Robot Programming

Robot integration is the process of combining industrial robots with control systems, software, and equipment that makes the industrial robots perform automated tasks in a repeatable, safe and efficient way. 

What is Robot Integration

At AG Controls, we turn robot capability into reliable production performance, from simple pick-and-place cells to complex process and bin-picking applications. Automotive is one of our core sectors, where robots are central to high-speed, high-precision production lines, but we also deliver across other industries. Our focus is on delivering solutions that improve speed, accuracy and flexibility while meeting cycle time and safety requirements.

Our Robot Integration service

Our robot integration service covers the full project lifecycle, combining initial engineering up to on-site delivery:

• Scoping and specification
  We meet customers, assess requirements and agree functionality, cycle time and system limits
  
• Proposal and planning
  Aclear proposal and delivery plan, including whether simulation or offline programming is required
  
• Offline programming and simulation
  Where needed we simulate robot paths and cell layout before any plant downtime is required
  
• Integration and software development
  We program across all major industrial robot platforms, including communication to vision systems and higher level systems, with experience including FANUC, KUKA, ABB, YASKAWA and EPSON.
  
• Installation, commissioning and testing
  On-site installation followed by commissioning and Factory Acceptance Test (FAT) and Site Acceptance Test (SAT) to verify performance in real use
  
• Support and optimisation
  Diagnostics, performance tuning and updates to keep cells running reliably and to improve throughput

We routinely deliver robot solutions for tasks such as:

• Pick-and-place, including bin-picking
• Gluing
• Screw processes
• Repetitive assembly operations.

Example applications of robot integration

In sectors like Automotive, demanding cycle times, repeatable accuracy and safety standards are especially critical. We manage robot integration projects from initial concept through to handover. This includes:

Many customers standardise on a single robot brand; where customers have no strong preference, we help them choose the best fit for the application and the organisation. Brand choice is frequently driven by customer standards and spare parts strategies. For example, Nissan standardises on FANUC and Mercedes on KUKA.

We take a pragmatic approach to simulation. Some applications are straightforward and can be programmed offline without prior simulation. Other projects, especially those with tight project schedules or complex cell layouts, benefit from detailed simulation to validate cycle times and prevent crashes. After offline programming, we proceed to installation, commissioning and FAT/SAT to ensure the system performs as intended in production.

Complex challenges and success stories

We handle complex integrations such as vision-guided bin-picking and micro-part handling. For example, a recent project required vision picking of very small components, multiple screws with thread M0.7. That application demanded careful vision tuning and accurate path teaching to minimise scrap rate.

On the safety front, we worked on a project involving FANUC robots where a homing routine was provoking intermittent crashes. 

We reprogrammed 27 robots to correct the underlying programming problem and since the change, that fault has not recurred. 

The outcome was a measurable improvement in uptime and a reduced safety risk.

Industries we work with

• Original equipment manufacturers,
• Production engineers
• Automation partners 

Our role is to turn robotic capability into safe and optimised production, tailored to each customer’s preferred hardware and standards.