Robotics & Industrial Automation

Concept and detailed design of robotic work cells including reach and payload studies, end-of-arm tooling (EOAT) selection, fixturing, guarding, and cycle-time optimization. We size the right robot and layout for each application before a single line of code is written.

Native controller programming across FANUC (TP/KAREL), ABB (RAPID), KUKA (KRL), and Yaskawa Motoman (INFORM), including motion paths, I/O handling, background logic, and macro libraries. Programs are structured for maintainability and fast changeover.

Rapid deployment of collaborative robots such as Universal Robots (URScript/Polyscope), FANUC CRX, and Techman for low-guarding, human-adjacent tasks. Includes power-and-force-limiting validation and application templates for fast redeployment.

Arc, MIG/MAG, TIG, spot, and laser welding automation with seam tracking, touch sensing, and weld-parameter management. We integrate power sources (Fronius, Lincoln, Miller) and positioners into coordinated multi-axis motion.

SCARA and delta-robot pick-and-place systems for assembly, sorting, and packaging at high throughput, including conveyor tracking and multi-part picking. Tooling and vision are tuned to sustain rated cycle rates in production.

End-of-line palletizing cells with pattern software (e.g., FANUC PalletTool), vacuum/mechanical grippers, pallet dispensers, and slip-sheet handling. Layer patterns are optimized for load stability and pallet density.

Robotic loading and unloading of CNC machines, presses, injection-molding, and grinding equipment with part buffering, gauging, and door/chuck interlocking. Cells run lights-out with fault recovery and part-quality gating.

Custom and off-the-shelf end-of-arm tooling — vacuum, servo-electric, pneumatic, and adaptive grippers (Schunk, OnRobot, Zimmer) — sized to payload, cycle, and part geometry. Includes tool changers and multi-part gripper design.

Structured PLC development in Siemens TIA Portal (S7-1200/1500) and Rockwell Studio 5000 (ControlLogix/CompactLogix) using ladder, function block, and structured text. Code follows modular, standards-based libraries for reuse and easy support.

Controller programming on Schneider EcoStruxure/Modicon, Mitsubishi GX Works, Omron Sysmac, and Beckhoff TwinCAT for OEM and process applications. We match platform choice to installed base and lifecycle requirements.

Operator interface design on Siemens WinCC/Comfort Panels, Rockwell FactoryTalk View, Ignition Perspective, and Wonderware, applying high-performance HMI (ISA-101) principles. Screens surface the right alarms and KPIs for fast, error-free operation.

Plant-wide SCADA architecture and build using Ignition, WinCC, FactoryTalk, or AVEVA, including tag databases, historians, redundancy, and remote access. We deliver scalable supervisory systems with secure client-server design.

Distributed control system engineering and migration on platforms such as Siemens PCS 7, Emerson DeltaV, ABB 800xA, and Honeywell Experion. Covers control-module libraries, graphics, and phased cutover of legacy systems.

Coordinated and single-axis motion engineering with servo sizing, tuning, electronic camming/gearing, and kinematics on Siemens SINAMICS, Rockwell Kinetix, Beckhoff, and Yaskawa drives. Axes are tuned for accuracy, settling time, and thermal margin.

Variable-frequency drive selection, parameterization, and network integration (PowerFlex, SINAMICS, Altivar, Danfoss) for pumps, fans, conveyors, and process loads. Includes energy-optimized control and drive fault diagnostics.

Design and configuration of PROFINET, PROFIBUS, EtherNet/IP, EtherCAT, Modbus TCP/RTU, and IO-Link segments with managed switching and VLAN/QoS design. We build deterministic, diagnosable control networks that scale.

Selection and installation of vibration, temperature, current, flow, and energy sensors with signal conditioning and wired/wireless acquisition. Sensor data is normalized and tagged for downstream analytics.

OPC UA server/client deployment and information-model design (companion specs, PackML) to expose equipment data securely and interoperably. We standardize namespaces so data means the same thing across the plant.

Edge hardware and software deployment (Siemens IEDGE, Advantech, Moxa, AWS IoT Greengrass, Azure IoT Edge) for local buffering, protocol conversion, and on-prem inference. Compute is placed at the edge to cut latency and cloud cost.

MQTT broker and Sparkplug B implementation with a Unified Namespace to create a single, event-driven source of truth for operational data. Enables report-by-exception data flow between OT and IT systems.

Store-and-forward pipelines from equipment to historians (AVEVA PI, Ignition, Canary) and cloud platforms (AWS, Azure, GCP) for time-series storage and analytics. Includes contextualization, buffering, and data-quality checks.

Segmented OT/IT integration using DMZs, data diodes, and brokered exchange aligned to the Purdue model and IEC 62443. We connect production data to enterprise systems without exposing control networks.

2D and 3D vision guidance for robotic picking, placement, and assembly, including bin picking and random part localization using Cognex, Keyence, or Zivid sensors. Robot paths adapt in real time to part pose and orientation.

High-speed inspection systems that detect scratches, cracks, contamination, and assembly faults using area/line-scan cameras and controlled lighting. Pass/fail logic and reject handling are integrated into the line.

AI-based inspection for variable or hard-to-rule defects using tools such as Cognex ViDi, Keyence, or custom models on edge GPUs. We train, validate, and deploy models with drift monitoring for stable production accuracy.

In-line and at-line dimensional gauging with vision, laser profilometry, and structured light for tolerance verification and SPC. Measurements feed process control and quality records automatically.

Optical character recognition/verification, 1D/2D code reading, and mark validation for date/lot codes and unique part serialization. Enables full genealogy and track-and-trace across the process.

Application-specific selection of lighting geometry, filters, lenses, and camera resolution to maximize contrast and repeatability. We integrate the vision system with PLC/robot I/O and result logging.

Deployment of automated guided vehicles and autonomous mobile robots (MiR, OMRON LD, Fetch, Geek+) for material transport, tugging, and delivery. Includes site mapping, path planning, and safety-scanner configuration.

Multi-robot fleet coordination, traffic management, and mission dispatch with VDA 5050-compliant interfaces to fleet managers. Robots, elevators, and doors are choreographed for collision-free throughput.

Integration of automated storage and retrieval systems, conveyors, sortation, and shuttle systems into a coordinated material-handling solution. We tie mechanical automation to WMS/WCS control logic.

Configuration and tuning of SLAM-based navigation, natural-feature and QR/reflector localization, and dynamic obstacle avoidance. Maps and cost parameters are optimized for reliable operation in changing environments.

Interfacing mobile robots and material-handling equipment with warehouse management/control systems and ERP (SAP, Oracle) for order-driven task creation. Ensures inventory and location data stay synchronized.

Automated piece-picking and goods-to-person stations combining AMRs, vision, and robotic arms for order fulfillment. Cells are engineered for SKU variety, pick rate, and ergonomic operator support.

Implementation and integration of manufacturing execution / operations management systems (Siemens Opcenter, Rockwell FactoryTalk PharmaSuite, AVEVA, Tulip) for work orders, genealogy, and OEE. We connect the shop floor to the ERP layer per ISA-95.

Recipe-driven batch control design following ISA-88 for pharma, food, and chemical processes, including phases, units, and electronic batch records. Delivers repeatable, auditable process execution.

Real-time OEE, downtime-reason capture, and production dashboards that tie automated data collection to actionable shop-floor visibility. Managers see availability, performance, and quality losses as they happen.

Offline programming and reachability/cycle-time simulation of robot cells in RoboDK and vendor tools (RobotStudio, ROBOGUIDE, KUKA.Sim) to validate designs before install. Cuts on-site programming time and de-risks layouts.

Virtual commissioning and dynamic digital twins using Emulate3D, Siemens Tecnomatix/Plant Simulation, and Gazebo to test control code against emulated equipment. Logic is proven virtually to compress startup on site.

Custom robotics application development on ROS/ROS2 for perception, motion planning (MoveIt), and multi-sensor integration on non-standard or research-grade platforms. Bridges advanced capability into industrial workflows.

Software robots that automate repetitive digital tasks — data entry, report generation, and system-to-system transfers — across UiPath, Automation Anywhere, Blue Prism, and Power Automate. We bridge OT data into back-office and MES workflows.

Continuous monitoring of vibration, temperature, and current signatures on motors, pumps, and gearboxes to detect bearing, imbalance, and alignment faults. Alerts are tuned to give lead time before failure.

Machine-learning models for remaining-useful-life estimation and failure prediction trained on historian and sensor data. Models are integrated into CMMS workflows to schedule maintenance before breakdowns occur.

Streaming and batch analytics that flag abnormal process behavior, drift, and quality excursions across multivariate signals. Findings drive root-cause analysis and closed-loop process adjustments.

Sub-metering and analytics for electricity, compressed air, and utilities to identify waste and support ISO 50001 and decarbonization goals. Energy is tied to production units for true intensity metrics.

Integration of monitoring and predictive insights with CMMS/EAM platforms (SAP PM, IBM Maximo, Fiix) to auto-generate work orders and track asset health. Closes the loop from detection to corrective action.

Risk assessments and safety concept design to ISO 12100, ISO 13849 (PL), and IEC 62061 (SIL), covering guarding, light curtains, interlocks, and safe-motion functions. We define and validate the required performance level for each hazard.

Safety-rated control programming on Siemens F-CPU/Safety, Rockwell GuardLogix, and Pilz PNOZmulti with documented safety functions and validation. Includes safe torque off, safe stops, and zone control for robots and cells.

Electrical control panel design and documentation to UL 508A and IEC 60204-1, including schematics, bills of material, thermal and short-circuit calculations, and enclosure layout. Panels are engineered for buildability and serviceability.

Production of intelligent electrical drawings in EPLAN Electric P8 or AutoCAD Electrical with wire numbering, cross-referencing, and as-built maintenance. Documentation supports fast troubleshooting and audits.

Instrument selection, sizing, and loop design with P&ID and loop diagrams following ISA-5.1 for process measurement and control. Covers transmitters, valves, and analyzers with calibration and loop-check plans.

Full integration of robots, PLCs, drives, vision, and safety into a unified system, verified through Factory Acceptance Testing against a functional specification. Issues are resolved in-house before shipment to site.

On-site installation support, I/O checkout, loop tuning, and Site Acceptance Testing to bring systems into stable production. We hand over verified performance against agreed acceptance criteria.

Operator and maintenance training plus turnover packages including manuals, sequence-of-operations, backups, and spare-parts lists. Teams are equipped to run and support the system independently after handover.