Your First Class on Cobots: How Manufacturers Can Begin Cobot Integration

Cobots can be leveraged in a variety of repeatable applications, like the pick-and-plac example shown here. (Image: Kassow Robots)

While many manufacturers are enjoying demand for their products and have innovations in the pipeline, their growth strategy can sometimes stall. The issue might be due to workforce shortages, which can evolve from temporary setbacks to long-term challenges. For a variety of industries, helping hands are often hard to find, and it’s an issue that’s been consistent in recent years. Given this, many companies are considering transitioning to automation, including through the use of collaborative robots or cobots, for short.

Overcoming Common Hesitations and Misconceptions

“It’s not worth our while.” “We’ve managed fine without them so far.” “It’s much too complicated.” These are typical responses from companies when they first consider implementing cobots. But the reality is much different, and the integration process has been reduced considerably as introducing cobots into an assembly or packaging line isn’t as complicated as many might think. Any business willing to embrace automation can do it. However, it’s important to consider the other extreme viewpoint, often deemed the “toaster myth” –— the notion that you can order a cobot, unpack it, and switch it on without any background knowledge.

A cobot’s versatility can be extended through the use of various end effectors, or end-of-arm tooling, like the one shown here. (Image: Kassow Robots)

Automation requires more than just plugging in a machine. While being curious and open to robotics is essential, automation must be approached thoughtfully. Exploring possibilities with cobots might reveal automation opportunities that an end-user hadn’t even initially considered. By asking the following questions, companies can have a better understanding of what these modern solutions can provide in terms of productivity and return on investment.

Question #1: How Much Space Do I Need for a Cobot?

Understanding the available space and determining the best area to automate processes is crucial. While cobots generally require less space than conventional robots, their placement still demands careful consideration.

In addition to fixed environments, cobots like Kassow Robots’ Edge Edition shown above can be utilized in mobile applications like on AMRs and AGVs throughout the factory or warehouse floor. (Image: Kassow Robots)

Typically mounted on a base or frame, cobots can even be attached to walls or ceilings thanks to their lightweight design. The key is ensuring that the cobot’s arm can reach the necessary pick-up points and cover the entire application area, including the maximum stacking height and reach.

Space constraints, especially in brownfield settings with legacy structures, can be challenging. Modern, seven-axis cobots offer a unique solution, as they don’t require as much room for movements as a six-axis cobot, because the extra axis allows the cobot to maneuver around corners like a human arm. This adaptability means that even if space becomes more restricted later, the cobot can be reprogrammed to perform new tasks, saving both space and costs while enhancing automation capabilities.

Question #2: Should I Enclose Cobots?

After conducting an individual risk assessment, cobots can operate alongside human employees in the same workspace. This assessment ensures that employees are not endangered by the robot’s speed, payload, range, or overall operation. Generally, there are three safety approaches:

1. Cobots operate without enclosures, relying solely on their inherent safety features.

2. Sensors and area scanners halt the robot arm’s movement if necessary. Cobots are programmed to slow down or stop when a person enters the monitored area.

3. Cobots are enclosed in a cage made of materials like Plexiglas or aluminum framing. Enclosing a cobot should be considered, even if your goal is barrier-free automation.

Ultimately, any automation solution must be tailored to the end-user’s needs. For instance, using machine guarding allows maximization of the cobot’s speed instead of operating at a lower speed without the added protection.

Additionally, enclosures can offer flexibility by enabling the cobot to be moved to different locations without requiring additional safety inspections each time. This mobility is particularly beneficial in settings where the solution needs to be relocated frequently. This approach ensures that cobot remains adaptable and efficient while maintaining a high safety standard.

Question #3: How Do I Deal with Cycle Times and Payloads?

Companies considering cobots need to keep in mind cycle times to make decisions based on what’s truly needed, and consulting with systems integrators can be highly beneficial. Third-party experts possess extensive experience and creativity, enabling them to optimize cycle rates technically. This optimization might involve handling multiple products in a single grasp or using special grippers that grab items from the side rather than from above.

When it comes to cycle times, smaller companies often fall into the trap of maintaining outdated practices, such as only cycling during the early shift because “that’s the way it’s always been.” However, rethinking these practices can be advantageous. Employing a robot that can work longer hours than a human can significantly impact productivity and throughput.

Payload limitations are a key consideration when evaluating cobots, as the heaviest of payloads typically require conventional robots. Still, cobots are ideal for numerous applications involving smaller payloads where using human workers may be less efficient. Additionally, applications for smaller items and quantities are often suitable for handling by a lightweight robot. This strategy can reduce your reliance on external robotics engineers for future product changes.

Question #4: How Many Product Lines Can a Cobot be Expected to Work With?

Dealing with various products or versions of a single product is sometimes a challenge in automation. This can lead to an obvious question: “Is buying a robot for each product worthwhile?” The answer depends on the exact application and product, but often, a single cobot can handle real-time adjustments for different tasks and product lines.

Cobots are designed to be easily programmable by individuals with basic technical knowledge, and their operation is even more straightforward. Endusers can create the necessary programs themselves, and once trained to handle various product versions, a single cobot can switch between tasks as needed. This flexibility ensures that a company retains valuable automation expertise.

As manufacturing processes continue toward a more automated environment, the integration of cobots will only increase. End-users should start exploring now how they can utilize these versatile solutions in an effort to maximize their efficiency and leverage technology that has repeatedly shown a clear return on investment.

This article was written by Dieter Pletscher, Global Sales Manager, Kassow Robots (Kastrup, Denmark). For more information, visit here  .