Future of Manufacturing: Cobots Vs. Industrial Robots

Are cobots the future of manufacturing, or do industrial robots still hold the crown? As automation evolves, the answer isn’t black and white.
This article explores the unique strengths of cobots and industrial robots, revealing how each fits into today’s dynamic production landscapes.
Understanding the differences between the two can help you choose the right robotic solution to improve efficiency, safety, and flexibility in your operations.
Whether you’re looking to integrate new robotic systems or optimize existing ones, this guide will help you make informed decisions tailored to your production needs.

Understanding Industrial Robots

Industrial robots are automated machines designed for a range of tasks in manufacturing environments. These robots are typically programmed to perform specific, repetitive tasks with a high degree of accuracy and speed.

Common Applications in Manufacturing

  • Welding: Joins metal parts with precision in automotive and heavy machinery manufacturing, ensuring strong and durable connections.
  • Assembly: Constructs components with accuracy in electronics and appliance industries, enhancing product reliability.
  • Painting: Applies coatings evenly in automotive and consumer goods sectors, improving aesthetics and protection.
  • Material: Handling: Transfers raw materials and finished products efficiently in warehousing and logistics, optimizing workflow and reducing downtime.

 

Evolution of Industrial Robots

The industrial robot began with simple automation in the automotive industry and has since transformed into highly sophisticated systems across various sectors

  • 1950s-1960s: The inception of basic automation, primarily in car manufacturing.
  • 1970s-1980s: Introduction of programmable robots, expanding capabilities beyond mere repetition to more complex tasks
  • 1990s-2000s: Advancements in robotics technology, including the integration of sensors and computer control, allowing for greater precision and flexibility.
  • 2010s-Present: The era of intelligent robotics, with enhanced AI, machine learning, and connectivity features, pushing boundaries in autonomous operations.

Advantages of Industrial Robots

Understanding the differences between the two can help you choose the right robotic solution to improve efficiency, safety, and flexibility in your operations.

High Precision and Repeatability

Industrial robots excel in performing tasks with a high level of accuracy, ensuring consistent quality in manufacturing processes. This precision reduces waste and enhances product reliability.

Ability to Handle Heavy Loads

These robots can manage and maneuver substantial weights that would be challenging or dangerous for human workers. This capability makes them invaluable in industries requiring heavy-duty operations.

Suitability for High-Volume Production

In environments where high-volume production is crucial, industrial robots shine. They maintain speed and efficiency, significantly boosting throughput and meeting the demands of large-scale manufacturing.

The Introduction of Collaborative Robots

Collaborative robots, or Cobots, represent a newer type of robotic technology designed to work safely alongside humans.
Unlike traditional industrial robots, cobots are built for direct human-robot interaction, prioritizing ease of use, adaptability, and safety.

Common Applications of Cobots in Manufacturing

  • Welding: Cobots offer precise and flexible welding solutions, perfect for small-batch production and custom jobs in automotive and metalworking industries.
  • Assembly: They excel in assembling delicate components, making them ideal for electronics, medical devices, and consumer goods, where precision and care are paramount.
  • Quality inspection: Cobots automate visual inspections, ensuring consistent quality and accuracy in electronics, automotive, and packaging sectors.
  • Machine tending: Involves loading and unloading parts, performing routine tasks in CNC machining, injection molding, and other automated processes.
  • Material handling: Efficiently manage the movement of materials, streamlining processes in warehousing, packaging, and logistics environments.

Key Features That Set Cobots Apart:

  • Safe collaborative operations: Built to share workspaces with humans, facilitating safe, flexible and dynamic interactions.
  • Simple integration: Can be integrated into existing workflows with minimal disruption.
  • Cost-effective: Typically require less infrastructure investment compared to traditional robots.

Development and Innovation

The concept of cobots emerged in the mid-1990s with the aim of creating robots that could safely interact with humans in a shared environment.
Technological advancements in sensors, artificial intelligence, and control systems have driven the evolution of cobots, making them increasingly sophisticated and capable of handling complex tasks.
  • 1990s: Early development focused on creating robots that could be physically guided by humans.
  • 2000s: Introduction of safety features that allowed cobots to operate safely around humans.
  • 2010s-Present: Integration of advanced AI and machine learning, improving the cobots’ ability to perform diverse tasks with high safety and efficiency.

Safety Advantages of Cobots

Cobots are specifically designed to operate safely around humans without the need for physical barriers. This is crucial for maintaining a safe workspace while enabling close human-robot collaboration.
Cobots operate in several modes, each tailored to improve safety and efficiency in various applications. Here’s an overview of the four main types of cobot operations:
  1. Power and Force Limiting Cobots

    • Function: These cobots stop immediately upon detecting contact with a human, preventing injuries.
    • Ideal for environments with frequent human-robot interaction, such as small-scale assembly or light manufacturing.
  2. Safety-Rated and Monitored Stop Cobots

    • Function:Equipped with sensors that halt the cobot’s operations if someone enters the workspace, resuming only when the area is clear.
    • Ideal for scenarios where human access to the robot’s workspace is occasional but necessary.
  3. Speed and Separation Cobots (Fenceless Cobots)

    • Function: Utilize safety laser scanners to adjust their speed or stop based on a person’s proximity, allowing safe, barrier-free interaction.
    • Ideal for applications requiring periodic human access while maintaining safety, such as material handling.
  4. Hand Guiding Cobots

    • Function: Allow manual guidance for easy reprogramming of tasks and positions, facilitating quick adaptation to new processes.
    • Ideal for mobile applications or scenarios requiring frequent task adjustments.

Risk Assessment

Effective use of cobots involves conducting thorough risk assessments to ensure they can operate safely within specific work environments. This includes evaluating potential hazards and implementing appropriate safety measures, such as sensors and emergency stop functions.

Flexibility in Various Applications

Cobots offer remarkable versatility, easily adapting to different tasks and applications without requiring extensive reconfiguration. Their flexibility allows manufacturers to quickly respond to changing production demands or introduce new product lines without significant investment in new equipment.

Ease of Programming and Deployment

One of the standout features of cobots is their ease of programming and deployment. With user-friendly interfaces that do not require advanced programming skills, cobots can be quickly set up and integrated into existing workflows.
This reduces downtime and training requirements, making them an attractive option for businesses looking to increase productivity without a steep learning curve.

Key Differences Between Cobots and Industrial Robots

Feature
Safety
Flexibility and Adaptability
Cost and Implementation
Space Requirements
Cobots
Designed for safe human-robot interaction following risk assessment.
Easily reprogrammed for different tasks. Great for high-volume production or HMLV.
Lower initial investment and quicker ROI. While the robots themselves are more expensive, the overall cell is often cheaper due to less safety equipment.
Smaller footprint, suitable for tight spaces.
Industrial Robots
Require safety cages and barriers.
Typically designed for specific, repetitive tasks. Programming knowledge needed.
Higher upfront costs and longer setup times.
Larger, requiring more dedicated space.

Use Cases for Industrial Robots

  • High-volume manufacturing: Industrial robots are integral to automotive assembly lines and other large-scale production environments. Their ability to perform repetitive tasks at high speed and with precision makes them perfect for producing large quantities of goods efficiently.
  • Heavy-duty applications: These robots excel in handling large and heavy materials, making them ideal for industries that require the movement and manipulation of substantial objects, such as in metal fabrication or construction.
  • Environments requiring extreme precision: In fields like aerospace and medical device manufacturing, where precision is paramount, industrial robots deliver the accuracy needed to meet stringent quality standards and ensure product reliability.

Use Cases for Cobots

  • SMEs and Startups: Cobots are well-suited for small to medium-sized enterprises (SMEs) and startups due to their lower cost and flexible deployment. They provide an accessible entry point into automation, allowing these companies to enhance productivity without significant upfront investments.
  • Custom and High-Mix Low-Volume Production: Cobots can quickly switch tasks and adapt to new processes. This capability makes them ideal for custom manufacturing and HMLV production. This flexibility allows manufacturers to handle diverse and changing product lines efficiently.
  • Visual Appearance-Sensitive Products: Cobots are invaluable for high-precision tasks like finishing and testing products where appearance and surface quality are critical. They ensure that visual quality standards are consistently met, making them ideal for sectors such as electronics and consumer goods.

Konica Minolta Cobot Solutions

This reduces downtime and training requirements, making them an attractive option for businesses looking to increase productivity without a steep learning curve.
  • CoboSense: Automates visual quality inspection, dramatically boosting speed and ensuring stringent quality standards are met.
  • CoboSpecim: Uses the Specim FX10 hyperspectral camera for advanced surface quality inspection that exceeds human capabilities.
  • CoboAesthetix: Combines advanced imaging technology with cobots for precise surface measurement and characterization across industries.
  • FORXAI Cobot: Integrates QA and Pick & Place with AI and Machine Vision, streamlining workflows and enhancing efficiency.
  • CoboVox: Simplifies cobot interactions with intuitive voice control and programming.
  • Autonomous Material Handling (AMH) Solutions: Our Solutions Autonomous Mobile Robots (AMRs) and proprietary software optimize material flow, enabling 24/7 operations, real-time tracking, and improved accuracy in processes like picking, putaway, and transportation.

Choosing the Right Automation for Your Needs

As manufacturing evolves, both cobots and industrial robots play crucial roles in improving productivity and efficiency.
Industrial robots excel in high-volume and precision-heavy applications, but require significant investment and safety measures.
Cobots provide flexibility, safety, and ease of use, ideal for SMEs, custom production, and visually sensitive tasks.
Explore Konica Minolta's innovative cobot solutions to elevate your manufacturing efficiency and flexibility. Whether you need advanced visual inspection, precise surface measurement, or streamlined material handling, Konica Minolta offers cutting-edge cobot systems designed to meet your unique production needs.

Visit our cobot solutions page or contact our sales team for a free consultation today to discover how these solutions can transform your operations.

FAQ

What makes a cobot safe to work with humans?

Cobots are designed with safety features such as force-limiting sensors, emergency stop functions, and advanced programming that allows them to detect and respond to human presence, making them safe for direct interaction without the need for physical barriers

Are cobots cheaper?

While the initial cost of a cobot arm might be higher, the overall investment is typically lower because cobots require fewer safety measures and infrastructure modifications. This leads to a quicker return on investment compared to traditional industrial robots.

How fast are cobots?

Cobots operate at speeds optimized for safety and efficiency in collaborative environments. While they are generally slower than industrial robots, their speed is sufficient for many tasks, especially where human-robot interaction is frequent.

How are cobots controlled?

Cobots can be controlled through user-friendly interfaces that allow for easy programming, often including teach pendants, hand-guiding, and sometimes voice control or intuitive software platforms, making them accessible even for non-experts.

Do cobots use AI?

Yes, many cobots incorporate artificial intelligence (AI) and machine learning to enhance their functionality. AI enables cobots to adapt to new tasks, improve precision, and interact more naturally with their human counterparts, making them versatile and efficient in various applications.