How does the commissioning of a turnkey robot system work?

The commissioning of a turnkey robot system comprises five clearly defined phases, ranging from initial planning to final acceptance. The following article explains what these steps look like in concrete terms and which aspects are particularly relevant.

What is a turnkey robot system?

A turnkey robot system is a completely pre-configured automation system in which all components, including the robot, controller and parts, are already perfectly matched to each other. The operator can use the system productively immediately after commissioning without having to carry out any additional configuration or programming work.

The 5 steps to successful commissioning of your turnkey robot system

The following steps are required to successfully commission a turnkey robot system:

1. installing the components and hardware

The installation of the robots and the associated hardware components forms the basis for operation. The robot cells, conveyor belts and components are assembled and aligned accordingly. Assembly is modular, flexible and compact to enable efficient use of the production environment.

2. Connecting and setting up the control system

The robot system controller is connected and configured. The technology includes intuitive interfaces and a user-friendly user interface. This simple operation allows users to operate the system quickly and efficiently.

3. programming and parameterization

The robot system is usually programmed by the manufacturer. However, fine adjustments and adaptations to the process parameters must be made on site during commissioning. Simulation and offline programming enable precise settings and a virtual check of the processes before actual operation.

4. test operation and optimization

Test operation takes place before regular operation. All automation steps are checked to ensure a high level of quality assurance. In particular, interfaces and visualizations are also tested in order to minimize possible downtimes right from the start.

5. training and acceptance

Finally, the operators are trained on site to ensure that the product can be operated effectively and safely. Only after successful completion of the training and a final check of the robot installation does the final acceptance take place.

Advantages of turnkey robot systems

The use of turnkey robot systems offers these four advantages, among others:

• Fast commissioning: the robot systems are already preconfigured and allow immediate use after a short installation time.
• Maximum efficiency: Thanks to optimum programming and coordination of the components, these systems achieve maximum efficiency and reduce downtimes.
• Flexibility: Systems have a modular design, offer a high degree of flexibility and can be adapted to many applications.
• Simple operation: The intuitive user interface ensures easy handling and reduces the need for highly specialized personnel.
• Compensating for a shortage of skilled workers: Automation solutions are designed to be as simple as possible to compensate for the shortage of skilled workers.
  
  

Areas of use and applications of turnkey robot systems

Turnkey robotic systems are used in various industries and application areas, including

• Automotive industry: robots perform activities such as welding, assembly and quality assurance.
• Production and manufacturing: Systems automate production lines, take over palletizing or order picking.
• Collaborative applications (cobots): Cobots work closely with humans and enable safe human-robot cooperation.
  
  

Quality standards and safety of turnkey automation systems

Modern robot systems meet the highest safety standards. This includes comprehensive safety checks and compliance with all relevant safety standards. Conveyor technology, sensors and the entire system control are designed to ensure maximum safety for operators and operation.

Challenges during commissioning

Despite all the advantages, there are some challenges when commissioning a turnkey robot system:

• Setting process parameters precisely: Precise settings are the only way to ensure product quality and efficiency in the long term.
• Integration into existing production lines: Systems often have to be integrated into existing structures, which requires careful planning and coordination.
  
  

Automation and robotics - looking to the future

The development of robotics and automation is progressing rapidly. Trends such as collaborative robots (cobots), virtual simulation and highly configurable robot cells are enabling ever more precise and efficient production. Robotic systems are becoming increasingly intelligent and user-friendly, enabling companies to remain competitive in the long term.

Conclusion

The commissioning of a turnkey robot system takes place in five clearly defined phases, which include installation, control, programming, test operation and final acceptance. The entire process aims to ensure efficiency, quality and safety right from the start. Modern robotic systems offer maximum efficiency, flexibility and ease of operation and are therefore an essential building block for the future-proof automation of industry.

FAQ on robot commissioning