With the rapidly evolving pace of technology, the manufacturing industry is quickly transitioning to automation. It is no longer a thing relegated to science-fiction, but rather becoming a must for manufacturers who are looking to keep up with their competitors. This is where collaborative robots – otherwise known as cobots – come in. They mainly help manufacturers and factories with streamlining and speeding up the assembly line, as well as other more repetitive processes. One thing that makes cobots stand out compared to other industrial robots is that they can safely work alongside human employees, meaning manufacturers are no longer required to cordon off areas for robots only. Cobots are also a cost-effective means for small businesses to automate their production line. Instead of investing in larger, unwieldy, and expensive robots, small businesses can use cobots to operate on small to mid-size production lines. Moreover, cobots are flexible enough to fill in any gaps that emerge.
Here, let us take a look at a few applications cobots can be used in the manufacturing process.
Common Tasks
Due to its flexibility, user-friendly software, compact size, and mobility, a cobot’s robotic arm can be used for a wide range of tasks. Putting these actions altogether results in a completely automated process. Some common tasks now being assigned to cobots are listed below, although the possibilities remain for cobots to branch out into other fields in the future.
Sanding and Polishing
While a vital task when it comes to manufacturing items, sanding, polishing, and deburring surfaces remains monotonous and repetitive. To achieve a smooth and consistent finish, the same amount of force must be applied to the surface continuously. However, this is often impossible to do for human workers, especially if they have to work at least 8 hours a day. This can result in quality problems in the end product, as well as repetitive strain injury (RSI) or white finger syndrome for human employees. Cobots, on the other hand, are ideally suited to this task. They are equipped with sensors to detect whether the same amount of force is being applied to a surface and can find bumps or contours that need to be sanded down. Cobots can also work around the clock, resulting in production being faster.
Screwing
Another simple, yet tedious task, screwing needs to be performed with the same strength and precision to deliver consistent quality in the final product. As such, cobots remain a great solution to automating screw processes. Cobots can be fitted with various screwdrivers and are accurate within 0.1mm. This means all products are of the same quality, with less margin for error. Cobots can also reduce employees’ health risks, as screwing by hand can lead to musculoskeletal disorders such as carpal tunnel syndrome. Moreover, cobots are flexible and easily programmable, so they can be converted to other screwing operations in the production line.
Pick and Place
In layman’s terms, pick and place just means picking up objects and putting them somewhere else. This can include picking certain components and sorting them on a treadmill, placing products on conveyor belts, or filling crates and boxes. The tasks are basic enough for cobots to get the hang of it, though a robotic arm might need to be outfitted with other tools if the process becomes more complicated. Examples include sensitive grippers or using robot vision systems to ‘see’ where an object is placed.
Palletizing
Similar to pick and place, palletizing refers to moving and stacking goods onto pallets so that they are ready to be transported or shipped. It can be exhausting and potentially dangerous, especially if the pallets are heavy or in large quantities. If mistakes occur, this can lead to injuries, as well as damage to the product. While larger manufacturing plants have industrial robots specifically designed for this task, smaller businesses cannot justify the costs or space needed. As such, cobots are a fantastic solution to this problem. While their lifting capacity is not as high when compared to industrial robots, cobots can still lift loads of up to 16kg. Furthermore, they can work together to hoist heavier items.
Bin Picking
A more complicated version of pick and place, except that the objects are not delivered in a standardized manner. While most pick-and-place tasks have a structured supply, which ensures the cobot knows exactly where the objects are coming from, bin picking does not. As such, cobots must be outfitted with vision technology and sensors so they can recognize the correct product. As a result of artificial intelligence (AI) such as machine learning and smart software, cobots can recognize an object’s color, shape, and size. This means it is now possible for cobots to sort objects by certain characteristics, thereby allowing them to load the conveyor belts themselves after receiving items in bulk.
Quality Assurance and Testing
Quality assurance and testing are essential for any production line. It ensures products meet the right standard and aims to reduce any faulty items delivered to customers. While this process is not completely automated yet, cobots are increasingly being used for quality inspection. Tasks well suited to cobots include PCB testing, touch screen device testing, and chip testing, as they are equipped with sensors that allow cobots to handle products carefully and with accuracy. Lately, automated optical inspection (AOI) is in development to replace cameras, so cobots can readily detect possible errors early during the assembly process.
Welding
With cobot technology becoming increasingly sophisticated, cobots are now being used for tasks that require extreme attention to detail. Welding is a task that must be performed with extreme precision, and cobots can automate the process quickly and easily. Unlike humans, cobots are accurate and consistent, meaning all products are of high quality and have minimal errors. Cobots are also flexible enough to be used in different types of welding applications, such as spot welding, arc welding, or plasma welding, and can be converted quickly if there is a sudden need. In addition, with a rise in the shortage of welding personnel, cobots are an ideal solution to this problem.
Ending thoughts
There is no doubt that cobots are revolutionizing the manufacturing industry as we speak, with more companies using them to automate repetitive tasks. This has freed up human employees to do more complex, creative work, thereby speeding up the production process. With the cobot market expected to hit $8 billion by 2030, we can expect them to become more sophisticated and versatile in the coming years. As a result of their reliability, it will not be long before factory workflows completely change in the next few years.
