Case Studies

ABB Pick and Place Robot Programming

Posted in Consumer Goods, Manufacturing Automation and Intelligence, PLC Programming


A long-time DMC customer required a pair of ABB robots in one of their machines but lacked in-house expertise. Fortunately, several of DMC's ABB robotics programmers were available and were able to perform the programming offline. Then, when the system was ready, DMC dispatched an ABB expert to the end-customer to commission the system and train the customer's programmers.

IRB910SC Robot


DMC first integrated with the Allen Bradley PLC using Anybus protocol to communicate digital and analog signals for the operation. We then instructed the robots to perform operations with simple Boolean commands. The robots can also be commanded to move to specific positions from the HMI panel, such as a maintenance position and a safe position. The PLC then receives back boolean data as well as integer statuses, alarms, and other data. The basic points, logic, and control programming were near completion before arriving for on-site commissioning.

Upon arriving at the customer facility, DMC downloaded the programming and configurations to the robots, updated the revolution counters and points, and was performing manual dry cycling on the first robot by the start of the second day. 

The cycle time was required to be within four seconds for the full operation. After about two days of refinement, DMC and the customer’s in-house programmer were able to get the cycle time to within four seconds, allowing for a small margin for error.

DMC also configured ABB World Zones to ensure that the robot was clear for the system to move. We utilized safety resetting, error reporting to the PLC, and performed programming so that the robot could perform basic operations without requiring a teach pendant.

Finally, DMC spent the last few days on-site training the customer's programmers on the ABB platforms. This including minor touchups to points, I/O configurations, and how to set up systems from scratch. The customer also learned from DMC how to use RobotStudio to perform updates to the robot programming offline. Training was provided to update revolution counters and recalibrate the robot in the event of a catastrophic collision or other loss of calibration.

Learn more about DMC's Robotic Automation and Integration services.

Customer Benefits

  • Expert level programming on a system new to them
  • Improved product quality
  • Training for their engineers
  • Reduced programming and debugging time on the robot
  • Increased end-user convenience, alarm information, and error recovery


  • RobotStudio 6.04
  • IRB 910SC Scara Robots
  • Anybus
  • ABB World Zones
  • ABB calibration tools and methodologies
  • RAPID programming