safety zone violations, as well as emergency stop procedures that protect personnel and equipment.
Application: Sectors where robots and people can share the workspace, for example laboratories or assembly of delicate products.
Application Versatility
Festo solutions with FTL can be used in the automotive, food, electronics, pharmaceutical, and many other industries thanks to the compact design and precision of Festo robots.
Application: Pick-and-place tasks, packaging, assembly, sorting, machine tending, and quality control.
FTL is a language unique, efficient, and flexible, tailored to the needs of devices Festo, which enables high productivity and precision. NexaRob provides comprehensive support for FTL implementation, from analysis and code design through testing and integration to operator training and ongoing service. This allows your production line to develop and compete effectively in the market.
Explore Different Ways to Create FTL Code for Festo Devices and Choose the Solution Best Suited to Processes in Your Facility
Main Programming Modes and Methods in Festo FTL
Robots and Festo devices controlled in FTL can be programmed in several ways, from entering commands on an operator panel through advanced simulation tools to remote editing over a network. This makes application implementation flexible, safe, and efficient, while NexaRob can help you select the appropriate method. Here are the main modes:
Teach Pendant (Online Programming)
- Direct editing: The operator uses the control panel to define movement points and sequences in FTL directly on the Festo device.
- Quick Corrections on the Line: Excellent for introducing minor changes or tests without requiring long production downtime.
- Limitations: More complex operations involving many points or complicated logic may require greater attention if relying solely on entering code through the pendant.
Offline Programming (Simulation Environment)
- Working on a computer: FTL code can be created and tested in a simulation environment, which minimizes errors and production line downtime.
- Time savings: After verification and optimization in simulation, the finished program only needs to be uploaded to the actual Festo device, reducing the number of corrections required on the line.
- Application: Ideal for projects requiring collision analysis, advanced paths, or precise cycle-time calculations.
Remote Online Programming, Network-Based Control
- Remote access: If the IT infrastructure is properly secured, the NexaRob team or your specialists can connect to the Festo controller over the network and modify FTL code on an ongoing basis.
- Expert support: Enables rapid response to problems and optimization without the need to bring an engineer to the facility.
Hybrid Approach
- Combining methods: In practice, the Teach Pendant is often used for calibration and minor corrections, while offline tools are used to design complex sequences and optimize trajectories.
- Gradual improvement: Code can be developed iteratively, testing alternatives in a simulator and introducing final corrections online, reducing the risk of errors and downtime.
Programming Methods in FTL are versatile and can be combined depending on project complexity and the need for frequent modifications. This allows the devices Festo perform well in both simple pick-and-place tasks and advanced assembly and inspection processes. In the following sections, we will examine how FTL integrates with vision systems and sensors, further improving production line efficiency and safety.
Discover how Festo devices programmed in FTL work with cameras and sensors to adapt to changing production conditions
Integration with Vision Systems and Sensors in Festo FTL
Festo robots and devices programmed in FTL are not limited to replaying fixed motion paths. Through communication with 2D/3D vision systems and sensors such as force sensors, they can actively adapt operations to current conditions on the line. Below we show how FTL supports this intelligent collaboration:
Vision Systems
- Protocols and libraries: FTL enables communication with industrial cameras, allowing information about the position or orientation of objects to be transmitted.
- Dynamic motion correction: When products are arranged irregularly, the robot or Festo device calculates an offset on the fly and corrects its movement, increasing speed and reducing errors in pick-and-place operations.
Force and Torque Sensors
- Delicate Assembly: In tasks requiring exceptional care, such as joining delicate electronic components, FTL controls the force level to avoid damage.
- Collision Detection: When torque or force exceeds a defined threshold, FTL code can immediately stop motion, protecting equipment and operators from the effects of a collision.
Support for Additional Axes and Peripherals
- Flexible Expansion: A Festo robot can work with additional axes, such as positioners, and devices such as grippers of different shapes, while FTL ensures their precise synchronization.
- Application: Automotive, multi-stage assembly, food, sorting and packaging diverse products, electronics, high product variability.
Application Examples
Food Industry
The robot recognizes products of different sizes using a camera, while FTL adjusts the trajectory so they can be placed gently into packaging.
Electronics
Gentle joining of components, where a force sensor protects them from crushing and a camera verifies assembly precision.
Logistics
Sorting packages by barcodes or labels, with dynamic motion correction based on shipment position.
Through integration with vision systems and sensors, the devices Festo in FTL gain the flexibility and intelligence required in modern production. NexaRob supports equipment selection, code development and optimization, as well as training, so that your industrial line can make full use of the potential of the solutions Festo.
See how FTL accelerated the assembly of delicate components in the demanding electronics industry while minimizing errors and costs
Precision Assembly and Quality Control in the Electronics Industry with Festo FTL
In the electronics industry, where thousands of precision components must be assembled with exceptional accuracy, Festo robots and devices programmed in FTL have proven to be an effective and flexible solution. Below we present an implementation example in which rapid adaptation to new models and the ability to dynamically correct motion resulted in a significant improvement in productivity and a reduction in production defects.
Context and Key Challenges
- Delicate Systems and Compact Dimensions: Even a minimal deviation in movement or inappropriate pressure force could result in damage to valuable components.
- Frequent product changes: The facility produced a variety of electronic modules requiring rapid changes to assembly parameters.
- Need for rapid quality control: With high volumes, reducing manual inspection and automating post-assembly verification became essential.
Solutions in FTL Code
Modular Division of Operations
Each activity, such as picking a component, placing it in a fixture, or performing a vision inspection, was implemented as a separate procedure in FTL, making the code easier to maintain and accelerating corrections. Speed, force, and position parameters were moved to external configuration files, allowing operators to change them quickly without modifying the entire program.
Integration with a Force Sensor and Vision System
While joining components, the Festo robot monitored force levels, slowing or stopping movement when permissible values were exceeded. The camera checked correct positioning and, in the event of minimal displacement, the FTL code automatically calculated an offset and corrected the trajectory in real time.
Automatic Quality Control
After assembly was completed, the robot performed a short verification sequence to check whether the component had been installed correctly and signaled any deviations to the operator. This reduced the number of units requiring manual inspection and accelerated the entire process.
Results and Benefits
- Productivity increase of approximately 20-25%: Efficient trajectory correction and the elimination of downtime associated with manual inspection accelerated the assembly process.
- Reduction of defective components: Dynamic force control and vision corrections reduced the number of damaged or incorrectly assembled modules.
- Easy Adaptation to New Models: FTL code proved easy to modify, shortening the implementation time of subsequent electronic device variants.
The use of FTL in this implementation made it possible to improve and accelerate electronic component assembly, increase quality and reduce the costs of errors. Comprehensive support NexaRob (analysis, code design, testing, training) enabled the customer to move quickly to mass production with a lower risk of downtime and material losses.
How to maintain high performance and compliance with occupational health and safety standards while rapidly developing applications based on Festo devices and FTL
Code Optimization and Safety Procedures in Festo FTL
After developing an application in FTL, it is important to continuously improve it and ensure compliance with applicable safety regulations. NexaRob recommends the following practices to support effective and reliable operation of Festo devices:
Cycle Time and Trajectory Analysis
- Collecting statistics: A Festo robot or device can report the number of cycles, errors, or delays. Regular analysis of this data helps identify areas for improvement, such as shortening trajectories.
- Code Refactoring: Small adjustments to speed, task sequence or removal of unnecessary motion points can often produce noticeable reductions in cycle time.
Code Structure and Modularity
- Avoiding Repetition: It is worth creating shared procedures and functions instead of copying code fragments, which reduces the risk of duplicating errors and accelerates updates.
- Clear Names and Comments: Consistent naming, such as pPickPos and nClampForce, makes debugging and code modifications easier for multiple programmers.
Safety Procedures
- Emergency stop conditions: FTL enables a robot or device to stop movement if force limits or safety zones are exceeded. These functions should be tested periodically to meet occupational safety requirements.
- Updating when standards change: Industries such as food, pharmaceuticals and automotive have strict standards. Code and configuration must be modified when new regulations are introduced.
Updates and development
- New firmware versions: Festo may release software updates. It is worth evaluating whether they introduce useful improvements, such as faster communication or new motion instructions.
- System scalability: If you plan to add more robots or axes, the modular approach in FTL makes it possible to expand workstations smoothly and adapt them to production growth.
Regular code optimization and attention to security in FTL provide devices with Festo efficient and stable operation. NexaRob help with code audits, hardware upgrades, and development consulting so that your company can keep pace with dynamic market needs while maintaining the highest standards of quality and safety.
Resolve Your Questions About Programming Festo Devices in FTL and Learn How NexaRob Can Support Your Project
Frequently Asked Questions
Below, we answer the most frequently asked questions about Festo robots and devices controlled using the FTL language. If you do not find the information you need here, please contact NexaRob. We will be happy to discuss your project and present specific proposals.
No. Although FTL offers extensive functions and motion instructions, a basic understanding of control logic is enough to start creating and modifying code relatively quickly. NexaRob provides training that helps teams learn FTL in a short time.
Stäubli robots are popular in electronics for precision assembly, the food industry for packaging and sorting, automotive for welding and assembly, and pharmaceuticals for delicate product handling. Their compact design and high precision make them suitable for many different processes.
Yes. Simulation tools are available that allow code to be created and verified without stopping production. Once testing is complete, the verified application can be uploaded to the Festo device, minimizing corrections in the real environment.
FTL supports communication with cameras (2D/3D) and different types of sensors such as force and torque sensors, enabling dynamic trajectory correction. This allows a Festo robot to adjust its motion path on the fly, significantly increasing precision and flexibility under changing conditions.
Most standard Festo models are industrial robots that usually require safety zones (light curtains, guarding). However, there are variants that provide greater interaction with people, and FTL itself allows speed and force limits to be defined, increasing the level of collaborative safety.
It depends on production dynamics. If assembly parameters or product ranges change frequently, code updates may be fairly regular. In a stable environment, changes are introduced mainly for optimization or adaptation to new standards.
Yes. We cooperate with a global network of suppliers, including Festo. We help select suitable models, write and optimize FTL code, and provide servicing and possible system expansion in the future.
Migration may require analysis of differences in syntax and motion logic. NexaRob supports such processes by assessing which sections can be transferred directly and where modifications are necessary. Sometimes partial import of logic is simpler than creating the entire application from scratch.
Contact us by email or phone. NexaRob will provide an initial analysis of your needs, advise on hardware and software, and develop FTL code together with operator training. This can help your production line operate more efficiently, safely, and flexibly in response to changing market conditions.
Do you have more questions?
Contact NexaRob. Our specialists can help design, implement, and maintain solutions based on Festo devices and the FTL language. Together, we will help maximize efficiency, minimize the risk of failures, and ensure full compliance with stringent industry standards.
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