The Top 5 Applications for Collaborative Robots in Manufacturing

The use of collaborative robots - or "cobots" - in the manufacturing sector has expanded. These robots are designed to work alongside humans in shared spaces, improving efficiency, reducing errors, and augmenting workforce productivity. Cobots are equipped with advanced sensors and safety features to facilitate safe collaboration with human workers ⁽¹⁾.

Non-collaborative robots are often referred to as “industrial robots”. Industrial robots are typically large systems that perform tasks in an isolated area. Contemporary images of industrial robots show them MIG welding car chassis or palletizing heavy boxes. These robotic systems have been a staple in high-volume, low-mix manufacturing applications for decades. 

However, the skill shortage in manufacturing continues to put pressure on the entire economy, particularly small to medium-sized enterprises (SMEs). The skill shortage is especially acute for these businesses. It is no surprise then that SMEs are increasing their investments in automation, specifically cobots. Cobots are known for their flexibility in low-volume, high-mix manufacturing environments. Collaborative robots in manufacturing have opened the door for automation in industries that were previously excluded. 

Below, we dive into the top five applications for collaborative robotics in manufacturing: Assembly, Machine Tending, Material Handling, Quality Inspection, and Welding.

1. Assembly

Collaborative robots in manufacturing have made a significant impact on assembly as a whole. Cobots can be programmed to perform repetitive and monotonous tasks, thereby preventing human error and boosting overall productivity. They can also share the workspace with human operators, adding an extra layer of versatility. Manufacturers using collaborative robots have reported a 30% reduction in production costs ⁽²⁾. 

Example Assembly Tasks for Collaborative Robots in Manufacturing:

• Part selection and orientation
• Dispensing of glue and adhesive
• Welding and joining parts
• Application of paint and surface treatments
• Soldering of electronics
• Fastening of screws, bolts, and nuts
• Finishing steps such as polishing, grinding, and deburring

It is difficult to build a comprehensive list of how cobots are being used in manufacturing. There are simply too many possible applications and industries. It should be noted that cobots are not resigned to a single task (as they can perform multiple steps) nor are they stuck performing the same task (they can be taught to perform different tasks).

2. Machine Tending

Cobots are designed to fit within the human environment. This means that significant changes, usually, do not have to be made for the cobot. A primary example of that is machine tending. Machine tending, often a mundane and repetitive task, can be optimized by using a cobot instead of asking a person to stand at a machine. Cobots can operate machines, load parts, and unload finished products - all by making minimal adjustments to the manufacturing floor. This frees up human operators for tasks that add real value. Manufacturers using collaborative robots in manufacturing have experienced a 40% increase in overall production output ⁽³⁾.

A widely used example of cobots working with another automated piece of equipment is the combination of a cobot and a CNC. Here, the cobot is not transforming the part but is responsible for supplying the parts to the machine. The cobot can load, start the machine, and unload until all the parts are completed. This robot can run 24/7 if provided with enough parts and space to unload.

There are many other machine tending roles beyond CNC machines (and some are even more dangerous). For example, cobots can tend plastic molding machines, 3D printers, bending machines, and metal stamping machines.

3. Material Handling

Manufacturing requires moving, sorting, and organizing a staggering quantity of parts. ‘Pick-and-place’ is a common term used to define the task of grabbing a component and moving it to a new location. An example of a pick-and-place operation is grabbing chocolate from a conveyor belt and positioning it in a tray. 

Since cobots can be used with different types of end effectors, they can handle a variety of materials. Cobots are ideal for tasks that involve primary packaging, secondary packaging, and palletizing. Their flexibility and precision help reduce both the time and cost associated with manual packaging and palletizing.

4. Quality Inspection

Quality inspection applications are using cobots in several different ways. Like machine tending, cobots can load and unload parts into inspection machines (think CMM). Cobots can also be outfitted with external sensors, such as vision systems, so they can perform the inspection. The cobot can also sort the products based on the results of the inspection. The use of collaborative robots can lead to a 50% decrease in defects ⁽⁴⁾.

5. Welding 

Welding and joining parts is a subset of the assembly process. Robotic MIG welding has been performed by industrial robots for a long time, however these bulky systems are expensive and require specialty training to support. Cobot welding has disrupted the market with their ease-of-use and attractive ROI.

Any industry with welding operations can use a welding cobot. Collaborative welding robots add precision and consistency to the welding process. When asked for feedback on their new cobot welder, fabricators often mention the measurable decrease in scrap and rework.

Welding cobots provide solutions for the growing number of businesses that are too dynamic for an industrial welding robot but can’t find enough welders to keep on staff. We found that Cobot Welders are no longer a business niche but a broadly adopted tool. Below we touch on three (of many) advantages of cobot welders.

Figure 1: Cobot welders augment human welding operator capabilities in the welding cell
 

Three Advantages of Welding with Collaborative Robots in Manufacturing:

1. Cobots bridge the gap between manual welders and industrial robotics. All companies - small, medium, large, and extra large - are struggling to find and hire welders. Manual welders are still the backbone of manufacturing, especially for small- and medium-sized businesses. While large and extra large manufacturing sites can invest in industrial MIG robots, the ROI calculation for these systems do not make sense for smaller businesses. Cobot welders provide the automation that these businesses need with an ROI that they can afford. 
2. Cobot welders can be scaled up or down. One of the defining characteristics of a cobot welder is its innate scalability. Skyvington Manufacturing in Mississauga, Ontario, was able to insource their subassemblies with the ESAB Cobot. When demand is high, Skyvington can operate the cobot welder around the clock. When the backlog is low, the ESAB Cobot will operate during one shift. This is a lot more flexible than increasing and decreasing the workforce. Skyvington is now able to maintain a smaller, cross-trained staff, rather than a larger, specialized staff - all awhile insourcing important subassemblies.
3. Cobots provide relief for understaffed manufacturing facilities. Collaborative welding systems can help take pressure off of overworked teams. They free up welding operators for higher-skill tasks, while reducing injury risk through repetitive movements. In addition, cobot welders often include welding libraries that can be used to quickly program the cobot. Whether it’s a MIG, TIG, plasma, arc, or laser welding, the cobot welder can be working on production parts the same day it arrives.

Conclusion

The adoption of cobots in manufacturing has exploded over the last decade. Cobots can now be found in almost every industry. Collaborative robots in manufacturing have opened the door for automation in industries that were previously excluded. 

In this article, we touched on the top 5 applications for cobots in manufacturing: assembly, machine tending, material handling, quality inspection, and welding. Since these robots work alongside humans in shared spaces, these robots provide a force multiplier for businesses all over the world. The use of cobots reduces production costs, increases production output, and decreases defects.

Could a welding cobot transform your business? The easiest way to find out is through a virtual demo. At ESAB, we have been in business for over 100 years and have solved many of these challenges for our client partners. We can support you in your next steps. When you are ready to discuss your project, contact us here.

Sources:

⁽¹⁾ What is a Collaborative Robot? (Tech Target, 2023)

⁽²⁾ Revolutionizing Manufacturing: How Robots Boost Productivity, Quality, and Safety (The Robot Report, 2023)

⁽³⁾ What Unique Benefits Does AI Bring to Cobot Performance? (Machine Design, 2023)

⁽⁴⁾ Human–Robot Collaboration in Manufacturing Applications: A Review (Matherson, Minto, Zampieri, Faccio, Rosati, 2019)