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Improving Insertion Reliability with Force Copilot

Insertion tasks using Copilot can fail or behave inconsistently if alignment conditions are not correct. This article explains the key factors that affect insertion reliability and shares best practices for using Copilot insertion and force control nodes effectively.

Understanding why insertion tasks are sensitive

Insertion operations are fundamentally constrained by physics. Unlike free-space motions, insertion requires multiple conditions to be correct at the same time.

The most common factors affecting insertion reliability are:

  • Linear position accuracy (X, Y, Z)

  • Angular alignment (Rx, Ry, Rz)

  • Contact forces and moments

  • Part stiffness and mechanical tolerances

Even if linear positioning is accurate, insertion can fail if angular alignment is slightly incorrect. In these cases, the robot may reach the target force, for example 8 N, before completing the insertion distance. This behavior is expected and does not indicate a Copilot limitation or programming error.

Because of this, insertion tasks should always be approached as alignment-driven processes, not force-driven ones.

The critical role of angular alignment

Angular alignment is one of the most important and most overlooked aspects of insertion applications.

A small angular misalignment between the part being inserted and the receiving feature can:

  • Prevent insertion from starting

  • Cause side loading or jamming

  • Trigger force thresholds prematurely

Force control cannot compensate for poor angular alignment. Force thresholds should be used to monitor and protect the process, not to correct alignment errors.

Before validating force or distance conditions, the insertion axis must be properly aligned.

Validating alignment before using insertion nodes

Before relying on Copilot insertion or force control nodes, alignment should be validated manually.

A recommended approach is:

  1. Manually insert the part to identify the natural insertion path and angle.

  2. Close the gripper on the part without inducing force or torque.

  3. If any force or moment is detected when closing the gripper, adjust the robot position and orientation until the part remains unloaded.

This process confirms that the robot TCP orientation matches the true insertion axis of the application.

Managing gravity and part movement during teaching

In some applications, the robot holds a part that is affected by gravity, such as a PCB or a flexible component. When released or partially supported, the part may shift or rotate, making alignment validation more difficult.

To improve repeatability during teaching:

  • Add temporary mechanical support under the part

  • Reduce free movement caused by gravity

  • Validate alignment with the part fully supported

These steps help ensure that the taught position reflects the real insertion axis.

Process design considerations for robust insertion

When possible, consider simplifying the insertion process mechanically.

A common best practice is to:

  • Fix the receiving part in a rigid fixture

  • Have the robot insert the mating component

This approach makes it easier to:

  • Validate alignment without induced forces

  • Teach repeatable start positions

  • Retract and reuse a stable approach pose

While not always possible, mechanical simplification often has a greater impact on success than software tuning.

Recommended Copilot insertion strategy

Once alignment is validated, Copilot insertion tools can be used more effectively.

Spiral Search

Use a Spiral Search to initiate insertion and compensate for small positional offsets.

Teach the target position with the part slightly inserted, approximately 1–2 mm. This confirms that insertion has genuinely started and that the parts are engaged correctly.

Linear Insertion

Use a Linear Insertion node to complete the insertion to the final depth. This allows insertion distance to be validated in a controlled and repeatable way.

This strategy applies to most insertion applications, regardless of the specific part geometry.

Using force control with compliance

In some cases, force control with compliance can help reduce side loading during insertion.

A typical sequence is:

  1. Use a Spiral Search to start insertion.

  2. Use a Force Control node to push along the insertion axis while enabling compliance on the other axes.

With compliance enabled, the robot can compensate for small moments and reduce lateral forces, allowing the part to self-align during insertion.

This technique is most effective when forces and moments are clearly measurable. In low-force applications, such as around 8 N, its effectiveness may be limited.


Conclusion

Successful insertion applications depend primarily on proper alignment and process design, not on force thresholds alone. Angular alignment must be validated before relying on Copilot insertion or force control nodes. Once alignment is correct, Copilot tools can be used reliably across a wide range of insertion tasks.


Need help? Contact Robotiq Support

Updated: February 2026