ENCY Hyper for Robot Programming Unifies Offline Precision with Real-Time Control

ENCY Software today announced the market release of ENCY Hyper, the company’s next-generation system for programming and simulating industrial robots and auxiliary equipment. ENCY Hyper blends the flexibility of offline programming with the responsiveness of real-time methods in a streamlined workflow designed for tablets and industrial PCs. The product will be officially presented at EMO Hannover 2025.

• Next-generation programming & simulation. A hybrid system for industrial robots and auxiliary equipment that merges offline precision with real-time responsiveness in a touch-optimized workflow.
• Key capabilities: real-time robot and sensor feedback; AI-powered auxiliary tools; built-in collision avoidance; complete digital twin of the robotic cell; easy multi-brand robot calibration and programming from a single interface.
• Use it solo or together with ENCY Robot. ENCY Hyper can be used independently for pick-and-place, palletizing, packaging, or assembly — or seamlessly paired with ENCY Robot for advanced applications like milling, welding, spraying, or grinding.
• Unified, interactive environment. The system communicates with the robot in real time, enabling immediate execution, testing, and adjustment of robot motion. Control logic and motion can be fine-tuned interactively and responsively, giving integrators and engineers full control from design to deployment.

To solve those issues, ENCY Hyper unifies a complete digital twin and CAM-level accuracy with live robot communication in one hybrid, touch-optimized environment—so you keep the strengths of both offline and online methods without their downsides.

Addresses online (teach-pendant) limitations

• Scale without point-by-point teaching. Define what to pick and where to place; Hyper generates and executes motion in real time for routine tasks like pick-and-place, palletizing, packaging, or assembly.
• See before you move. Keep the responsiveness of online edits while gaining simulation of the complete robotic cell, so you’re not “testing blind” on production hardware.
• Safer, faster debugging. Stream commands to the controller, step through with live robot and sensor feedback, pause instantly, and resume safely.

Fixes offline (CAM + simulation) hand-off issues

• Eliminates the office↔cell loop. Instead of exporting, copying, and walking files back and forth, Hyper streams programs directly to the robot for immediate execution and on-the-spot adjustment.
• Closes the twin-to-reality gap. Use point-and-confirm calibration: show a few real pick/place points; Hyper updates the digital twin and automatically recalculates the rest.
• Built-in collision avoidance. As you adjust on the cell, Hyper continuously checks and generates obstacle-aware paths to keep edits safe.
• Multi-brand, one interface. Calibrate and program robots from different vendors through a single UI; add drivers to expand coverage without retooling your process.
• Right-sized effort for quick jobs. Skip heavyweight CAM rebuilds when you only need small changes; make them directly with immediate, real-time feedback.

ENCY Hyper’s hybrid workflow applies from straightforward cells to advanced toolpaths, combining digital-twin confidence with live, on-cell execution. Examples below are illustrative, not exhaustive.

Simple operations

• Brownfield palletizing with drifting fixtures (6-axis robot on a 7th axis, palletizing/depalletizing) — Stream programs to the controller, tweak layer patterns at the cell, and quickly recalibrate offsets from a few real pick/place points; collision checks help maintain clearances near posts and guards.
• Kitting and light screwdriving (collaborative 6-axis cobot, assembly/screwdriving) — Nudge targets on a tablet and stream updated moves in real time; I/O feedback confirms each step without point-by-point reteaching.

Advanced operations (with ENCY Robot)

Everything you can program in ENCY Robot can be run with ENCY Hyper. The advantage is where you make changes: at the robot, without a round-trip to the office. Operators and engineers can interactively adjust part locations, approaches and exits, batch size, tray/box destinations, step size, and number of passes right in Hyper. If you need to process a different part, you update the CAM project in ENCY Robot; for day-to-day production changes on the same part, you use Hyper.

• Robot milling (6-axis robot, optional linear 7th axis; spindle) — Programs are generated in ENCY Robot and tuned on the floor in Hyper (approach/exit edits, feeds, local adjustments).
• Grinding/polishing/deburring (6-axis robot; abrasive/finishing tools) — Generate toolpaths in ENCY Robot; in Hyper, adjust passes, step size, and approach/exit moves interactively next to the robot.
• Coating/painting (6-axis robot + rotary table) — Use ENCY Robot for path definition; in Hyper, refine process parameters like number of passes and start/stop timing at the cell.
• Arc welding (6-axis robot + 2-axis positioner; GMAW/TIG) — Define and simulate in ENCY Robot; at the cell, Hyper lets you adjust weld parameters such as weave step, pass length, and strategy without rebuilding the CAM project.

By removing the false choice between fast-but-risky online tweaks and precise-but-brittle offline workflows, ENCY Hyper accelerates commissioning, improves flexibility on short runs and changeovers, and reduces downtime. It’s especially valuable for manufacturing and robotics engineers (one environment from design to deployment with easy last-mile corrections), shop-floor operators and technicians (safe, guided on-cell edits without point teaching), system integrators (shorter FAT/SAT cycles, fewer site revisits), and OEMs/machine builders (consistent multi-brand workflows and simpler field updates).

ENCY Hyper will be unveiled at EMO Hannover 2025, with a product presentation outlining its hybrid workflow — digital-twin simulation, real-time robot communication, collision-aware motion, and point-and-confirm calibration. Visit ENCY Software in Hall 6, Booth B42 for details on availability and supported models.

For those who can’t attend, the ENCY Hyper pre-release demo premiered at ENCY World 2025 is available on video.