Smart E/E Design Framework for Industrial Robotics Manufacturer
Overview
The client required a configurable electrical and electronic (E/E) design system for industrial linear robots that could address diverse customer requirements with master–slave multi-axis control, integrated safety protocols, and scalable peripheral options, while ensuring compliance with international safety standards and minimizing engineering effort
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Challenges
Required modular configuration for various robot options based on customer-specific needs
Integration of master-slave control units for synchronized robotic operations
Need for safety-compliant design aligned with industry standards
Solution
- Developed a configurable E/E design with option libraries (axes, payload, conveyors, networks) auto-generating I/O maps, motion objects, HMI pages, and BOMs
- Implemented master–slave gantry control with electronic gearing, anti-racking, and absolute encoders
- Enabled deterministic motion via EtherCAT/PROFINET with jerk-limited profiles, blended moves, and safe homing
- Integrated Pilz PNOZ hardware (E-Stops, gates, light curtains) with LASAL Safety Designer for safe logic (STO, SS1/SS2, SLS, SOS, mode select, zone control)
- Delivered modular peripheral kits (EOAT, pneumatics with diagnostics, multi-sensors, carriers, scanners, vision)
- Designed HMI with guided setup/homing wizards, recipe/alarm/maintenance views
- Factory integration with OPC UA/MQTT, OEE hooks & condition monitoring
Outcomes
- Reduced new robot design cycle times by 30% through modular, configurable E/E architecture, accelerating time-to-market
- Achieved IEC 61508 SIL3 safety compliance while lowering engineering effort with reusable design modules, enabling scalable deployment across multiple industries
