Four Commonly used Industrial Robots which will be Revolutionized by the Archimedes Drive.
At IMSystems, we talk to you a lot about industrial robots through shows, blog articles, and brochures. However, let’s be honest, “industrial robot” is a broad term. Inside it exist all kinds of robots. We are proud of our Archimedes Drive for its ability to improve industrial robots’ performance in many ways (efficiency, speed, precision, etc.). But we also must humble ourselves towards the reality: not every robot is a perfect application for the Archimedes Drive. Of course, using our traction-based drive could improve many applications, but we believe it is important to focus on robots where the Archimedes Drive is undoubtedly a revolution.
This is why we have put together different kinds of industrial robots which we believe are a great application for our drive: Articulated Arms, Delta Robots, SCARA robots, and COBOTS. These are the robots we mean when we talk about industrial robots with great performance opportunity development.
To better understand why our Archimedes Drive could improve their performance, we decided to create this article as an introduction to those four types of robots. It will help you to know what they are, how they are coded, and their strengths and weaknesses. This article compiles a lot of information in a small format!
Note: You will notice that all four types of robots are related to high-speed and high-precision operations because these are the ideal applications for the Archimedes Drive.
1 – Articulated Arm Robots
Overview: An articulated arm is a mechanical arm that can be programmed and is made up of several joints that may rotate or move along an axis. Robotic arms come with a diverse number of axes. The smallest number is 2, but usually, Articulated Arms have 6 axes. Articulated Arms are usually presented by robot builders following these key characteristics:
- Axes: Determined by the number of joints and DOF allowing the robot to perform a variety of tasks.
- Max Payload: Indicates the weight capacity of the robot. Varying significantly based on the design and application from a few kilos to hundreds of.
- Reach: Describes the distance the robot can extend its arm from the base to the end effector.
Applications: Articulated Arm robots are incredibly versatile and can be used in a wide range of applications including but not limited to welding, material handling, packaging, assembly, painting, and palletizing. Due to their versatility and strength, Articulated Arms are heavily used in the automobile industry. For lightweight tasks, other types of robots like Delta or SCARA robots are often preferred due to their lower cost unless the task requires the agility of an Articulated Arm.
Note: This list of applications can be extended when we talk about mobile manipulators, which combine a ground robot with an Articulated Arm on top, allowing the robot to move around in a workplace.
Note 2: Although automobiles are the traditional sector of application for Articulated Arms, those same factories are also the first to equip their factories with humanoid robots.
Advantages:
- High Flexibility: Can handle a wide variety of tasks due to their multiple DOFs.
- Wide Range of Motion: Can reach different positions and orientations within their workspace.
- Complex Task Handling: Suitable for tasks that require intricate movements and precision.
Disadvantages:
- Cost: Initial purchase and setup can be expensive.
- Space Requirement: Often requires significant space and safety enclosures (cages or safety fences) to operate, which can be a limiting factor in smaller facilities and reduce flexibility.
- Difficulty to Code: Setting up the robot for its tasks requires proper programming, and there is currently a scarcity of qualified personnel for this task in the market.
Market:
According to the International Federation of Robotics (IFR), in 2020 more than 2.7 million robots were working in factories around the world. According to Stratistics MRC, the Global Robotic Arms Market is accounted for $23.84 billion in 2023 and is expected to reach $157.84 billion by 2030 growing at a CAGR of 31.0% during the forecast period
CONCLUSION: Articulated Arm robots remain a cornerstone in industrial automation due to their versatility and capability to perform complex tasks across various industries. Despite the initial cost and space requirements, their advantages in improving productivity and precision make them a valuable investment.
2 – SCARA robots
Overview: SCARA robots (Selective Compliance Assembly Robot Arm) are among the most popular and easy-to-use industrial robotic arms. Known for their unique ability to move freely in three axes while maintaining stiffness in a fourth, these robots are especially well-suited for tasks such as pick and place, sorting, and assembly operations.
Reach and Payload: The average reach of SCARA robots typically ranges from about 300 mm to 1000 mm, depending on the specific model and application requirements. SCARA robots can be categorized by their workspace height. The payload capacity usually ranges from several grams to 20 kg.
Axis Configuration: SCARA robots typically have four axes:
- Base Rotation: This allows the robot to rotate around the base.
- Horizontal Extension: Enables the arm to move horizontally.
- Vertical Movement: Allows the arm to move up and down.
- Wrist Rotation: Enables the end effector to rotate.
Applications SCARA robots are incredibly versatile and can be used in a wide range of applications, including pick and place, assembly, packaging, and precision tasks.
Advantages of SCARA Robots
- Speed and Precision: SCARA robots are renowned for their fast cycle times and high positioning accuracy. They excel in environments such as electronics assembly and food manufacturing.
- Ease of Programming: Simpler kinematics make SCARA robots easier to program.
Disadvantages
- Limited Payload: SCARA robots generally have a lower payload capacity, typically maxing out around 30-50 kg, but on average more around 10 kg.
- Restricted Workspace: The design of SCARA robots limits their operational workspace and flexibility in approaching tasks from different orientations. Unlike Articulated Arms, their task possibilities remain limited.
- Limited Degrees of Freedom: Due to their design, SCARA robots have fewer degrees of freedom (typically four) compared to articulated robots. This limitation restricts their ability to perform tasks that require complex, multi-directional movements,
Market:
In 2023, the SCARA robot market was valued at approximately USD 5 billion. This market is expected to grow at a compound annual growth rate (CAGR) of 13%, reaching around USD 16.5 billion by 2032 (Global Market Insights Inc.).
CONCLUSION: SCARA robots continue to be a reliable choice for industries that require fast, precise, and repetitive movements, especially in applications like electronics assembly and food manufacturing. However, their limitations in payload and workspace mean they are best suited for specific tasks where their unique advantages can be fully utilized.
You can read more about SCARA here.
3 – Delta Robots
Overview: Known for their spider-like appearance, Delta robots consist of three or four actuators mounted on a rigid frame. Each actuator is equipped with an arm, all mounted to a centred end-effector.
Delta robots are a sub-category of parallel robots, characterized by their high speed and precision. The movements of the joints cause the tooling plate to move across the X, Y, and Z axes, creating a cylindrical work envelope ideal for high-speed assembly and pick-and-place tasks. Some Delta robots can pick up to 300 parts per minute, making them highly suited for high throughput rates.
Applications: Invented in the early 1980s by Professor Reymond Clavel at EPFL in Switzerland, Delta robots were initially used for packaging chocolate pralines. Today, they are employed in various industrial applications, including high-speed pick and place, sorting, packaging, and assembly of lightweight part.
Control Challenges of Delta Robots:
Delta robots, known for their high-speed face significant control challenges due to their complex dynamics and parallel kinematic structure. These challenges include:
- Complex Dynamics: The parallel arrangement of arms leads to intricate interactions requiring sophisticated control algorithms like model predictive control (MPC) and adaptive control.
- Precision Requirements: High-speed operations demand precise control to avoid errors such as overshooting or oscillations, crucial for tasks like pick-and-place.
- Model Dependency: Model-based control algorithms need accurate models, which can be difficult to achieve, posing robustness issues. In contrast, data-driven algorithms, while not dependent on model accuracy, must maintain optimal performance and robustness.
- Singularities: Avoiding specific positions where the robot’s kinematic model becomes indeterminate is essential to prevent erratic behavior and potential damage.
Advantages:
- High Speed and Precision: Delta robots are renowned for their ability to perform tasks with incredible speed and accuracy.
- Efficiency in Space: The compact design of Delta robots makes them efficient in terms of space utilization, eliminating the need to allocate extra space.
- Affordability: Delta robots are generally more affordable than other types of industrial robots.
Disadvantages:
- Limited Payload: Delta robots typically handle lightweight parts. Their structure does not support heavy payloads, restricting their use to specific applications involving lighter items, making it difficult to use them for heavy products such as glass bottles and heavy boxes.
- Lack of precision: Delta robots are able to pick-and-place products with efficiency, but they lack precision for more delicate task, which are usually dedicated to SCARA robots.
- Maintenance: The high-speed operation and precise mechanics of Delta robots can lead to higher wear and tear, necessitating regular maintenance to ensure consistent performance.
- Specialized Use Cases: Delta robots are highly efficient for specific tasks like pick-and-place but may not be versatile enough for other types of industrial applications that require different movements or heavier handling.
Market:
The Delta robots’ market is now forecasted to grow by USD 1.41 billion during 2023-2028, accelerating at a CAGR of 13.46% during the forecast period. The 3-axis segment is estimated to witness significant growth during the forecast period, being the largest segment and valued at USD 416.37 million in 2018. Furthermore, the APAC region is estimated to contribute 50% to the market growth by 2028.
CONCLUSION:
Delta robots, with their parallel kinematic design, are ideal for high-speed, high-precision tasks. Their unique structure and advanced control systems make them suitable for applications requiring rapid and accurate movements, such as pick-and-place, sorting, and packaging. Despite their limitations in payload capacity, Delta robots remain a crucial component in modern industrial automation.
4 – Dynamic Balance
Introduction Cobots, or collaborative robots, are designed to work alongside human workers without the need for safety barriers such as cages and walls. Equipped with advanced sensors and software, Cobots ensure safety and ease of programming and reprogramming, allowing them to adapt quickly to new tasks or changes in the production line. This adaptability results in shorter downtimes and has made automation accessible to smaller businesses, transforming the economic landscape by democratizing technology previously reserved for large corporations.
Applications Cobots are versatile and can be used in various applications, including:
- Assembly
- Pick and Place
- Machine Tending
- Quality Inspection
- Additive Manufacturing Tasks
Cobots vs. Industrial Articulated Arm Robots:
Industrial articulated arm robots typically require safety systems like cages, whereas Cobots are designed to work alongside humans with built-in sensors to prevent collisions. Both types of robots exhibit similar repeatability and agility, ensuring high precision.
Furthermore, Industrial robots work safely behind a security wall, meaning they can carry much heavier payloads with higher velocities Cobots need to limit their speed and payload to avoid hurting a human in case of collision.
Design-wise, Cobots differ significantly from industrial articulated robots, featuring mechanisms and housings tailored for human interaction (smooth, no sharp edges, etc.). Cobots need to be backdrivable, easy to grasp, and should minimize external cabling to avoid safety issues.
Advantages
- Safety Features: Cobots come with advanced sensors and software to prevent collisions, ensuring safe operation around humans.
- Support for SMEs: They provide an affordable entry point into automation for small and medium enterprises, enhancing their production capabilities without extensive capital investment.
- Enhanced Safety Standards: Cobots adhere to rigorous international safety standards such as ISO 10218 and ISO/TS 15066, minimizing the risk of accidents.
- Space-Efficient: They are light, compact, and mobile, making them easy to move and integrate into different workspaces.
Disadvantages
- Programming Expertise: Although easier to program than industrial robots, Cobots still require expertise for effective programming.
- Speed: To ensure human safety, Cobots operate at slower speeds, which can limit efficiency in some applications.
- Workplace Adaptation: Businesses may need to redesign workflows to integrate Cobots effectively.
- User Experience: Ensuring that Cobots are user-friendly and do not require significant cognitive load can be challenging.
Market:
The global collaborative robot (cobot) market is experiencing significant growth and is projected to expand substantially over the next decade. As of 2023, the market size for cobots was valued at approximately USD 1.58 billion and is expected to reach USD 11.04 billion by 2030, reflecting a compound annual growth rate (CAGR) of 32.0% from 2023 to 2030 (Grand View Research).
CONCLUSION: Cobots represent a significant advancement in robotics, offering numerous benefits such as improved safety, flexibility, and ease of use. They are transforming industries by making automation more accessible and efficient, promoting collaborative work environments, and driving innovation. As Cobots continue to evolve, addressing the technical challenges and optimizing their deployment will be key to maximizing their potential in industrial settings.
This is a common question for which we will try to give a general mainstream answer. The simplest way to understand how Cobots and industrial Articulated Arm robots differ is that Cobots are designed to work alongside human employees, while industrial Articulated Arm robots work in place of those employees.
However, keep in mind that with the evolution of workplaces and the higher space constraints for companies, more and more industrial robots are being designed to be safe to work next to humans, exhibiting characteristics usually reserved for Cobots. We also have the case of several companies using cobots as replacement for industrial articulated arm robots without a cage, but not doing collaborative tasks with humans. But that is not the topic of this question.
Industrial robots and collaborative robots (Cobots) differ primarily in their application and interaction with humans:
Industrial Articulated Arm Robots:
An industrial robot is an automated, programmable machine used in manufacturing to perform tasks such as welding, painting, assembly, and material handling. Industrial robots are categorized into various types, including SCARA robots, Delta robots and Articulated Arm robots.
These are designed for high-speed, high-precision tasks in controlled environments. They often operate in isolation from human workers due to safety concerns. They excel in repetitive, hazardous, and labour-intensive jobs. Industrial robots especially articulated arms are made of robust materials and are very heavy, explaining why they can’t work next to humans and need to be enclosed to avoid interaction. Many videos on YouTube show horrific accidents involving these robots. In most cases, these accidents are the result of human workers not respecting the security measures, such as entering the robot cage.
Cobots: These are designed to work alongside humans safely. Cobots are typically equipped with advanced sensors and safety features to ensure human workers’ safety. They are more flexible and easier to program, making them suitable for tasks that require human-robot collaboration.
According to ISO 10218, from the International Organization for Standardization, there are four requirements for a robot to be termed as Cobot. Obliging to one or a plurality of these requirements would enhance the safety of the robot and position it as a collaborative robot (Cobot). The requirements are:
- Safety-rated monitored stop
- Hand guiding
- Speed and separation monitoring
- Power and force limiting
Both speed and force comply with ISO/TS 15066:2016.
They also usually have the following features:
- Backdrivable Joints: These joints are designed to stop or reverse if they encounter an obstacle (such as a human), or they can be pushed away.
- Housing and Cable Management: The housing is usually composed of gentle curves to be safe and easy to grab for a human hand. Furthermore, the cables are typically located inside the robot (thanks to hollow shaft actuators), so they can’t hook a human arm accidentally.
- Accessible coding interface: Cobots are designed to be user-friendly, often programmed through interfaces resembling tablets.
- No requirement for extensive safety cages: which saves space and costs, making them suitable for more agile and versatile applications.
As explained, technology is increasingly moving towards the development of cobots for efficiency and safety. The recent development of mobile manipulator robots (a mobile robot with an articulated robot connected) shows that industrial robots are getting out of their cages and need to become safer for close human interaction.
Supporting article:
– Cobots: The Future of Industrial Robotics in 2023 and Beyond.
– Why Cobots hold the key to unlocking operational efficiency in large manufacturers.
– Cobot sales hit $1 bn and will grow faster than 20%.
Selecting an industrial robot is a complex process influenced by various factors, unique to each company’s industry, tasks, and level of automation. Companies often collaborate with integrators, whose experience and the level of data they receive can vary significantly. Some companies provide to integrators a small database, while others have dedicated teams to monitor their automatization. Each robot performs different tasks in various setups, with varying degrees of complexity. Additionally, each company has a unique work floor with different levels of traffic and space, making it challenging to create a definitive checklist. However, a few common steps can be identified.
Selecting a robot involves considering several factors:
- Primary function:
- Payload Capacity: Ensure the robot can handle the weight of the materials or tools.
- Reach and Workspace: The robot must have adequate reach and fit within the available workspace.
- Precision and Speed: Match the robot’s accuracy and speed to the task requirements.
- Environment: Consider environmental factors like temperature, dust, and humidity.
- Integration: Ensure the robot can be integrated with existing systems and processes.
- Cost: Evaluate the total cost, including installation, maintenance, and operation.
Keep in mind that these steps are just a small part of the robot integration process. Selecting a robot depends on your factory, your team, the type of robot you choose, and what you want it to do. Techniques exist to develop a strategy to address these questions. Consulting a professional, such as an integrator, is a solution to avoid future security problems, especially if you are considering integrating a Cobot into your production line
Article supporting:
– How to Choose the Right Industrial Robot?
– How to Select the Best Industrial Robot for Manufacturing Applications
Selecting an industrial robot is a complex process influenced by various factors, unique to each company’s industry, tasks, and level of automation. Companies often collaborate with integrators, whose experience and the level of data they receive can vary significantly. Some companies provide to integrators a small database, while others have dedicated teams to monitor their automatization. Each robot performs different tasks in various setups, with varying degrees of complexity. Additionally, each company has a unique work floor with different levels of traffic and space, making it challenging to create a definitive checklist. However, a few common steps can be identified.
Selecting a robot involves considering several factors:
- Primary function:
- Payload Capacity: Ensure the robot can handle the weight of the materials or tools.
- Reach and Workspace: The robot must have adequate reach and fit within the available workspace.
- Precision and Speed: Match the robot’s accuracy and speed to the task requirements.
- Environment: Consider environmental factors like temperature, dust, and humidity.
- Integration: Ensure the robot can be integrated with existing systems and processes.
- Cost: Evaluate the total cost, including installation, maintenance, and operation.
Keep in mind that these steps are just a small part of the robot integration process. Selecting a robot depends on your factory, your team, the type of robot you choose, and what you want it to do. Techniques exist to develop a strategy to address these questions. Consulting a professional, such as an integrator, is a solution to avoid future security problems, especially if you are considering integrating a Cobot into your production line
Article supporting:
– How to Choose the Right Industrial Robot?
– How to Select the Best Industrial Robot for Manufacturing Applications
Electric power has emerged as the undisputed frontrunner in robotics power sources, offering an unmatched blend of efficiency, precision, cleanliness, scalability, and mobile compatibility, making it the most advantageous choice for powering robots across a diverse range of industries and applications.
AC (Alternating Current): Many industrial robots are powered by AC (Alternating Current), which is supplied through the electrical grid. AC power is typically used for large robots that require substantial energy. AC power can be distributed as either single-phase or three-phase power.
DC (Direct Current): Some robots use DC power, especially for smaller or more precise applications. DC motors are often used in robotic joints and actuators due to their ability to provide precise control and high torque at low speeds.
The costs associated with acquiring and using a robot can be classified into two categories: direct and indirect.
Direct costs directly relatable to a process or object: recurring maintenance, operator costs, energy consumption, depreciation, etc.
Indirect costs which are not relatable to the robot itself, but are mandatory for the general operation (management, building, training, utility costs…)
Components of Direct Costs
- Robot’s Base Price: Initial purchase cost of the robot.
- Optional Add-ons: Additional software or hardware options that can enhance robot functionality.
- Peripherals: End-of-arm tooling (EOATs), vision systems, and safety features.
- Extended Warranty: Cost for extended coverage beyond the standard warranty period.
- Training: Expenses for training personnel to operate and maintain the robot.
- Support Packages: Costs for basic or premium support services offered by the manufacturer.
- Logistics: Lead times, shipping, and installation fees.
Components of Indirect Costs.
- Engineering Costs: Expenses for system setup, development, and commissioning.
- Downtime Costs: Losses incurred during robot downtime for repairs or maintenance. Downtime should be avoided in any situation because the shutdown of a production line can cost thousands of dollars to a company within minutes.
- Operation Costs: Power consumption and space requirements (machine footprint).
- Upgrade Costs: Expenses for software or hardware upgrades over the robot’s lifecycle. This cost can vary significantly, with some robot suppliers offering updates for free, while others may charge for them.
- Spare Parts: Costs for replacement parts over the robot’s lifetime. This sometimes needs to be planned long in advance due to the shortage of some components, especially those composed of very delicate and complex-to-produce gears.
Supporting article:
– Robots – Total Cost of Ownership (TCO)
– Method for Assessing the Total Cost of Ownership of Industrial Robots
– Total Cost of Ownership: KUKA Robotics’ Approach to Assessing the Value of Robots
- Complexity of the Teach Pendant:
Industrial robots typically have a much more complex teach (or teach box) pendant compared to Cobots. An industrial robot’s teach pendant can have 30 to 60 buttons, requiring operators to remember dozens or even hundreds of button combinations to control the robot effectively. This complexity makes programming more challenging and time-consuming.
In contrast, Cobots have simpler teach pendants with just a few buttons or a touchscreen, making them easier and more intuitive to operate.
- Programming Methodology:
Industrial robots require detailed and precise programming for each coordinate in their trajectory, which often needs to be done using the teach pendant. This process is not only more complex but also requires a high level of skill and precision from the programmer.
Cobots, on the other hand, can be programmed by physically guiding the robot arm to the desired positions and then setting the coordinates, making the process more intuitive and requiring less technical expertise.
- Offline and Online Programming:
While both types of robots can utilize offline programming, industrial robots often require more advanced and detailed programming efforts. This includes creating virtual environments and accurately mapping out the robot’s path to avoid collisions and optimize efficiency.
Cobots, however, often come with more user-friendly programming interfaces and can sometimes eliminate the need for extensive offline programming through more straightforward block programming methods.
- Integration and Safety Features:
Industrial robots typically require extensive safety systems and integration with other industrial equipment. This includes ensuring that the robot operates safely within its environment, which can add to the programming complexity.
Cobots are designed to work alongside humans and come equipped with advanced sensors to prevent collisions, making them inherently safer and simpler to integrate and program for collaborative tasks.
- Legacy Code:
In industrial robotics, a significant amount of code can be considered as “legacy code.” This term is used to describe old or existing computer code that is still in use but may no longer be considered efficient or up to date by current standards. The challenge lies in the knowledge transmission between generations of developers to be able to manipulate this legacy code, which does not always happen effectively. This situation often puts new engineers in difficult positions.
Cobots (collaborative robots) also face this problem. However, since many cobots have been developed more recently, the code might be less old and therefore more flexible or accessible to edit. However, it is important to keep in mind that legacy code can be present in any robot.
- Skill Level Required:
Programming industrial robots often necessitates a highly skilled robotic operator or programmer. Knowing that programming robotic knowledge are rarely shared outside of a company making the passage of knowledge to a new generation difficult.
Whereas cobots are designed to be more accessible and user-friendly. This design philosophy means that even less experienced users can program cobots for various tasks, significantly reducing the entry barrier compared to industrial robots. Coding a Cobot still requires expertise, but at a relatively lower level than an industrial robot.
Supporting article:
Data Summary:
Robot Type | Market Value (2023) | Projected Market Value | CAGR | Key Applications |
Articulated Arms | USD 23,84 billion | USD 157,84 billion (2030) | 31% | Automotive, Electronics, Pharmaceuticals |
SCARA Robots | USD 5 billion | USD 16.5 billion (2032) | 13% | Electronics assembly, Automotive manufacturing |
Delta Robots | USD 2.39 billion (2022) | USD 6.14 billion (2030) | 11.6% | Packaging, Sorting, Assembly (Food & Beverage, Pharma) |
Cobots (Collaborative Robots)
| USD 1.77 billion | USD 12.71 billion (2030) | 32.6% | Assembly, Pick-and-place, Machine tending, Quality inspection |
| Total Cost of Ownership | Precision | Payload | Speed | Implementation Difficulty |
Articulated Arm | High | Good
| Great | Good | High |
Scara | Medium | High | Low | Great | Medium |
Delta | Low | Medium | Low | Great | Low |
Cobot | Medium | High | Medium | Low | Low |
Glossary:
Degrees of Freedom (DOF): Number of independent movements a robot arm can make. For instance, a robot with 6 DOF can move in six different ways, allowing for complex and precise positioning.
Model Predictive Control (MPC): A type of advanced control algorithm that uses a model of the system to predict future outcomes and make real-time adjustments to optimize performance.
Adaptive Control: A control method that adjusts its parameters in real-time to maintain optimal performance despite changes in the system or environment.
Singularities: Positions where the robot’s kinematic equations become undefined, leading to unpredictable or erratic movements.
Payload: The maximum weight that a robot can handle, which affects its performance and application suitability.
ISO/TS 15066: aims to improve the safety, efficiency, and integration of collaborative robots in various industrial applications, providing a structured approach to risk assessment and design criteria.
Reach: The maximum distance the robot arm can extend from its base to its end effector.
End Effector: The device at the end of a robotic arm designed to interact with the environment, such as a gripper, tool, or sensor.
Parallel Kinematics: A robot design where multiple arms work together in parallel to control the end effector, resulting in high precision and stability.
Serial Kinematics: A traditional robot design where each joint moves sequentially in a single chain.
ROS (Robot Operating System): An open-source framework for writing robot software, providing tools and libraries to build and control robotic applications.
URScript: A scripting language used for programming Universal Robots, designed for ease of use and flexibility in controlling robotic actions.
Backdrivability: The ability of a robot’s joints to be moved by external forces, allowing safe and responsive interaction with human operators.
Safety-Rated Monitored Stops: A safety feature where the robot can detect the presence of humans and stop or slow down to prevent collisions.
Speed/Separation Monitoring: A safety mechanism that adjusts the robot’s speed based on the proximity of humans, ensuring safe collaboration.
