What Is Commissioning? How Industrial Robots Are Prepared for Production.

What Is Commissioning?

Commissioning is the process of verifying, configuring, testing, and preparing installed equipment or systems for their intended operation.

In industrial robotics, commissioning occurs after equipment has been installed and involves confirming that its mechanical, electrical, software, and operational components work together correctly.

For example, a newly installed robotic packaging system may need its sensors calibrated, motion programs tested, safety functions checked, and connections to existing production equipment verified.

Commissioning helps turn installed machinery into an operational production system.

Key Takeaways

• Commissioning verifies that installed equipment and connected systems operate as intended.
• It includes activities such as configuration, calibration, functional testing, troubleshooting, and operator preparation.
• Commissioning is related to acceptance testing but focuses on making and verifying the system's readiness for operation.

How Does Commissioning Work?

Commissioning typically follows installation and proceeds through progressively more complete tests.

Consider a factory introducing a robotic palletizing cell.

Engineers may begin by checking electrical connections, air supplies, and mechanical installation.

They then verify sensors and communication interfaces.

The robot's movements can be tested under controlled conditions before operating with actual products.

The team also verifies the operation of applicable safety functions.

Once individual components work correctly, the complete system is tested together.

Further adjustments may be required to achieve the desired production behavior.

What Happens During Robot Commissioning?

Typical activities include:

• Verifying mechanical and electrical installation.
• Configuring communication between connected equipment.
• Checking sensors, actuators, and control signals.
• Calibrating robot tools and reference positions.
• Testing robot movements and operating sequences.
• Verifying applicable safety functions.
• Training operators and maintenance personnel.

The specific process depends on the equipment and industry.

Commissioning vs. Acceptance Testing

Commissioning focuses on preparing and verifying equipment for operation.

Acceptance testing determines whether specified requirements have been met.

The two processes frequently overlap.

For example, commissioning may identify and correct a sensor problem before the customer performs a final acceptance test.

In some projects, acceptance tests occur at several stages, including before shipment and after installation.

Why Is Commissioning Important?

A robot may perform correctly on its own while failing to work properly when connected to other equipment.

A conveyor might deliver products at the wrong interval, or a sensor might send an unexpected signal.

Commissioning helps identify these integration problems before routine production begins.

Frequently Asked Questions

How long does robot commissioning take?

It depends on system complexity, installation conditions, integration requirements, and the problems discovered during testing.

Is commissioning required for every automation project?

The formality varies, but installed automation systems generally need appropriate verification and startup procedures before routine operation.

The Bottom Line

Commissioning is the bridge between installing automation equipment and using it in production. Thorough testing and preparation help ensure that the complete system operates as intended.