Mastering External Axes: The Hidden Challenge in Robot Programming – And How to Solve It

The Challenge No One Talks About 

In industrial automation, external axes—like linear rails, turntables, and positioners—are a double-edged sword. They expand a robot’s reach, making it capable of handling larger, more complex workpieces. Yet, they introduce a major programming nightmare: synchronizing movements between the robot and external axes.
For years, manufacturers have struggled with tedious manual programming, leading to delays, inefficiencies, and costly errors. What if this process could be greatly simplified? 

Why External Axes Are So Difficult to Program 

External axes offer robots enhanced flexibility, but that comes at a cost. In industries like welding, painting, and media blasting, external axes extend the robot’s workspace and improve precision. However, they introduce four major pain points: 

1. Complex Coordination: Typically, operators must manually synchronize the movement of the robot arm with the external axes. This requires precise coordination across multiple points, which is not only time-consuming but prone to error. The slightest misalignment between the robot and external axis can lead to process inefficiencies or, worse, equipment damage.
2. Inconsistent Tool Velocity: Maintaining a consistent tool velocity when external axes are involved is particularly challenging. Each axis may operate at different speeds, and manually programming these velocities requires extensive trial and error, often leading to suboptimal performance.
3. Collision and Singularity Risks: As robots and external axes move in complex, multi-dimensional environments, the risk of singularities (where the robot’s joints lock in specific configurations) and collisions increases. Predicting and avoiding these situations manually demands a deep understanding of robot kinematics, which can be difficult to achieve without extensive experience.
4. Time-Intensive Programming: Traditionally, programming robots to work with external axes using a teach pendant involves jogging the robot to each desired position and testing its interaction with the external axis. This can be an exhausting process that requires repetitive adjustment and reprogramming, particularly for highly complex tasks.
   
   

The Augmentus Solution—Path Optimizer 

What if external axes could be programmed automatically? 

With Augmentus and its Path Optimizer, the cumbersome process of synchronizing external axes is completely streamlined. Here’s how it solves every pain point: 

1. Automatic Multi-Axis Synchronization: The Path Optimizer removes the need for manual synchronization by automatically coordinating the movements of the robot and its external axes. This means that all axes are programmed to move smoothly and in harmony, ensuring that the robot reaches every waypoint precisely, without the need for manual fine-tuning. This not only speeds up programming but also drastically reduces the risk of errors caused by manual input. 
2. Consistent Tool Velocity Across Axes: Using advanced velocity profiling algorithms, Path Optimizer ensures that the tool maintains a consistent speed across both the robot arm and external axes. This is especially crucial for processes like welding, painting, or sanding, where uneven speeds can compromise the quality of the operation. The optimizer automatically adjusts velocities for each axis, resulting in higher process consistency and better-quality outcomes. 
3. Collision Avoidance and Singularity Handling: Path Optimizer integrates intelligent path planning that detects and resolves potential collisions, singularities, and reachability issues. It automatically adjusts the robot’s movements and even adapts the tool’s pose within defined tolerances to avoid these pitfalls. This ensures that the robot operates safely and efficiently, even in complex environments involving multiple axes.
4. User-Friendly Interface and Rapid Programming: Augmentus provides an intuitive interface that significantly simplifies the programming of external axes. Rather than relying on manual jogging and adjustment, operators can easily input the desired parameters, and the system generates an optimized path that accounts for all axes. This drastically reduces programming time and effort, allowing operators with less expertise to achieve expert-level results. 
5. Customizable for Various Applications: The Path Optimizer is highly adaptable, allowing users to customize settings based on their specific needs. Whether limiting wrist motion to prevent cable wear or prioritizing linear rail movement for smoother spraying, Augmentus provides flexibility to tailor robot motion to the unique requirements of each application.

Conclusion: Turning a Pain Point into an Advantage 

External axes have long been a programming nightmare, adding complexity, inefficiency, and risk to industrial automation. But with Augmentus’ Path Optimizer, external axes become an asset, not a headache. By automating synchronization, ensuring smooth motion, and preventing costly errors, Path Optimizer transforms external axis programming from a time-consuming struggle into a seamless, efficient process. 

For industries that rely on multi-axis robotic systems, this isn’t just an improvement, it’s a game-changer.