How are industrial robots controlled?

Fundamentally, industrial robots are similar to standard printers connected to standard computers. The robot arm consists of electric motors that need to be carefully coordinated. Amplifiers control the motors by boosting small control signals to the required electric current levels.

Sensors provide feedback to the amplifiers and controlling computer system regarding motor position, velocity, electric current, and even force applied. This allows for collision detection and safety measures.

Industrial robots also have physical I/O systems and digital fieldbus connections to interface with external machines. This enables motion coordination, collision prevention, and remote control. Physical I/O controls end-effectors such as grippers, welders, and paint guns. Specialized dual-channel physical I/O is used for safety functions like fence gates, area scanners, and emergency stop devices.

The robot controller typically has a simplified programming language, making it easy for users to operate the robot with simple motion instructions. Complex math related to multidimensional motion control is handled seamlessly in the background.

While some applications can be complicated, simple pick-and-place tasks can be achieved with just a few lines of code. Positions can be taught manually by jogging the robot to the desired position and recording it, or more complex programs can be designed using CAD software and uploaded remotely.

Many modern robots are equipped with vision systems that use digital cameras for decision-making. They can check for object presence, verify object quality through pixel-based measurements, locate objects in space, read barcodes, identify text, and more.