What does the implementation of welding robot programming look like from inquiry to commissioning?

After receiving an inquiry, our team analyzes your needs and technical requirements. We then prepare a detailed solution proposal that includes the scope of work, schedule, and cost estimate. After the offer is accepted, we begin programming, simulation, and configuration work. In the next stage we carry out on-site implementation, testing, and staff training. The entire process is transparent and based on regular communication.

What determines the project completion time for welding robot programming?

A typical preparation stage for project commissioning can last from several weeks to several months. It depends on the scale of the undertaking, the number and complexity of machines, as well as the functions and processes handled. A detailed schedule is determined individually for each project.

What information do you need from the client to prepare an offer?

For an efficient and accurate project estimate we need a detailed description of technical requirements, which may include technical drawings (including production line layout), a description of the machine and/or process operation, a list of suggested components, a work schedule, and any control concept.

In which industries and countries has Amister already executed projects?

We have executed projects in many demanding industries, such as automotive, machinery manufacturing, energy, heavy industry, and household appliances, both in Poland and on foreign markets, including Germany, Sweden, Austria, Romania, France, the United Kingdom, and Italy. We have experience working with the standards in force at the largest corporations.

How is coordination and communication handled during welding robot programming?

Communication with the client is based on transparency and regular dialogue. At the start of the project, expectations and preferred communication channels are agreed. During implementation the client receives regular progress reports, and key stages are discussed and approved. A dedicated Team Leader is responsible for ongoing contact with the client.

Do you provide on-site support during commissioning of welding robots?

Yes, the nature of our work requires it. We provide the presence of our engineers on-site during testing and production start-up to ensure a smooth transition to production operation and immediate resolution of any issues.

Do you integrate welding robots with higher-level systems (MES, SCADA, ERP)?

Yes, in most of our installations integrating the machine control system with the client's management system, such as MES or ERP, is a key stage. This process is carried out according to the client's strict assumptions and recommendations.

Do you work with peripherals and controllers from different manufacturers?

We program PLCs from Siemens (families S7-300/400, S7-1200/1500), Allen-Bradley, Beckhoff, Emerson, Omron, Phoenix Contact, Wago. We also work with robots from manufacturers such as KUKA, ABB, Fanuc, Epson, Yaskawa, Kawasaki.

Do you modernize existing welding robot software?

We offer commissioning of new systems from scratch as well as modernization and improvements of existing installations. We can integrate new technologies with existing infrastructure, optimizing the performance of older production lines.

How do you ensure workplace safety during welding robot programming?

Each robotic cell we implement meets rigorous safety standards through the use of functions such as ProfiSafe and technologies like SafeOperation, SafeMovePro, DCS. We ensure compliance with ISO 10218 and other safety requirements.

Why choose Amister for welding robot programming?

We approach each client individually and relate to them in a partnership manner. We offer a professional approach based on openness, advisory services, and full commitment to the tasks entrusted to us. We guarantee technical competence, reliability, and timeliness, as confirmed by a number of satisfied clients.

Programming of Allen-Bradley PLC controllers

Q: Do you provide training for operators?

Yes, in almost every project we carry out we provide training for operators and maintenance staff in the final commissioning phase. The scope, duration, and location of the training are agreed individually with the client.

We provide advanced control systems. We support machine manufacturers and automation system integrators in carrying out demanding projects – from optimizing existing lines to full greenfield implementations. Gain confidence in process continuity and coding standards that make subsequent maintenance easier.

What is included in the Allen-Bradley PLC programming service?

Programming Allen-Bradley PLC controllers We carry out projects based on a full project cycle – from analysis of technological assumptions, through the implementation of algorithms, to commissioning and on-site technical assistance. We adapt the code structure and network architecture in each case to the client’s plant standards and the specifics of the given production process. Our competencies include the following areas:

Analysis of requirements and technical specifications of a machine or production line.

Design of control logic, including defining variables, functions and operational sequences.

Programming PLC controllers using the dedicated RSLogix or Studio 5000 software.

Configuration and programming of input/output modules, motion control, and network communication.

Creating operator interfaces (HMI) for process visualization and interaction with the operator.

Simulation and testing of control logic in a virtual environment or on a test bench.

Commissioning of the system on a machine or production line, including adjustment of parameters and optimization of cycles.

Documenting program code, electrical schematics and user manuals.

Technical support and post-warranty service, including modifications and software updates.

Integration with higher-level systems, such as MES, SCADA or production management systems.

Programming dedicated control algorithms for specific processes, e.g. quality control, dosing, or motion synchronization.

Configuration of industrial networks PROFIBUS, PROFINET, EtherNet/IP and other communication protocols.

Amister – Your trusted partner in programming Allen-Bradley PLC controllers

Our knowledge and experience gained during the implementation of complex projects for leading companies in Europe and around the world allow us to deliver solutions that go beyond standard expectations. We approach every task from a partner’s perspective, taking care of your business goals.

No more delays due to “re-encoding”

We know perfectly well what happens when, halfway through a deployment, the automation engineer changes and the new engineer spends weeks deciphering someone else’s code. This is the most common cause of downtime and missed deadlines. With us this problem does not exist.

Predictability and risk control: We reserve the capacity of a permanent team of experienced engineers for your project with appropriate lead time. We minimize the risk of delays by adhering to the mutually agreed schedule.

Continuity of work: We plan our specialists’ workloads in such a way as to ensure smooth task execution and the meeting of key milestones, even with tight schedules.

Expert support at every stage: You have direct contact with the people who know your installation inside out, from the first line of code through deployment.

Transparent communication and a partnership approach

Clients often have to contact multiple people to obtain information about the progress of a project. With us, every project has a dedicated Team Leader who is your main point of contact.

A single point of contact: You communicate with one person thoroughly familiar with the specifics of your project, which streamlines management and ensures full transparency of activities.

Relationships and openness: Our approach is based on open communication and building partnerships, which allows for effective problem-solving and the joint achievement of goals.

Precise arrangements: We ensure a clear definition of the scope of work and expectations from the very beginning, which eliminates misunderstandings and conflicts at the integrator–client interface.

Competencies confirmed in demanding industries

Many integrators use the services of random subcontractors or people without appropriate experience. At Amister, our full-time specialists are the core of every project and take full responsibility for the system from concept to launch.

Standards of automotive giants: Our team possesses specialist knowledge backed by certifications, including rigorous software development standards for corporations such as Daimler and BMW.

Full responsibility from A to Z: We do not abandon projects halfway. The same engineers who design the system implement it on site, which eliminates communication errors.

Multidisciplinary approach: We implement projects based on a wide spectrum of technologies: from Allen-Bradley controllers, through advanced vision systems, to full robotization.

Are you looking for Allen-Bradley programmers for your next project?

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Technologies and software that we use when programming Allen-Bradley PLCs

The selection of appropriate software and hardware tools is crucial for ensuring the efficiency, scalability, and reliability of control systems. Our team selects solutions best suited to the specifics of each project, ensuring optimal results.

Allen Bradley ControlLogix

Programming advanced Allen-Bradley controllers for comprehensive management of production processes, including handling multiple axes and complex control logic.

RSLogix 5000 / Studio 5000

Software for creating and modifying Allen-Bradley controller programs, enabling the implementation of complex control algorithms, the handling of communication protocols, and diagnostics.

EtherNet/IP

Configuration and programming of an EtherNet/IP industrial network to ensure fast and reliable data exchange between PLCs, HMI panels, drives, and other devices.

Cognex vision systems

Integration and programming of Cognex vision systems for quality control, object identification, and positioning tasks that can be controlled by PLCs.

Does your Allen-Bradley controller need specialist support?

Minimize the risk of failures – choose experience in configuring and diagnosing Rockwell Automation controllers.

In which industries and processes do we carry out programming of Allen-Bradley PLC controllers?

Our experience in PLC programming encompasses a wide spectrum of industrial applications where the precision, repeatability, and reliability of the operation of automation systems are crucial.

Industries:

Automotive

Assembly of subassemblies, quality control, application of adhesives, welding and resistance welding processes.

Electronics

Precise assembly processes, operation of production machines, quality control.

household appliances

Assembly lines, functional testing of products, control of production processes.

Food industry

Automation of the processes of packaging, labeling, dosing, and control of production parameters.

Pharmacy

Automation of production and packaging lines, control of processes requiring high cleanliness.

Logistics and intralogistics

Control of intralogistics transport systems, automated warehouses, sorters.

Production of machines

Automation of special-purpose machine functions, integration with robots, motion control systems.

Metal industry

Operation of CNC machines, control of presses, resistance welding, welding.

Processes:

Pick-and-place

Fast and precise picking up and placing of elements.

Assembly

Automation of screwing, riveting, gluing and other assembly operations.

Dosing

Precise dosing of liquids, powders, or pastes.

Labeling and marking

Automatic application of labels to products.

Quality control

Automatic verification of dimensions, surface characteristics, and assembly completeness.

Testing

Performing functional, pressure, and electrical tests of machines and equipment.

Palletizing and depalletizing

Automated arranging of products on pallets in order to prepare them for transport.

Machine operation

Automation of machine loading and unloading, control of operating cycles.

How do we work with our clients?

Our Allen-Bradley PLC programming services are flexible and tailored to the diverse needs of our clients. We offer two main models of cooperation that allow for the optimal use of our experience and resources.

Model 1: Software subcontracting

If you are a machine manufacturer or an automation systems integrator, you can take advantage of our support as a software subcontractor. We deliver high-quality PLC code for your machines, allowing you to focus on the mechanical and electrical construction. This cooperation model works perfectly when you need specialist knowledge in Allen-Bradley programming and want to retain full control over the rest of the project.

Model 2: General contracting “turnkey”

For end users of production lines or companies planning comprehensive investments in automation, we offer turnkey project implementation. We take responsibility for the entire process – from needs analysis and concept, through PLC controller design and programming, to commissioning, testing, and personnel training. This model of cooperation guarantees a comprehensive solution tailored to your business and production requirements.

Clients and locations where we carried out projects

Star Assembly SRL

Sebeș, Romania

Audi

Gyor, Hungary

BMW

Steyr, Austria

Stellantis

Mirafiori, Italy

BMW

Dingolfing, Germany

Daimler

Brühl, Germany

NIDEC

Niepołomice, Poland

Skoda

Mlada Boleslav, Czech Republic

Liebherr

Bischofshofen, Austria

Festo

Budapest, Hungary

Daimler

Untertürkheim, Germany

Dana

Amal, Sweden

Examples of projects with programming of Allen-Bradley PLC controllers

Stellantis – engine production plant in Tychy, Poland

Project objective: Implementation of an advanced-generation assembly line for internal combustion engines, modernization of existing stations and integration of new, automated production processes.

PLC Automation: The project included the integration and programming of Siemens S7-1500 and Allen-Bradley ControlLogix controllers for new and modified assembly stations.

Scope of work: Comprehensive modifications were carried out on automatic and manual stations, and two new automatic stations were commissioned: a valve assembly station in the cylinder head controlled by Siemens controllers and a camshaft assembly station utilizing Allen-Bradley controllers. A Dobotech oil feeding system and a Bosch screwdriving system were implemented.

Technologies: PLC controllers: Siemens S7-1500, Allen-Bradley ControlLogix; Process equipment: Dobotech – oil supply system, Bosch – screwdriving system.

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FAQ – Frequently Asked Questions

How does a project involving programming Allen-Bradley PLCs proceed from inquiry to commissioning?

Upon receiving an inquiry, our team conducts a preliminary analysis. Next, we have a discussion with you to clarify requirements and prepare a detailed estimate. After the offer is accepted, we begin work on the project, stage by stage, providing regular progress reporting and communication with your team. On-site system deployment is always preceded by intensive testing.

How long does the implementation of Allen-Bradley PLC software take and what does the time depend on?

The project implementation time depends on its scale and complexity, that is, the number of controllers, machines, the complexity of the control logic, and the required integrations. A typical preparation and commissioning phase can take from a few weeks to a few months.

What do the costs of programming Allen-Bradley PLCs depend on, and how is the pricing determined?

The cost of the project depends on the complexity of the system, the number of devices to be programmed, the type of controllers, the need to integrate with higher-level systems, and the time required for testing and documentation. For a precise estimate, we need a detailed description of the technical requirements, drawings, the control concept, and a work schedule.

In which technological processes do you have the most experience with Allen-Bradley PLCs?

We have extensive experience in the automation of production processes such as assembly, pick-and-place, dispensing, quality control, testing of machines and equipment, operation of production machines, and palletizing.

What does coordination and communication look like during the project?

Each project is coordinated by a dedicated Team Leader who is your main point of contact. We provide regular progress reports, and we discuss and jointly approve key stages, ensuring transparency and a rapid response to the Client’s needs.

Do you integrate Allen-Bradley PLCs with higher-level systems (MES, SCADA, ERP)?

Yes, integration with higher-level systems such as MES or ERP is often a key element of our projects. This process proceeds according to the Client’s strict assumptions and recommendations, ensuring smooth data exchange.

Do you modernize older installations based on Allen-Bradley PLC software?

Yes, we offer not only the commissioning of new systems from scratch, but also the modernization and improvements of existing installations. We migrate older controllers to newer units and optimize the existing program code.

Do you provide training for operators and engineers?

Yes, in almost every project we undertake we conduct training for operators and maintenance staff. The scope, time and place of the training are always determined individually with the client.

Contact us – we’ll respond within 24 hours!

Do you have questions regarding programming of Allen-Bradley PLC controllers? Fill out the contact form, and our team will contact you within 24 hours – by phone or email.

During a conversation or correspondence, we will jointly determine the scope of the work and services you are interested in. We will then conduct an internal analysis of your inquiry to prepare the best possible solution.

We will get back to you within a maximum of 5 business days with information about the next steps.

Take a step towards modern automation – fill out the form now!

Jakub Urbańczyk

Vice President of the Management Board