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Case Study

Painting Robot Retrofit Application

There were four ABB painting robots that needed to be refurbished with a new robot controller. The application required satellites to be identified by line and painted according to a saved painting recipe. The RapidPaint UI provided a way for teaching new painting profiles and associate them with specific ID tags.



Company Name: Global Skyware

Date: December, 2018




Value Proposition


Customer was advised to purchase four new robots. Upon inspection, the robot body and internals (example: motor, gear reducer, and wiring) were found to be in great condition.

RSI’s Robot Retrofit package has allowed the customer to quickly get back into production at fraction of the cost that would been devoted towards new robot, certification,  installation, robot software training and programming.


Drive and motion controller cards inside the electrical cabinet were broken. The customer could not find replacement parts and no upgrade package was available by the robot manufacturer.

In this instance, RSI provided the customer with appropriate electrical hardware and wiring diagrams to rebuild a new controls cabinet. The customer was able to secure two cabinets for four robots in an effort to reduce the footprint and cost from repetitive hardware inside the enclosure. The customer has engineers on staff so the labor costs were also minimized.

Note: RSI can provide a fully assembled electrical cabinet if a customer does not have the electrical resources.


Using latest software tools and programming practices, RSI was able to deploy a software solution that not only adds precision to the painting process but also provides diagnostic information to the operator and throughput data to management.

The customer purchased the robot more than ten years ago. Many features that are taken for granted today did not exist back then.

RSI provided a HMI (aka RapidPaint) catered towards robot painting task. RapidPaint has eliminated the customer’s need to use consulting services of a robot programmer. It enables an operators to be trained within hours to create new recipes and programs. The ability to create new recipes easily has enabled the customer to easily add new dish designs to the robot painting job. It will allow the customer to add additional robots easily as they continue to grow their operations. The HMI runs on a Windows PC. This means the customer will never have to worry about their controls software getting outdated.


As the dishes comes down a conveyor line, the four robots are able to divide the paint task without the need to slow down the conveyor line.


RSI added RFID sensor to the beginning of conveyor line in an effort to realize which dish is being fed into the robot chambers. This feature allows RapidPaint to automatically load a paint recipe file. This allows for minimal human intervention as operators can focus on other tasks on hand.

RSI added an encoder to the conveyor line in an effort to take advantage of “conveyor tracking” feature. This feature allows motion profiles to be adjusted on-the-fly when painting a moving dish. This has led to a much higher quality paint job and less paint being wasted.


RapidPaint allows the customer to easily jog and teach a robot. The customer can use a PC or Teach Pendant to perform the teaching process. The customer no longer needs to rely on outdated Teach Pendants and multiple button hit processes to teach a profile.


User Interface

RSI developed an intuitive HMI for the customer so that an operator can be easily trained to use and troubleshoot the robotic solution.

Overview Tab

Allows you to see the system’s status and performance.

IO Tab

Allows users to view their Digital Outputs’ state and rename them.

Teaching Tab

Allows users to start teaching robot points that will be used by the recipe(s).

Recipe Tab

Allows you to create an entire motion profile for your robot.

Control Tab

Allows operators to see the current state of the valve and allow them to take control manually if needed.

Program Tab

Allows users to match a RFID tag to a recipe and run your program.

Profile Tab

Allows operators create a custom motion profile which slows down towards the end of the move to eliminate water hammer.

Hamburger Menu

Allows users to further configure the UI or exit the application.

RapidPaint Online Manual

Use the manual to learn how to use the RapidPaint UI.

Solution Technologies

  • Industrial Robot Arm
  • New Controller Box
  • Top of the line Motion Controller
  • Custom UI
  • New Robot Controller

Customer Benefits

  • Extremely reliable control solution for robotic painting applications.
  • Robot controller with Cartesian and Joint motion features.
  • High performance conveyor tracking ability.
  • Intuitive UI for great control and teaching.
  • Industrial teach pendant for safety and ease of use.
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