Author: David Kuhlmann
Collaborative robots, also called cobots, work directly and in close proximity with people. In contrast to traditional industrial robots, they are not operated in safety cages in order to avoid accidents. So that the human being and machine can work simultaneously on a risk-free workpiece, cobots are equipped with sensors, cameras and advanced algorithms which enable them to perceive and respond to their environment.
Collaborative robots are used in many industries, including production, the health sector and logistics, in order to support tasks such as assembly, packaging and quality control. Through the cooperation with human beings, the robots increase efficiency and productivity and relieve employees from monotonous or physically demanding jobs.
Reasons for procurement
Why should a company invest in cobots? Their simple handling and quick operational readiness make them suitable for companies of any size, also for companies with no robot experience. The devices can be connected according to the plug-and-play principle, without having to install device drivers or make settings. “Cobots provide simple access to automation and are perfect for pick-and-place as well as handling tasks and the loading and unloading of machines”, says Steffen Günther, Key Technology Manager Machine Tool Automation and Industry & Strategic Channel Management at Kuka in Augsburg. “Their application is primarily useful in companies, which have to cope with a wide variety, small to medium-sized quantities and ergonomically demanding tasks.” The Boston Consulting Group forecast that companies can lower their labor costs by 30 per cent with cobots, adds Günther. The IFR Annual Report from 2020 detected a 50 per cent increase in productivity with the aid of collaborative robots.
“For medium-sized companies, cobots offer a great opportunity to increase productivity and thus retain success in national and international competition”, highlights Lennart Kraft, Product Manager from Lorch Cobot Welding World at the EMO exhibitor Lorch in Mörlenbach Germany. Thanks to integrated safety technology and less training and integration effort, cobots with respect to Total Cost of Ownership can often be more cost-effective than traditional industrial robots and also take up less space. “Lightweight cobots are portable and as a result can be easily used at different locations in the company”, states Nils Tersteegen, Marketing Manager at Fanuc Deutschland, Neuhausen a.d.F.
However, it is recommended to analyze in detail and consider what type of robotics can best support the operational processes. “Cobots generally have a lower load capacity compared to traditional industrial robots”, Lennart Kraft points out. The cobots are also slower than industrial robots, simply to avoid endangering human beings, he adds. Specialist robots may be more suitable for very complex or precise tasks, according to the expert from Lorch. “Even if it is solely about maximum productivity for very high quantities in terms of cycle time optimization, industrial robots have an advantage.”
Keeping a sense of proportion and not going over the top with your demands is another important point that should be considered at the start. “An individual cost-benefit analysis helps to decide whether a cobot is the right investment”, recommends Steffen Günther from Kuka.
Industries that benefit from cobots
Where is the biggest potential for using cobots in industry? This largely depends on the applications, according to Nils Tersteegen from Fanuc. “In areas where classic industrial robots are not yet established, like in the food industry, precision mechanics or in laboratory environments, there is an increased interest in cobots. In manufacturing companies, it is often about steps with which the manual skill of the employees is indispensable, but they should be relieved – for example, in precision assembly.”
Collaborative robots are also increasingly being used in the intralogistics of production companies. They are often mounted on an autonomous mobile robot (AMR) and, in this combination, take on tasks such as transporting goods, sorting or packaging as so-called mobile manipulators, or they help with order picking.
Focus on safety measures
Making the human-robot collaboration safe is a key topic and prerequisite for the use of cobots in production or in the warehouse. The highly developed sensor technology with which the robots are equipped enable force-based applications without additional force/torque sensors, explains Steffen Günther from Kuka.
Once the analysis has been evaluated, protective measures such as automatic speed reduction of the cobots or the integration of warning signals are implemented. The process forces can be measured using articulation sensors, adds Günther. “The robot arm also reacts immediately to the slightest touch and thus provides safe collision protection for the human being.” According to Lennart Kraft from Lorch, the correct definition of collaboration space and installation environment is important, but so too are measures in operational practice such as observing safety notices or wearing personal protective equipment. Ultimately another risk assessment in the case of relevant changes to the system is also essential, adds Kraft.
However, when assessing safety the entire task must also be examined, states Nils Tersteegen from Fanuc. “If cobots work, for example, with heavy weights or sharp objects, additional safety measures are required.”
Challenges for the user
As simple as the actual implementation of cobots is, the user may still face challenges, which must be considered and overcome. For example, experienced programmers are required for interface programming or complex tasks, states Tersteegen.
The legal side also requires the user’s full attention. The Machinery Regulation (EU) 2023/1230 and the amendments to the safety standard DIN EN ISO 13849 raise the question of how to deal with robots that are already in use and now also have to meet the requirements of the legislator. The situation is similar when it comes to cyber security: the Cyber Resilience Act, a regulation of the European Union, aims to standardize the rules for cyber security of products with digital elements across the EU. There will therefore also be new regulations for AI-supported safety functions that are used in cobots.
Outlook
In what direction is the area of collaborative robots heading? “The cobot manufacturer market is getting bigger and new market players are establishing themselves. Many of the traditional industrial robot manufacturers are taking the cobot topic more seriously and playing a more active role in cobot innovations”, observes Lennart Kraft from Lorch.
These innovations are increasingly integrating artificial intelligence, be it in the “visual detection of different objects, which are then gripped by the robot, or the programming of robots using simple commands”, reports Nils Tersteegen. The cobots are becoming more flexible, mobile and modular, allowing them to conquer new fields of application, sums up Steffen Günther from Kuka. They are now performing “simpler palletizing tasks but have also established themselves in the welding area”, confirms Tersteegen from Fanuc. The combination with autonomous mobile robots as well as the integration in human-centered work processes increase their efficiency, argues Günther. The interaction of cobots and industrial robots is another trend that is emerging. “In the machine tool industry both technologies complement each other – cobots for flexible automation and assistance, industrial robots for high efficiency in large-scale production”, adds the expert from Kuka.
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