🤖 KUKA Robotic Pick & Place with IIoT Integration

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📌 Project Overview

This project demonstrates the programming, simulation, and IIoT integration of a KUKA ERS 3.0 robotic arm to perform a Pick & Place operation.

Developed during my Robotic Systems Programming & Operation Internship at Otto-von-Guericke University Magdeburg (May 2025 – Ongoing), this project goes beyond a basic Pick & Place exercise by showcasing remote robot operation via OPC-UA and Python, bridging the gap between classical robotics and Industry 4.0 smart factory concepts.

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⭐ STAR Contribution

Situation
The task was to automate a Pick & Place sequence on a 6-axis KUKA robotic arm, while also extending the system into an IIoT-enabled environment to enable remote, multi-user control.

Task

• Program the robot using KUKA Robot Language (KRL).
• Validate motions through RoboDK simulation before execution.
• Establish OPC-UA connectivity and integrate Python for real-time remote control.
• Deliver both a functional on-site demo and a scalable digital workflow.

Action

• Built and imported CAD models into RoboDK for trajectory simulation and collision detection.
• Programmed robot movement in KRL, tested locally on KUKA Robot Controller (KRC) and SmartPAD.
• Integrated OPC-UA server with a Python-based client-server system to enable Industry 4.0 connectivity.
• Configured SmartHMI & PLC-level controls for local testing and fallback.

Result

• Achieved a fully automated Pick & Place cycle, validated in both simulation and on a physical LEGO-based KUKA ERS 3.0 robot.
• Enabled remote, multi-user operation through OPC-UA and Python integration.
• Demonstrated strong skills in robotics programming, IIoT connectivity, PLC systems, and automation integration.
• Produced comprehensive documentation, source code, CAD models, and demo video for reproducibility.

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🖼️ Project Highlights

Stage	Image
1. RoboDK Simulation
2. SmartPAD & KRL Programming
3. Physical Robot Execution

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📂 Repository Structure

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📑 Reports & Documentation

• 📘 KUKA Pick & Place Guide (PDF): KUKA_PickPlace_Guide.pdf
  (includes step-by-step workflow, screenshots, and technical explanations)

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💻 Source Code

• 📝 KUKA Pick & Place Program: kuka_pick_and_place.src

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🎥 Demo Video

▶️ Watch Demo Video

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🗂️ CAD Models & Simulation Assets

To keep the repository lean, the full CAD package is provided as a downloadable Release:

👉 Download KUKA ERS 3.0 CAD Models (WRL, STEP, IGES)

Contents include:

• ERS3.0 assembly & parts (.wrl, .iges, .step)
• RoboDK project setup (.rdk)
• Robot workspace layouts

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🛠️ Tools & Technologies

• KUKA Robot Language (KRL) – trajectory programming
• KUKA Robot Controller (KRC) & SmartPAD/SmartHMI – on-site testing
• RoboDK – offline programming and collision-free simulation
• OPC-UA – robot-to-cloud communication protocol
• Python (Client-Server) – remote, multi-user control integration
• PLC Interfaces – local control and safety redundancy

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🔑 Key Takeaways

• Delivered a working robotic system that integrates classical programming + Industry 4.0 remote control.
• Showcased the end-to-end robotics workflow: CAD models → simulation → programming → physical execution → remote operation.
• Provided a recruiter-friendly demonstration of skills in robotics, automation, IIoT, and digital manufacturing.
• This project reflects my ability to bridge hardware, software, and connectivity layers in real-world robotic systems.

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⚖️ License

Distributed under the MIT License.