Today, from picking and placing materials/products into containers to welding metal and performing various assembly line tasks, manufacturers recognize that collaborative robots (Cobots) can be widely applied across multiple fields. Additionally, these Cobots can work safely alongside humans, which explains their growing popularity in the manufacturing industry.
According to research firm SkyQuest, the global collaborative robot (Cobot) market was valued at $815.40 million in 2022 and is expected to grow from $914.88 million in 2023 to $2,297.77 million by 2031. This represents a compound annual growth rate (CAGR) of 12.2% from 2024 to 2031.
Some key applications of Cobots include material handling, gluing and sealing, quality control and testing, machine tending, packaging and palletizing, grinding, polishing, deburring, and sanding. SkyQuest researchers predict that the automotive industry will be the largest adopter of Cobots, with those capable of handling payloads up to 5 kg being the most preferred.
The International Federation of Robotics (IFR) describes four types of Cobots based on the level of collaboration between humans and robots. These types include:
On the other hand, according to ISO 10218 (Parts 1 and 2), four different types of Cobots are defined, all of which incorporate varying levels of safety stops, speed and distance reduction, force limitation, resistance, and hand guidance. The ISO 10218 robot types include:
Cobots can perform repetitive and tedious tasks that often lead to fatigue in human workers, as well as tasks that pose a risk of injury or danger. By taking on these responsibilities, Cobots not only enhance workplace safety but also improve production efficiency by handling challenging or high-risk operations.
Cobots can adjust the operating speed of the entire production line, thereby improving the efficiency of the entire workforce. Their presence not only helps optimize processes but also minimizes errors, resulting in higher-quality products.
One of the standout strengths of Cobots compared to traditional robots is their flexibility. They can be deployed without the need for rigid barriers. This allows Cobots to move easily between machines and complete different tasks without requiring extensive adjustments.
The use of Cobots enables humans to transition from manual labor to managing and operating robots. This not only enhances professional skills but also allows people to focus on higher-value tasks, such as quality control or process optimization, instead of performing repetitive work.
One of the biggest concerns when deploying Cobots in manufacturing is the fear of job loss. Many workers worry that robots will replace them, leading to workforce reductions. Although Cobots are designed to collaborate with humans, this concern persists and may impact employee morale.
Although Cobots are designed to operate safely alongside humans, there are still concerns about potential risks, especially when they operate at high speeds. Safety is an extremely important factor in the manufacturing environment, and some workers may feel uncomfortable or fearful when working near machines with significant power and speed.
Although Cobot is advertised as easy to manage and deploy, they are still complex machines that require safety barriers when operating at high speeds. Integrating them into production systems is not always as easy or quick as expected. This process may require significant effort and time, especially in complex applications or specialized work environments.
Although Cobots can perform a variety of tasks, they are not a perfect solution for every job. Tasks that require finesse, high-level judgment, or complex human-like decision-making may still be challenging for Cobots. This necessitates careful consideration by businesses regarding the capabilities and limitations of Cobots when integrating them into their production processes.
The primary use of Cobots is to perform tedious or repetitive tasks that humans originally had to do. However, they are capable of much more, and over time, Cobots will take on increasingly complex tasks.
Justin Garski, OEM Segment Manager for the U.S. at Rockwell Automation, stated: “Some of the top applications for Cobots include slow-paced palletizing, low-cycle machine tending, and quality inspection. These applications do not require high speeds or exceed the pace that humans can handle. For humans, performing these tasks is inconvenient because it either requires a lot of time moving around or waiting idly. Neither of these options is ideal for a workforce already constrained by labor shortages.”
Kim Losey, CEO of Rapid Robotics, believes: “I often start with customers’ pain points in the market and tasks that do not require high throughput. Additionally, for tasks where humans are frequently injured (such as palletizing/depalletizing), highly repetitive tasks like machine tending for complex operations, or tasks where human errors impact profitability or product performance—specifically, oversights in quality inspection.”
Losey also stated: “We are on the verge of a new generation of Cobots, or perhaps redefining their role. The reality is that we need robots to work alongside humans to address the growing labor shortage. Today's Cobots can handle a wide range of tasks, but they need significant improvements to meet the increasing speed and complexity of supply chains.”
Although the use of Cobots is increasing in manufacturing, this technology is still relatively new. Like any emerging technology, manufacturers will continuously seek new and creative ways to apply robots most effectively.
One new way to use Cobots that Losey mentioned is packaging embalming fluid into boxes. "That job is not suitable for humans, so robots are the perfect solution," she said.
Another example she mentioned involves Behren, a manufacturer of metal buckets and containers. Here, the robot "has been used to drill holes in the buckets to attach handles. This is the perfect type of job for a robot – a stressful, repetitive task," she said.
Garski added: "One of the more interesting things I see related to cobots is their mobility. The fact that people are putting them on carts and moving them around like an open toolbox opens up production opportunities that weren't possible before. Similarly, I've seen them mounted on autonomous mobile robots, but that requires batteries and a power source to operate. So while it's unique and interesting, it hasn't yet reached the tipping point to become practical."
In recent years, success stories of cobots have flourished as manufacturers share their experiences of using these robots. Here are some prominent examples of four typical applications in manufacturing industries:
SEAT Componentes, a manufacturer of car gearboxes for Volkswagen and Audi in Spain, sought to automate the unloading of 18,000 machined gears each day at its factory. For this new project, 10 cobots were integrated to handle the unloading process. Without the need for external integrator support and with prior experience using cobots, the company significantly saved on installation and future maintenance costs.
Xcelicut Precision Machining, a contract manufacturer in Pennsylvania, faced challenges in finding labor for the repetitive task of loading and unloading CNC machines. The solution for this project was to integrate a cobot to serve a custom CNC machine with Xcelicut’s machinery. Xcelicut’s owner, Will Fennell, said, “They brought it in and integrated it in less than an hour. We started training and had the product running the same day.”
The result of this implementation was an increase in production from 100 parts per day to 160 parts per day, while also improving operational efficiency thanks to the cobot’s ability to function like a human employee.
Roechling Industrial North America in North Carolina, a supplier of thermoplastic and composite materials for various applications, is facing a labor shortage issue. Steve Wilson, the production coordinator at Roechling, said: "Our challenge is finding people to operate these parts across three shifts, five days a week continuously. We have a very high labor turnover because this is a repetitive job." Roechling partnered with cobots to address this production issue.
Quality Tooling and Repair Inc. (QTR), a machining shop in Pennsylvania specializing in machining and welding, faced what they called the 90-minute challenge. Using precise but slow tungsten arc welding technology, it took 90 minutes to weld a single part. To shorten this process, QTR integrated laser welding capabilities by pairing a handheld laser welder with a cobot. The cobot system allows the operator to control the handheld laser welder with flexibility. With this system, QTR reduced welding time from 90 minutes to just 10 minutes per part.
Source: Automation World
>>> View more: 5 ways that Cobots support humans
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