Duke Control Systems delivers automation engineering for the most demanding automotive production environments. With experience on BIW projects in excess of 200 robots, our engineers understand what it takes to deliver complex automotive automation on time, to quality.
Our team has worked alongside OEM and Tier 1 engineering teams on projects across body-in-white, paint, assembly and powertrain. We understand the pace, the standards and the pressure — and we deliver accordingly.
Automotive projects involve hundreds of robots, complex interlock logic, strict safety requirements and uncompromising quality standards. Experience at this level is non-negotiable.
Automotive project timelines are fixed and non-negotiable. Late delivery is not an option. Our structured approach and virtual commissioning capability keeps projects on track.
OEM and Tier 1 quality standards are exacting. Code structure, documentation, FAT/SAT processes and handover procedures must all meet stringent requirements.
Automotive cells involve complex safety systems — area scanners, safety PLCs, emergency stop circuits and protective fencing. These must be right first time.
We develop robot OLPs in Process Simulate and validate PLC logic in a digital twin before site — minimising risk and ensuring a fast, confident on-site start-up.
Systematic I/O verification, safety system testing and automatic sequence validation under real production conditions. Structured, documented and thorough.
Bringing offline programs to life on the shop floor — refining paths, tuning weld parameters and achieving cycle time targets alongside OEM and Tier 1 teams.
Body-in-white welding, handling and assembly programming across ABB, FANUC and KUKA platforms. Experience on projects in excess of 200 robots.
Safety PLC programming, area scanner configuration, safety gate interlocks and emergency stop systems — validated to functional safety standards.
Factory acceptance and site acceptance testing support — working alongside your QA team to validate system performance against agreed specifications.
Our team has delivered BIW projects with over 200 robots. That scale of experience is rare and invaluable on complex automotive projects.
We've worked directly alongside OEM engineering teams and Tier 1 suppliers — understanding their standards, processes and expectations.
Our offline-first approach using Process Simulate is now standard practice on automotive projects — reducing on-site time and risk significantly.
Functional safety programming and validation to IEC 62061 / EN ISO 13849 — protecting your people and your production.
Documented code, formal FAT/SAT processes, thorough handover packs — the professional approach that automotive projects demand.
Our team has delivered automotive automation projects globally — bringing international experience and best practices to UK projects.
"Working with Duke Control Systems gave us confidence throughout the project. Their engineers clearly knew the systems inside out and their commissioning approach was methodical and professional."Engineering Manager — UK Manufacturing Client
Whether you need robot programming for a new BIW line or PLC commissioning support on an existing plant, our team is ready. Get in touch or book a free line review.