Offline Programming (OLP)
Robot programs are prepared on the cell's digital twin without stopping production. Weld paths are derived from CAD; collision and reach are validated virtually.
Digital Twin & Simulation
The technology's role in the cell
Teaching a program at the pendant means taking the robot out of production. Offline programming moves that work to a desk: the welding program is built on the 3D model of the cell while the robot keeps producing. One part is being welded while the next one is being programmed; idle robot time stops being programming time.
The program runs virtually first. Torch approach angles, reach limits and collisions are seen on screen instead of on the shop floor, and weldability is tested before the investment decision. Similar parts are reprogrammed with copy, mirror and macro functions; no variant is taught from scratch.
The payoff is largest in high-mix, low-volume production. In a shop welding different parts every month, on-line programming would consume most of the robot's life and the investment would never pay back.
At Robentex offline programming is not a separate software line item but part of cell engineering: fixture design, positioner synchronization and welding parameters are resolved together on the same model.
Capabilities
- STEP / IGES CAD import
- Brand-agnostic robot code generation
- Reach and collision analysis
- Cycle time estimation
- Variant programming via copy, mirror and macros
- Visual planning of multi-pass welding
- Positioner and linear axis simulated in sync with the robot
From CAD Data to the Program on the Cell
The program is built at a desk, validated virtually, and once downloaded to the robot only a short on-cell check remains.
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CAD Model
The 3D model of the part (STEP/IGES) is imported; if none exists it is built from dimensions and drawings.
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Cell Digital Twin
Robot, positioner, linear axis, fixture and surroundings are placed in the scene at their real dimensions.
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Joint & Path Definition
Weld joints are picked on the model; torch angles, approach and retract moves and the pass plan are defined.
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Simulation & Validation
Reach, collisions and axis limits are checked virtually; the cycle time estimate comes out here.
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Post-Processing
The program is translated into the language of the cell's controller and packaged with the welding parameter set.
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On-Cell Verification
The program is downloaded, fine-tuned against reference points and the first part is welded.
Inputs and Outputs
| CAD input | STEP · IGES · common 3D solid models |
|---|---|
| Cell model | Digital twin with robot, positioner, linear axis, fixture and surroundings |
| Generated output | Brand-agnostic welding program plus the welding parameter set |
| Virtual validation | Reach, collisions, torch angles, axis limits, cycle time estimate |
| Way of working | The program is built at a desk while the robot stays in production |
| Variant handling | Similar parts reprogrammed with copy, mirror and macro functions |
About Offline Programming
No. The program is built on the 3D model of the cell while the robot keeps producing. Only downloading the finished program and validating it on the cell requires a short stop.
Common 3D solid formats, primarily STEP and IGES. If you have no model, one can be built from part dimensions, or we can work from technical drawings.
The program is prepared brand-agnostically and translated into the language of your controller. It can also be added to an existing cell as part of a retrofit.
That is exactly where it pays off most. With few, constantly changing parts, on-line programming makes the robot spend its life being taught. Similar parts are reprogrammed in minutes with copy and mirror functions.
That is the goal. Operator training is built so your welder can run the cell and the offline programming independently; we do not create dependence on an external robot programmer.
Offline programming works from the theoretical model; real deviations are compensated by laser scanning and seam tracking. The two technologies are engineered together.
Technologies That Complete Offline Programming
See this technology on your own part.
We start with a sample welding trial and evaluate the results together.