Cobots and Collaborative Robots

Chapter 1: What is the principle of collaborative robots?

This chapter will explore collaborative robots and provide key considerations for selecting the right collaborative robot for your needs.

What is a Collaborative Robot?

Collaborative robots, often referred to as cobots, represent a cutting-edge advancement in robotics technology, revolutionizing automation by working alongside human operators. Unlike traditional robots, cobots are equipped with sensors that enable them to sense and respond to their environment. This allows them to safely collaborate with humans by entering a protective mode if any disruption or safety issue is detected, thereby preventing potential injuries that might occur with conventional robots that operate without such safety measures.

Automation Equipment

Collaborative robots are a subset of automation equipment, a broad category of machinery used to automate various production processes. Other types of automation equipment include automation cells, conveyors, industrial robots, and specialized devices such as turn-over machines and lifters.

Different Tools for Collaborative Robots

Collaborative robots utilize similar tools to those used by traditional robots for various positions and applications. Numerous manufacturers globally are focused on developing tools specifically for collaborative robots, enhancing their ability to learn new tasks and increase versatility. These tools can be categorized into several types: Vision systems, End of Arm Tooling (EOAT), Grippers, Software, Range Extenders, Supply components, and Safety Systems.

Cobot Vision Systems

Vision systems equip collaborative robots with the capability to see and interpret their surroundings. By using 3D or 2D cameras, cobots can identify and locate objects, recognize patterns, and read barcodes. One of the major advantages is the flexibility in handling product supplies; unlike traditional methods that require organized arrangements, vision systems allow cobots to pick up items based on visual data. Additionally, these systems can be used for optical inspections, such as detecting product defects. The integration of Artificial Intelligence further enhances these capabilities, offering more advanced functionalities and efficiencies.

In the realm of vision systems for collaborative robots, various options are available, each suited to different applications based on flexibility, cost, and ease of use. The primary choices are 3D and 2D camera systems. The selection between these types depends on the specific requirements of the task the collaborative robot is intended to perform.

2D Vision Systems

2D cameras are more affordable compared to 3D cameras but offer fewer capabilities. While they can measure the width and length of an object, they lack the ability to measure height.

3D Vision Systems

3D cameras can measure the width, height, and length of an object, significantly expanding their applications. However, they come with a higher cost. Their ability to measure height makes them ideal for handling objects with varying heights or stacked items, such as in packing or palletizing processes.

End of Arm Tooling (EOAT)

End of Arm Tooling (EOAT) encompasses a variety of tools that can be attached to collaborative robots. This includes sanders, screwdrivers, sensors, tool changers, glue dispensers, welding equipment, and soldering tools. Recent advancements in these tools have significantly increased their capabilities, allowing collaborative robots to assist more effectively in boosting production capacities for many companies.

Different Kinds of End-of-Arm Tooling

EOAT has opened numerous avenues for training collaborative robots (cobots) in new tasks. The advancement of these tools will enable cobots to handle an even broader range of applications in the future. Listed below are some examples of the diverse EOAT tools available:

EOAT Glue Dispensers

A dispenser is used to attach a glue or sealant syringe to the end of a cobot. This setup allows the collaborative robot to follow a specific path and apply glue or sealant with great accuracy and consistency. As a result, there is minimal wastage since the exact amount of glue or sealant required can be precisely controlled.

EOAT Screwing Machines

Screwing machines allow collaborative robots to perform fastening tasks either autonomously or alongside a human operator. Since screwing is a repetitive and often monotonous task, it can become tedious for people. A cobot, paired with a screwing machine, can efficiently handle this job for extended periods with high precision.

EOAT Sanders

Equipped with a sander, a collaborative robot can effectively sand, polish, or deburr various surfaces. Its integrated sensors enable the cobot to apply a uniform amount of pressure throughout the process, ensuring consistent results. Additionally, user-friendly software makes it simple to program the robot to follow specific paths.

Cobot Sensors

Collaborative robots are equipped with built-in sensors to enhance their sensitivity and ability to work alongside humans. However, for tasks requiring even greater precision, additional sensors can be used. An external force torque sensor is available to provide this heightened sensitivity when needed.

Cobot Soldering and Welding Tools

Soldering and welding require a high level of precision. Collaborative robots are ideally suited for these tasks due to their accuracy. By equipping a cobot with a welding torch or soldering iron, it's possible to automate both soldering and welding processes effectively.

Cobot Grippers

Grippers enable collaborative robots to handle objects by picking them up and placing them in different locations. Various types of grippers are available to suit different tasks, including vacuum grippers, magnetic grippers, and finger grippers. Each type is designed for specific applications, such as using a vacuum gripper for lifting boxes or a soft gripper for handling delicate food items. Key specifications for grippers include gripping width, force, and payload capacity.

Different Kinds of Cobot Grippers

Different types of grippers are suited for handling various materials. To determine the most suitable gripper, it's important to consider the weight and material of the objects to be manipulated.

Electric Grippers

Electric grippers are ideal for complex tasks due to their ability to be finely tuned across various parameters, such as finger positioning and grip strength.

Pneumatic Grippers

Pneumatic grippers, operated by compressed air, are suited for simpler tasks. They tend to be easier to use, more cost-effective, and lighter compared to other types of grippers. Additionally, they offer a high grip force, making them a practical choice for many applications.

Finger Grippers

For tasks requiring high precision, three- or two-finger grippers are the optimal choice. These grippers can adapt to the shape of the object, ensuring a secure and stable hold.

Cobot Software

There are numerous options for designing and programming applications for collaborative robots. Each robot comes with intuitive, user-friendly software tailored to its functionality. Additionally, simulation tools are available to help develop and refine the robot’s integration before moving on to actual implementation.

Traditional robots often demand significant time and expertise to program and are typically limited to a few predefined actions. In contrast, collaborative robots are designed for ease of programming. With intuitive software and mobile applications, cobots can quickly learn new tasks. They can also be manually repositioned and programmed through the software. This simplicity allows for swift deployment and the flexibility to perform a variety of tasks.

RoboDK

RoboDK is a powerful and affordable robot simulation tool. It features an extensive library of over 500 robot arms and offers a user-friendly interface that requires no prior programming knowledge. With RoboDK, robot simulations can be quickly and easily set up. The software supports offline programming, allowing you to develop and test cobot programs outside the production environment. It is suitable for a range of applications, including machine tending, pick-and-place operations, welding, packaging, and palletizing.

Cobot Range Extenders

Range extenders enhance the capabilities of collaborative robots by increasing their reach both horizontally and vertically, expanding their automation potential. Typically, cobots operate within the confines of their base axis. By incorporating a range extender, these robots can achieve greater movement in both directions, thereby enlarging their operational area. This extension not only broadens automation possibilities but also boosts productivity. For example, in palletizing applications, robots can stack boxes higher and more efficiently. Additionally, a cobot equipped with a range extender can maneuver in front of a large machine to perform tasks at various points in the workflow.

Collaborative robots are known for their ease of use and rapid installation. They can be quickly and effortlessly mounted onto range extenders. Additionally, user-friendly software ensures that setting up communication with the cobot is straightforward and hassle-free.

Cobot Safety

Safety encompasses all tools that contribute to the secure interaction between humans and collaborative robots, including screens and sensors designed to detect when a person is approaching too closely to the robot.

Cobot Supply Systems

Supply systems consist of equipment that provides items to the robot for handling. For instance, a tool can consistently position screws in a designated spot for the cobot to pick up, while screw-feeding machinery gathers and delivers them for assembly. Additionally, vibrating plates help to separate and organize items that have become mixed together.

Cobot Tool Changers

To enhance the versatility of collaborative robots, various automatic tool changers are available on the market. These tools allow a cobot to autonomously switch between different tools, enabling it to perform a range of operations. For example, in an assembly task, a collaborative robot might initially use a gripper to position all the components and then switch to a screwdriver to complete the assembly. This capability boosts the robot's productivity, increases output, and improves its return on investment.

Considerations for Selecting a Collaborative Robot

When choosing a collaborative robot, several factors should be considered:

Applications for Collaborative Robots

Collaborative robots (cobots) are well-suited for tasks that are dirty, dull, hazardous, or physically challenging. These include assembly, material handling, inspection, and packaging. Cobots are designed with features such as reach, accuracy, and payload capacity to work alongside human operators effectively. While they may not match traditional industrial robots in terms of power and speed, they excel in safety and adaptability. This makes them ideal for filling gaps where there is a shortage of staff and allowing human employees to focus on more complex, cerebral tasks.

The international standard ISO 10218-1 and ISO 10218-2 describe four key features of cobots: stop, hand guiding, speed and separation monitoring, and force and power limiting. These features ensure safe and efficient operation in various applications. For example, speed and separation monitoring are essential for tasks that involve close human-robot interaction, while force and power limiting are crucial for delicate operations. These standards help ensure that cobots can be integrated safely and effectively into diverse work environments.

Systems Integrator

Incorporating a collaborative robot (cobot) into your operations requires substantial skill and expertise. It’s important to assess whether someone within your company has the necessary time and skills to handle the integration or if you need to engage a systems integrator. Systems integrators bring valuable experience from working with various clients and can provide tailored solutions that avoid the pitfalls of starting from scratch. By leveraging their expertise, you can often achieve cost-effective results and ensure a smoother integration process.

Robotic Integrators

Incorporating a collaborative robot (cobot) requires significant skill. You need to determine if someone within your company has the necessary expertise and time, or if you should hire a robotic integrator. A robotic integrator, also known as a systems integrator, will assess your machine shop and advise on what will and won't work. With extensive experience in various setups, integrators can often provide cost-effective solutions by avoiding the need to start from scratch and reinvent the wheel.

Risk Assessment

A crucial factor in deciding whether to use a collaborative robot is risk assessment. While collaborative robots are equipped with sensors designed to stop their motions and prevent injuries, there is still a potential risk of harm. To ensure the safety and proper functioning of collaborative robots, they must be fully guarded to protect workers effectively.

Answers About Collaborative Robots

Thirdly, open communication is essential for successful implementation. It's important to engage everyone involved, from executives who need to be on board with the decision to the workers who will interact with the cobot daily. Ensuring that all stakeholders are informed and aligned can significantly contribute to a smooth integration process.

• What are the advantages of this kind of automation?
• How much of an investment is it, and what is the expected ROI?
• Will machine shop employees be doing anything different if a cobot is gotten? Can they be freed to other, more intellectual tasks on the machine shop floor? What does it look like?
• What opportunities for training and learning are available? Who can control this? (Frequently the systems integrators offer to train staff as part of the package purchase.)
• Once the cobot is incorporated, what support access is available?
• How can this aid with staff shortage, if relevant?
• What are the business’ future strategies for automation?

Chapter 2: What are the types of collaborative robots?

Collaborative robots represent a recent advancement in the robotics industry, encompassing various types. The distinctions between these types are based on their programming capabilities and safety features. Each type of collaborative robot utilizes unique technologies and methods to ensure a safe working environment.

Power and Force Limiting Cobots

When people refer to collaborative robots, they often mean Power and Force Limiting robots. These cobots are designed to work safely alongside human operators without requiring additional safety barriers, external scanners, or vision systems.

To enhance human safety, force and power limiting collaborative robots are designed without exposed motors, sharp edges, or pinch points. These cobots are equipped with sensitive built-in collision sensors that detect potential impacts and stop immediately if they come into contact with a person. Currently, force and power limiting collaborative robots are generally suited for smaller-scale applications.

Safety Monitored Stop Cobots

Safety monitored stop collaborative robots are typically used in applications with minimal human interaction. This type of cobot involves a conventional industrial robot outfitted with safety sensors that detect when a person enters its workspace. When a human is detected, the robot immediately halts its operations to ensure safety. After the human has finished their task, the robot can be restarted with the push of a button.

Speed and Separation Cobots

Speed and separation collaborative robots, often referred to as “fenceless” cobots, are ideal for scenarios where there is limited human interaction but easy access to the robot is required. Safety laser range scanners are typically used to define zones around the cobot’s workspace. When a person approaches, the robot’s speed reduces, and it will stop entirely if the individual moves closer. Once the person moves away from the workspace, the robot automatically resumes its normal speed.

Hand Guiding Cobots

Hand guiding collaborative robots are equipped with a safety-rated component at the end of the robot’s arm that allows an operator to manually move or direct the robot. This feature is particularly useful for quickly programming new paths and positions. It is ideal for mobile applications where robots move between different stations and require retraining for various tasks, as well as for scenarios where the robot needs frequent reprogramming.

The four main types of collaborative robots are designed for varying levels of human interaction during operation. While not all are intended for continuous collaboration, each type incorporates safety features to prevent serious injuries.

Collaborative robots represent a major advancement in the automation industry, enabling safe interaction with human workers directly. In a relatively short period, four distinct types of cobots have been developed, and as the industry continues to evolve, more types are likely to emerge.

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Chapter 3: What are the applications and benefits of collaborative robots (cobots)?

This chapter will explore the various applications and advantages of collaborative robots.

Impact of Collaborative Robots on Workers

Tasks such as packing goods, restocking inventory, and assembly line work are often repetitive and monotonous. These types of tasks can lead to Repetitive Strain Injury (RSI), a condition resulting from the repeated performance of the same movements.

When robots take over repetitive tasks, human workers can focus on more complex and creative responsibilities, such as quality control or maintenance.

Assigning workers to solution-oriented and creative tasks not only enhances their job satisfaction but also fosters personal growth. This approach encourages flexibility and diversity, contributing to a more positive work environment. Such factors help workers find greater meaning in their roles, leading to increased engagement and productivity.

Applications of Collaborative Robots

Collaborative robots, equipped with various tools and intuitive software, are capable of handling a wide range of tasks. Their versatility allows them to integrate multiple functions into a single automated process. While theoretically, a cobot can be trained for numerous applications, certain tasks are commonly automated, as outlined below.

Sanding and Polishing

Tasks like sanding, polishing, or deburring require precise control. Thanks to built-in sensors, a collaborative robot can follow designated paths while applying a consistent force on the surface, ensuring uniform quality. This makes them ideal for processing wooden, stainless steel, or metal surfaces.

Screwing Jobs

Repetitive screwing tasks are well-suited for cobots. With the right tools and software, a cobot can be programmed to align objects with precision, apply consistent force, and maintain accuracy over long periods. This is challenging for humans but manageable for a cobot operating continuously throughout a workweek.

Pick-and-Place

Pick-and-place tasks involve picking up objects from bins and arranging them on conveyors. While this application is straightforward, it can become more complex with additional tools, such as double grippers or adjustable grippers for different materials and sizes.

Bin Picking

Bin picking is similar to pick-and-place but involves retrieving items from a non-standardized arrangement. Using vision systems and intelligent software, cobots can identify and pick items from bins one by one, and can also supply items to conveyor belts.

Machine Tending

Machine tending involves placing parts into machines like CNC lathes or bending equipment. By automating this task, operators are freed up to focus on more complex activities, enhancing safety and productivity while allowing for extended operational hours and increased output.

Cobots and Palletizing

Collaborative robots can significantly streamline the palletizing process. Using an electric vacuum gripper, a cobot can efficiently pick up boxes and place them onto pallets. Advances in technology have eliminated the need for external air supplies and hoses, simplifying integration and reducing costs.

Quality Testing and Inspection

Cobots are highly effective in performing quality control and inspection across various industries. They can handle tasks like placing items in testing equipment and sorting them based on visual inspections, thanks to advanced vision technology.

Gluing and Sealing

Gluing and sealing are ideal tasks for collaborative robots. By attaching a glue or sealant syringe to the cobot, it can follow a specified path and apply the adhesive consistently, ensuring uniform application.

Soldering and Welding

Soldering and welding require high precision, making collaborative robots an excellent choice for these tasks. Cobots offer consistent quality and precision in welding and soldering applications, surpassing human capabilities.

Different Industries for Collaborative Robots

Collaborative robots are highly adaptable and can be utilized across various industries. Their versatility allows them to be effectively integrated into many sectors, each with its unique requirements and challenges.

Food Industry

Automation in the food industry has increased due to factors such as higher demand and stricter safety regulations. While automating food handling presents challenges, advances in cobots and gripper technology have addressed these issues, enabling effective integration.

Plastics Industry

The plastics industry is characterized by low-volume, high-mix production, which presents challenges for automation due to frequent changes in production processes. Collaborative robots, with their flexibility and ease of reprogramming, have adapted well to these requirements.

Packaging Industry

As the demand for customized packaging solutions grows, collaborative robots are increasingly used for tasks like packing products into boxes and stacking them on pallets. Cobots can handle physically repetitive tasks, improving both production efficiency and worker satisfaction.

Electronics Industry

In the electronics industry, where precision and careful handling of small components are crucial, collaborative robots equipped with advanced sensors are well-suited for tasks like quality control and testing. Their sensitivity and accuracy make them ideal for these applications.

Pharmaceutical Industry

The pharmaceutical industry benefits from automation due to its need for high accuracy and low error margins in large-scale production. Collaborative robots excel in maintaining consistent performance, reducing errors, and improving overall efficiency.

Automotive Industry

The automotive industry has long utilized industrial robots for assembly. With increasing demands for customization and small production runs, collaborative robots are now becoming valuable for various automotive applications.

Metal Industry

In the metal industry, where low-volume, high-mix production is common, collaborative robots are advantageous due to their adaptability. They can perform tasks such as soldering, welding, and loading CNC machines efficiently, meeting diverse production needs.

Benefits of Collaborative Robots

Collaborative robots offer several advantages, including:

Compact – Cobots are compact and can be integrated into production environments without occupying significant space.

Installing and Programming – Cobots are easy to install and program. With user-friendly software for both desktops and smartphones, they can be up and running quickly.

Flexible – Cobots can be easily programmed to perform new tasks, making them versatile for various stages of the production process.

Mobile – Lightweight and easily movable, cobots can be placed on mobile workstations to perform different tasks in various locations within a facility.

Consistent and Precise – Cobots deliver consistent actions with precise force, ensuring uniform quality and accurate component placement.

Positive Impact on Employees – By handling dangerous or monotonous tasks, cobots allow employees to focus on more creative and meaningful work, enhancing job satisfaction.

Reduction of Costs of Production – The efficiency and increased production capabilities provided by cobots contribute to cost savings and improved profitability.

Drawbacks of Collaborative Robots

Collaborative robots may require a restricted working area to ensure worker safety. Initial setup costs can be high, and safety measures might slow down operations. Cobots may need to stop when a person enters their workspace, impacting workflow. Additionally, some cobots are designed to slow down or shut down completely in the presence of humans, which could necessitate costly safety measures. Since they rely on human supervision, they cannot operate entirely independently.

To achieve effective integration, significant investment in safety and operational measures may be required. Collaborative robots' dependence on human oversight means they cannot function without continuous human support.

Safety Standards of Collaborative Robots

The RIA ISO/TS 15066 technical specifications and ISO 10218 safety standards provide guidelines on the safety performance and functionality of collaborative robots. Published in 2016, the RIA TR15.606-2016 Cobots document outlines safety requirements for robot systems and collaborative robots, reflecting the U.S. adoption of ISO/TS 15066. Under TS 15066, collaborative robots' speed and force limits are configured based on human contact areas, application data, and workspace hazards.

The RIA TR15.806-2018 Guidance on Testing Force and Pressure in Collaborative Robot Applications offers guidelines for measuring device conditions, test measurements, and testing methods. It includes metrics and methods for evaluating forces and pressures associated with both transient and quasi-static contact in collaborative applications.

Conclusion

Cobots have leveled the playing ground for small to medium-sized industries. For years, large industries have had the benefits of automation by utilizing traditional industrial robots. But these expensive, complex and large robots were made for high volumes, low volume, and constant production operations, opposed to the high-mix production typical of smaller manufacturers.

Collaborative automation has turned into an adaptive, affordable, and user-friendly technology which allows companies of just about any size (and any level of technical capability) to improve productivity, better quality, and respond more rapidly to varying customer demands.

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