Skip to main content

General description and structure

The modular robot system is used to automate production processes.

The system is based on a scalable modular design in which individual functional modules can be flexibly combined. The system architecture enables rapid adaptation to varying production requirements while reducing integration complexity.

System structure​

The system consists of the following main components:

  • Base module (base drive): The base module is the central motion unit of the system and is responsible for the precise generation of rotational or translational motions within the kinematic structure. The base module is secured to the foundation and serves as a mechanical connection to the next module. The base module is equipped with connectors for transmitting power and data from the control unit to the robot system.
  • Actuator modules: Mechanical units (drive modules, link modules, end effectors) that are connected to the base module and other modules through standardized interfaces. Each module functions built-in drive and control electronics.
  • Sensor modules: Extensions for capturing environmental and process data (e.g., force, position, image processing). These modules provide real-time data for adaptive control.
  • Power and communication interfaces: Standardized connectors for power supply and data transmission.
  • Control unit: Central processing unit for controlling all connected modules. It handles the processing of sensor data, motion planning and communication with external systems.
  • Power unit: Advanced power supply unit for XL (BD193) with increased power output. Does not include a computing or data processing unit. A control unit is required.

System structure

Illustration 2: System structure

  1. Connecting terminal
  2. Link module
  3. Drive module
  4. End effector flange
  5. Basic module
  6. Control unit
  7. Enabling unit

Modular connection concept​

The modules are mechanically and electrically connected through standardized interfaces. After connecting a new module and then powering on the system, the module is automatically detected, configured and integrated into the existing system.

  • Mechanical connection: Connecting terminals:
  • Electrical connection: integrated contacts for power and data
  • Software integration: automatic detection, parameterization and initialization

Control principle​

Control is implemented by means of a decentralized architecture with centralized coordination:

  • The control unit calculates motion sequences and assigns setpoints.
  • Module controllers control the actuators independently.
  • Sensor readings are reported continuously.

which enables high control performance and real-time capability.

Programming and operation​

Configuration and programming are performed on a user-friendly software interface:

  • Graphical representation of movement sequences
  • Configuring individual modules
  • Simulation and fault diagnosis

In addition, standardized interfaces can be used for integration into higher-level systems.

Safety functions​

The system functions built-in safety functions in accordance with ISO 10218-1:2025.

The system does not include a safety function for power and force limiting (PFL). Applications that require a PFL function to mitigate risk are not permitted with this system.

Hand-guided control (HGC) and reduced speed manual mode are implemented as a single operating mode.

The system must be used as intended and the permitted operating modes must be observed. Information on the safety functions, operating modes and the resulting requirements for safe operation can be found in the safety manual.

See also

Work areas, maintenance areas and danger zones​

The following section describes the work areas, maintenance areas and danger zones of the system.

It is permitted to enter the work areas while the system is in operation.

The danger zone may only be entered if the system is turned off or if a safety function designed for this purpose has been activated. Only the machine operator is permitted to enter the danger zone during manual operation. No other people are allowed to be in the danger zone during this time.

The maintenance area may be entered only for the purpose of performing maintenance work. Before entering, the system must be turned off and secured against accidental restarting. If the integrator determines that it is appropriate, an exception to this requirement may be made.

Work areas, maintenance areas and danger zones

Illustration 3: Work areas, maintenance areas and danger zones

  1. Danger zone (the range of motion of the robot within the virtual safety zone)
  2. Maintenance area
  3. Work area (operator station)
  4. Control unit