Karobotics Ltd

Choosing to collaborate with Karobotics will enhance your existing or new robot facilities with the use of robot offline programming (OLP), where we can develop a bespoke solution to your process by creating, testing, and debugging robot programs in a virtual 3D environment on a high-specification CAD computer using Siemens Process Simulate, without physically stopping the actual robot in a production environment. This enables us to design and validate entire robotic work cells and processes before real-world deployment including all aspects of robot safety with the use of visual confirmation of all robot safety zones. 

Core Concepts

• Virtual Environment (Digital Twin): A precise digital replica of the physical robot and its surrounding work cell (tools, fixtures, safety equipment, workpieces) is created using software that imports 3D CAD models.

• Programming Off-Production: The key feature is that programming and testing occur on a CAD spec computer, meaning is an existing facility the physical robot can continue its current production tasks, eliminating costly downtime.

• Simulation & Validation: The software uses realistic physics engines to simulate robot motion and interaction with the environment, allowing engineers to check for potential issues like collisions, reachability errors, and singularities in a safe, risk-free setting.

• Code Generation (Post-processing): Once the virtual program is validated and optimised, a post-processor converts the simulation data into the specific programming language such as ABB RAPID / KUKA .KRL & FANUC .TP required by the physical robot controller. In conjunction of this we can control the simulation to RCS with allows the simulation to use the robot vendor specific robot data allowing accurate cycle time & motion validation. 

• Deployment: The generated program is then uploaded to the actual robot for execution, usually with a final low-speed test run to confirm everything is working as planned. 

Key Benefits

• Minimised Downtime: This is the primary advantage, as robots remain in production while new programs are developed and tested offline.

• Increased Safety: Testing in a virtual environment removes the risk of accidents, injuries, or damage to expensive equipment that could occur during physical trial-and-error programming along with development of robot safety zones which can then output & load to the robot ready for completion of a safety but off. 

• Improved Quality & Accuracy: Programs can be better optimized for shorter cycle times, consistent quality, and higher precision compared to manual "teach pendant" programming.

• Faster Setup & Commissioning: New applications or product changeovers can be implemented much more quickly, from weeks down to a single day.

• Flexibility: It enables the cost-effective use of robots for short-run, high-mix production scenarios where frequent reprogramming would otherwise be a major bottleneck.