Robot Programming & Robotic Programming for Industrial Automation
Professional robot programming & robotic programming services for industrial automation. ABB, FANUC & more. UK-based experts.
Robot Programming Training | Robotic Programming & Automation Skills
Industrial Robot Programming & Robotic Automation Solutions
We specialize in programming solutions for robots that help you streamline operations and enhance productivity. Our team delivers tailored services to meet your unique needs.
Industrial Robot Programming
- Robot programming on-site and remote
- Commissioning of new cells and line starts
- Optimising cycle times and refining processes
- Improving payload, reach, and motion
PLC & Robot Integration
- Direct communication between robots and PLCs
- Integration of safety PLCs and interlocking systems
- HMI setup for operator control
- Complete system validation
Process-Specific Programming
- Material handling & palletising
- Machine tending (CNC, presses, injection moulding)
- Welding, dispensing, sealing & assembly
- Milling and cutting
Multi-Brand Robot Expertise
We support a diverse range of industrial robot brands, including:
- ABB
- FANUC
- KUKA
- Yaskawa / Motoman
- Any refurbished robots
Robot Programming Costs - FANUC, ABB, and KUKA
Robot programming costs vary based on the brand of the robot, the complexity of the application, and the level of integration required. We offer transparent and fair pricing according to the project’s scope and specifications. Please review our estimate for Robot Programming Rates (UK), but for an accurate quote tailored to your specific needs, do not hesitate to contact us.
On-Site Robot Programming
Hands-on
Real robot
On-site
Remote Robot Programming
Theory & virtual
Simulation software
Simulated tools
Simulated tasks
(*) Prices vary based on project scope. Travel and expenses are additional and not included in the listed prices. For more information, please contact us.
what typically includes on-site and remote robot programming
Robot programming services come in two forms: on-site programming, which is done at the customer’s location with the actual robot, and remote programming, conducted off-site via remote access or simulation. Here’s a summary of what each service includes.
Remote Robot Programming
Remote robot programming enables engineers to create, modify, or fix robot programs without needing to be on-site. This practice is becoming more common due to advancements in remote access technologies and simulation tools.
1. Offline Robot Programming
Engineers use simulation software to develop robot programs before transferring them to the robot controller. This minimizes downtime, allowing programming while production is ongoing. Common tools used are:
- ABB RobotStudio
- RoboDK
- KUKA.Sim
With offline programming, engineers can:
- Create robot paths
- Simulate motion
- Test cycle times
- Identify potential collisions
2. Remote Robot Program Updates
Engineers can update robot programs directly on the controller through secure remote connections. This enables quick adjustments without needing an on-site visit. Typical remote tasks include:
- Modifying programs
- Adjusting motion
- Changing speed or cycle times
- Adjusting process parameters
3. Troubleshooting and Technical Support
Remote programming services usually offer diagnostic support for any issues that may arise. This helps reduce production downtime. Engineers can:
- Access robot logs
- Identify program errors
- Modify robot parameters
- Recover lost or corrupted programs
4. Robot Program Optimization
Remote engineers can review production data and enhance robot programs. These improvements boost efficiency without needing physical access. Common optimization tasks entail:
- Improving cycle times
- Smoothing motion
- Eliminating unnecessary movements
- Enhancing program structure
5. Backup and Program Management
Remote services frequently provide program management and backups. Reliable backup systems are essential for protecting critical production programs. This involves:
- Version control for programs
- Backing up robot programs
- Recovering lost or damaged programs
- Software updates
On-Site Robotic Programming
On-site robotic programming involves an engineer working directly at the factory where the robot is installed. This is usually required during installation, commissioning, or when physical adjustments to the robot or tooling are necessary.
1. Robot System Setup and Commissioning
Robots need to communicate with other automation equipment. Typical tasks include:
- Robot controller configuration
- Calibration of robot axes and tools
- TCP (Tool Center Point) setup
- Work object or coordinate system configuration
- Verification of robot communication with machines and PLCs
- This stage ensures the robot is correctly aligned with the production process.
2. Teach Pendant Programming
Engineers use the teach pendant to create motion paths and sequences:
- Typical programming tasks include:
- Teaching robot positions and paths
- Defining motion types (linear, joint, circular)
- Setting speeds and acceleration
- Programming process actions such as welding or gripping
- Creating pick-and-place sequences
3. End-of-Arm Tooling Configuration
Proper tool configuration is vital for accurate performance.
- On-site programming may include:
- Configuration of grippers, welding torches, or cutting tools
- Tool offset calibration
- I/O configuration for tool activation
- Testing tool operation and repeatability
4. Integration with Factory Automation Systems
Robots rarely operate independently. They must communicate with other automation equipment. These integrations ensure that robots operate in coordination with the entire production line. Integration work may include:
- PLC communication setup
- Sensor and vision system integration
- Conveyor synchronization
- HMI interface configuration
- Safety system integration
5. Robot Path Optimization
Once the robot program is created, engineers refine it to improve performance. Optimisation tasks include:
- Cycle time reduction
- Motion smoothing
- Collision avoidance
- Path accuracy improvements
6. Testing and Production Validation
Before a robotic system enters full production, thorough testing is performed. This typically includes:
- Dry cycle testing
- Full production cycle testing
- Quality verification
- Error handling validation
- Safety system checks
7. On-Site Operator Training
Training helps operators maintain the system after installation. Typical training includes:
- Robot operation basics
- Program selection and editing
- Troubleshooting procedures
- Safety procedures
Robotic Programming for Industrial Robot
Robotic programming refers to the process of creating software code to control and program robots to perform specific tasks. Therefore, there are various types of robots, and each requires a different type of programming depending on its functionality.
The significance of the kinematic model in robot programming
A kinematic model explains how a robot moves by focusing on its motion and shape while ignoring forces. In simple terms, it shows the positions the robot’s joints need to be in for its tool to reach a specific point and angle in space.
A robot integrator carries out a structured set of steps when programming an industrial robot. In simple terms, it usually looks like this:
- Process analysis
Understand the application (welding, palletising, painting, handling, etc.), cycle time, payloads, accuracy, and safety requirements. - Cell design & simulation
Define robot reach, tooling, layout, fixtures, sensors, and run offline simulations where required to validate feasibility and cycle time. - Robot & tooling setup
Install the robot, end-of-arm tooling (EOAT), safety devices, and connect field I/O, vision systems, conveyors, or other machinery. - Base & tool calibration
Teach robot bases, user frames, and tool center points (TCPs) to ensure precise positioning. - Robot programming
Teach points (manually or offline), define paths, speeds, and motion types. Program logic, routines, error handling, and integrate sensors and vision. - PLC & system integration
Link the robot with PLCs, HMIs, and other equipment for sequencing, interlocks, and production control. - Testing & optimisation
Debug the program, improve cycle time, enhance path smoothness, and ensure repeatability. - Safety validation
Verify compliance with standards (e.g. UKCA/CE), test safety functions, and validate risk assessments. - Commissioning & acceptance
Run full production trials and support Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT). - Training & handover
Train operators and maintenance teams, and provide necessary documentation and backups.
Programming Robots for Manufacturing Automation
Robot Programming Training
While programming services are essential during installation and integration, robot training is equally important for long-term operation and maintenance.
Robot training programs help engineers, technicians, and operators develop the knowledge required to program, operate, and troubleshoot robotic systems.
Training courses typically cover:
- Robot safety procedures
- Basic robot operation
- Programming fundamentals
- Motion control and path planning
- Tool configuration
- Fault diagnosis and troubleshooting
How to Avoid Programming Mistakes
- Use offline programming and simulation when possible.
- Keep your program well-structured and documented.
- Back up your programs regularly to avoid data loss.
- Implement safety limits and collision detection to identify issues early.
- Train operators on robot handling and basic troubleshooting skills.
Identifying and fixing programming errors boosts robot reliability, minimizes downtime, and supports safe and efficient manufacturing automation.
How to Identify Programming Errors in Robots
- Check Robot Alarms and Fault Codes
Look at the teach pendant or HMI for error codes and warnings. Be familiar with common codes such as joint limits, TCP errors, or safety violations. - Review Program Logic
Go through the robot program step-by-step. Confirm conditional statements, loops, and action sequences are correct. - Inspect Motion Paths
Ensure positions, orientations, and paths are correct. Check that speed, acceleration, and joint limits are safe. - Confirm End-of-Arm Tooling
Verify tool dimensions, weight, and I/O commands. Test grippers, welding torches, or other tools to ensure they work properly. - Check I/O and Communication
Test signals with PLCs, sensors, and conveyors. Make sure communication protocols are correct. - Simulate Production Cycles
Run tests at low speed to catch collisions or errors. Confirm the full sequence operates correctly. - Review Program Variables
Check that setpoints, offsets, loop counters, and variables are accurate. Use robot diagnostics and logging. - Examine event logs for issues
Look for recurring or intermittent problems. Work with operators and maintenance staff to gather feedback on any unexpected behaviors. - Make Incremental Changes
Implement small fixes, test them, and document changes to avoid introducing new errors.
Methods of Programming Robots
Teach Pendant Programming
- Manually guide the robot through positions and record movements.
- Common for welding, assembly, and pick-and-place tasks.
Offline Programming (OLP)
- Program robots in simulation software before deploying to the real robot.
- Reduces downtime, detects collisions, and optimizes paths.
Lead-Through Programming
- Operator physically moves the robot through desired motions.
- Produces smooth, natural paths; used in painting, coating, and surface finishing.
According to the British Automation Association (BARA), over 90% of robots are programmed using a teach pendant. The operator moves the robotic arm in jogging mode to select waypoints for the trajectory and then saves the position as either point-to-point or linear moves. Once the trajectory is built, the user can run the program to confirm correct operation.
Our Working Process for FANUC, ABB AND KUKA AUTOMATION
Consultation
Free Consultation to ensure we understand what the company needs are.
Proposal
We will prepare a proposal based on your requirements and our understanding.
Testing
We test all equipment before shipping it. In this way, we ensure everything is working properly.
Installation
Phoenix schedule the installation based on the working process of our customer.
Robotic Simulation and Robotic Programming Software
Robot simulation software enables programming without the actual robot. Major manufacturers offer simulations to validate cell designs and confirm reach and cycle times. Additionally, CAD-CAM software generates robot programs without hand teaching and allows importing CAD files, such as data for workpieces and tooling.
Phoenix Robot Programming
Phoenix collaborates with simulation software for all robot manufacturers and conducts testing and cycle time analysis for robot cell solutions. We also have experience with leading CAD-CAM programming software for robots like Robotmaster, KUKA, and ABB. Contact us to request our Robotic Packages.
Robot Programming for Manufacturers
Phoenix provides solutions for robotic applications, including Cutting, Painting, Welding, and Palletising. We utilize both new and refurbished robots like FANUC and ABB. Turnkey solutions are available for installations where customers manage some of the work. Phoenix offers robot programming and integration for existing or new systems. Contact Us
