Robot controller

01

Match robot range, extra axes and motion performance

ABB describes its OmniCore C30 as an ultra-slim controller for collaborative, Delta, SCARA and articulated robots up to the IRB 1600, giving path accuracies down to 0.6 mm even with multiple robots at speeds up to 1,600 mm/s. It integrates major communication protocols, offers regeneration that returns power to the grid for up to 20% energy savings compared with its predecessor, and allows the teach pendant to be unplugged during operation and shared among robots. [1]

KUKA's KR C5 micro is a compact controller for its small robots with Ethernet and digital I/O interfaces, support for current fieldbus standards and hardware for vision and other compute-heavy applications; it can drive one to two extra axes through an external axis drive box (two-channel, up to 12 A, software-activated) and takes an optional 24 V power supply. [2]

Editorial note: path accuracy figures depend on robot model, payload, speed and calibration; ask the supplier for accuracy on your robot and path, and for the number of extra axes (tracks, positioners) the controller can coordinate.

The same sheet lists job memory of 200,000 steps and 10,000 instructions, a 1,500-step ladder, two PCI Express expansion slots, 8 general digital inputs and 8 outputs plus 7 specialised inputs and 1 output, network I/O options including EtherNet/IP, EtherCAT, PROFINET, PROFIBUS, CC-Link, DeviceNet, Modbus/TCP and POWERLINK, and absolute encoders; Yaskawa says its acceleration control can improve cycle time by up to 10%. [3]

Give the supplier the robot models and payloads, number of robots per controller, extra axes (tracks, turntables, positioners), required safety functions and performance level, fieldbuses and protocols, I/O count, vision or force-control needs, cybersecurity requirements, supply voltage, installation (cabinet, rack, desktop), ambient temperature and protection rating, teach pendant needs and quantities.

02

Check safety, cybersecurity, size and installation

ABB states that OmniCore includes up to 100 different safety configurations for different use cases, that the C30 is rated IP20, and that it can be fitted in standard 19-inch cabinets with a rack kit or mounted vertically with rear hanging brackets. KUKA states the KR C5 micro measures 449 × 300 × 89 mm and is IEC 62443 compliant for industrial cybersecurity. [1] [2]

Editorial calculation: a 449 mm wide controller fits the nominal 19-inch (482.6 mm) rack width with about 33 mm to spare for mounting ears; at 89 mm high it occupies about 2U (2 × 44.45 mm) if rack-mounted. Its volume is about 12 litres (449 × 300 × 89 mm). [2]

Editorial note: an IP20 controller must sit in a clean cabinet or room; for wash-down or dusty areas ask for higher-rated versions or enclosures, and confirm the safety performance level certified for each safety function.

Yaskawa's YRC1000micro data sheet gives a fuller installation picture: 425 × 125 × 280 mm, about 10.5 kg, direct cooling, IP20, operation at 0–40 °C and storage at −10 to 60 °C, up to 90% humidity non-condensing, and primary power of 200–230 V AC single-phase or 200–220 V AC three-phase (+10%/−15%, 50/60 Hz). It can mount horizontally, vertically or in a 19-inch rack. Its safety circuits are rated Category 3 PLe with safety-rated emergency stop and gate inputs, its optional functional safety unit Category 3 PLd SIL2 with 32 position-monitoring zones, speed limiting and tool monitoring, and it states compliance with ANSI/RIA R15.06-2012 and CSA Z434-03. [3]

03

Compare compact controllers by size, mass and supply

Compact controllers for small and collaborative robots differ in volume, mass and supply, which decides whether they fit under a table, in a cabinet or on a mobile platform. FANUC Europe describes its R-30iB Mini Plus as the controller for its CRX collaborative series, weighing 19 kg and measuring 410 × 277 × 370 mm, light enough to integrate on mobile platforms. It is a single-phase controller for 200–240 V AC that needs no three-phase supply, and FANUC states that with its initial setup guide the robot can be installed within 30 minutes. FANUC adds that the R-30iB Plus family runs FANUC's own software rather than a Windows-based PC, and is ready for vision, force and interference-check functions as standard. [4]

Editorial calculation: the FANUC box is about 42 litres (410 × 277 × 370 mm), against about 15 litres for Yaskawa's YRC1000micro (425 × 125 × 280 mm) and about 12 litres for KUKA's KR C5 micro (449 × 300 × 89 mm); the FANUC unit is the tallest at 370 mm, so check enclosure depth and height as well as width before choosing a mounting location. [4] [3] [2]

04

Compare what suppliers offer

Suppliers linked to this page list robot controllers; each card links to the page reviewed.

Listings include EtherCAT robot controllers, robotic controllers on industrial computers, robot controllers sold with robot arms and AMR (mobile robot) controllers.

05

Trace the controller components

This is a functional reference built from the sources cited; it is not one maker's design.

06

Fill the specification fields with values for your cell

A robot controller quotation needs values for your cell. The table explains each field, gives published values where a reviewed source states them, and says what to obtain from the supplier.

07

Send the robot, axis and cell data together

Paste it into your enquiry below or into an email to a maker, then replace every bracket.

Robots: [models; payloads; number]
Axes: [extra axes; type]
Safety: [functions; performance level]
Connectivity: [fieldbus; I/O; cybersecurity]
Installation: [cabinet; rack; IP; ambient]
Supply: [pendant; software; quantity]

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