ROBOGUIDE Offline Simulation: Cell Build and Program Creation

Objective. Students build a virtual robot cell in FANUC ROBOGUIDE, create a pick-and-place program with at least eight motion instructions, simulate it to check for collisions, and export the program for upload to a physical controller.

FANUC ROBOGUIDE is offline simulation software that lets you build a virtual robot cell, write and test programs, and check for collisions — all before touching the physical system. Because you can catch path errors and timing problems on screen, you reduce the risk of machine damage and injury during commissioning. Offline programming is a core skill tested in the FANUC CERT technician credentials (FCR-T1 and FCR-T2).

Why Offline Simulation Matters

When a new robot cell is installed or a program is revised, running untested code at full speed on a live robot is dangerous and can damage tooling, fixtures, or the robot itself. ROBOGUIDE lets you:

Visualize the robot's reach and verify that every target point is reachable without exceeding joint limits.
Detect collisions between the robot arm, end-of-arm tool, fixtures, and worktable before any real movement occurs.
Measure cycle time from the simulation to support production planning.
Create and refine the LS-format program file that will be loaded directly onto the physical controller.

Building the Virtual Cell

Launch ROBOGUIDE and create a new cell using the Workcell Wizard. The two most important choices at this stage are the robot model and controller software version. These must match the physical controller in the lab exactly — a program created for one controller version may not load correctly on a different version. Select the HandlingTool application software to match the lab cell.

Once the robot is placed, add a worktable and at least two fixture objects from the ROBOGUIDE library. Position each object by entering exact X, Y, Z coordinates and orientation angles rather than dragging freehand. This replicates the physical lab layout and ensures that the virtual program will transfer to the real cell with minimal touch-up. Save the cell file after each major step — cell builds can be lost if the software closes unexpectedly.

Writing the Pick-and-Place Program

A HandlingTool pick-and-place program moves the robot to a part, grips it, carries it to a destination, and releases it. A well-structured program contains at least eight motion instructions plus I/O commands and a loop.

Typical program sequence:

1. `J P[1] 100% FINE` — JOINT motion to a home position.

2. `J P[2] 60% CNT50` — JOINT motion to an approach point above the pick location.

3. `L P[3] 500mm/sec FINE` — LINEAR motion down to the pick point.

4. `WAIT DI[1]=ON` — Wait for a sensor signal confirming a part is present.

5. `DO[1]=ON` — Turn on the gripper (digital output).

6. `L P[2] 500mm/sec FINE` — LINEAR motion back up to the approach point.

7. `L P[4] 300mm/sec FINE` — LINEAR motion to the place point.

8. `DO[1]=OFF` — Release the gripper.

9. `L P[5] 300mm/sec FINE` — LINEAR motion to a retract point.

10. Loop back using a `FOR / ENDFOR` register structure to repeat for multiple parts.

Motion types: JOINT (J) moves each axis simultaneously to reach the target — fast and efficient for large moves where the path does not matter. LINEAR (L) moves the tool center point (TCP) in a straight line — required near the pick and place points where a predictable path avoids fixtures. `FINE` termination brings the robot to a full stop at the target; `CNT` (continuous) blends motion for smoother transitions.

Frames: Set the correct tool frame for your end-of-arm tool and a user frame aligned to the worktable. Accurate frames are what make an offline-created program transfer cleanly to the real controller.

Running the Simulation and Resolving Collisions

After recording all teach points, run the simulation using the ROBOGUIDE Run Panel. Watch for red collision indicators. If a collision is detected:

1. Note which link or tool is involved and at which program line it occurs.

2. Adjust the approach point or path to clear the obstacle — increase the approach height or shift the point laterally.

3. Re-run until no collision warnings remain.

4. Log all collisions found and resolved in your lab log. This record is required for sign-off.

Exporting and Uploading the Program

ROBOGUIDE saves programs in LS format (`.LS` files), which is the standard FANUC ASCII program format readable by the controller. To transfer:

1. In ROBOGUIDE, use File → Save TP Program as LS to export the file.

2. Copy the `.LS` file to a USB drive or transfer via Ethernet FTP to the controller.

3. On the teach pendant, load the file using the FILE menu.

4. Before running, set speed override to 10% and confirm all personnel are outside the safety fence.

5. Perform a dry-run: step through the program line by line first, then run continuously at 10% override, and verify that the physical path matches the simulation within visible tolerance.

Safety Requirements

Even during a slow dry-run, the robot can move unexpectedly. Apply these rules without exception:

ANSI/RIA R15.06 / ISO 10218: All personnel must be outside the safeguarded space before any automatic motion begins.
OSHA 29 CFR 1910.147 (Lockout/Tagout): When adjusting fixtures or tooling inside the cell, de-energize and lock out the robot controller before entry.
OSHA 1910.212 Machine Guarding: Safety fencing interlocks must be functional and must not be bypassed.
NFPA 79: Electrical connections to the controller must be inspected before power-up.
The teach pendant deadman switch (enabling device) must be held in the partially pressed position during manual operation; releasing or fully squeezing it stops motion.
Never increase speed override from 10% until the path has been fully verified step-by-step.

Key terms10

ROBOGUIDEFANUC's offline simulation software used to build virtual robot cells, create and test programs, detect collisions, and generate LS-format files for upload to a physical FANUC controller.

LS formatFANUC's ASCII-based program file format (extension .LS) that can be created or edited offline and loaded directly onto a FANUC controller.

Tool frameA coordinate frame defined at the robot's tool center point (TCP); accurate tool frame calibration ensures that LINEAR motion paths are correct when a program is transferred from simulation to the real robot.

User frameA coordinate frame aligned to a workpiece or fixture surface; it allows teach points to be recorded relative to that surface so the program remains valid if the fixture is repositioned.

JOINT motion (J)A robot motion type in which all axes move simultaneously to reach the target position; the TCP path is not straight and is used for large, free-space moves where path shape is not critical.

LINEAR motion (L)A robot motion type in which the TCP travels in a straight line between two points; required near pick and place locations to maintain a predictable, fixture-safe path.

FINE terminationA motion termination type that brings the robot to a complete stop at the programmed point before executing the next instruction; used at pick and place points where precision is required.

CNT (Continuous) terminationA motion termination type that blends the robot's path through a point without fully stopping, reducing cycle time for transit moves where exact positioning at the intermediate point is not needed.

Speed overrideA controller setting (expressed as a percentage of programmed speed) that scales all robot motion; set to 10% during initial dry-runs to allow safe verification of a new or transferred program.

Enabling device (deadman switch)A three-position switch on the teach pendant that allows robot motion only when held in the middle position; releasing or fully squeezing it immediately stops all motion as a safety measure.

In class: ROBOGUIDE cell setup exercise: students launch ROBOGUIDE, select the correct robot model and controller version matching the lab cell, add a worktable and two fixture objects from the library, and position them using coordinate entry to replicate the physical lab layout — saving the cell file at each milestone. · Offline program creation: students write a HandlingTool pick-and-place program with JOINT motion to an approach point, LINEAR motion to a pick point, WAIT I[1]=ON, a grip command (DO[1]=ON), LINEAR motion to a place point, and a loop register with a FOR/ENDFOR structure; they run the simulation and resolve any collision warnings. · Program export and upload: students export the LS-format program file from ROBOGUIDE, transfer it to the physical controller via USB or Ethernet, load it, and perform a dry-run at 10% speed override with all personnel outside the fence, verifying path against the simulation.
Materials: PC workstations with FANUC ROBOGUIDE installed (school-licensed), USB drives, FANUC controller with Ethernet or USB port, FANUC HandlingTool programming manual, ROBOGUIDE user guide, lab log
Check: ROBOGUIDE cell file reviewed by instructor: correct robot model, no unsaved collisions, program has required eight motion instructions plus I/O and loop logic. Physical dry-run: program completes without fault alarms and path matches simulation within visible tolerance. Lab log entry with collision notes required. Pass = all items complete.

Practice check8

Answer each question, then check it. Nothing is recorded; this is your own practice.