The global market for collaborative robots (cobots) is experiencing explosive growth. Valued at some 1.2 trillion US dollars in 2023, the market is projected to almost triple by 2030. This surge in adoption reflects the growing recognition of cobots’ potential to revolutionize manufacturing by boosting productivity and flexibility.
However, there’s often confusion surrounding cobots and industrial robots, with many mistakenly assuming they’re interchangeable. While both are robotic automation solutions, they have distinct characteristics and applications.
This guide is going to break down the world of cobots vs industrial robots. We’ll clarify the key differences between them, explore their strengths and weaknesses, and help you determine which technology is the right fit for your unique manufacturing needs. Whether you’re involved in low-volume or high-volume manufacturing, we’ll give you the knowledge to make informed decisions about collaborative automation.
What is a Cobot?
A cobot, short for collaborative robot, is a type of robot specifically designed to work safely alongside humans in a shared workspace. Unlike the traditional seven types of industrial robots that operate in isolation behind safety protocols such as cages and safety curtains, cobots are equipped with advanced safety features that allow them to interact directly with human workers. This collaborative nature opens up new possibilities for automation, allowing humans and robots to combine their strengths for increased efficiency and productivity.
Cobots are typically smaller, lighter, and more user-friendly than their industrial counterparts. They’re designed to be easily programmed and reprogrammed for a variety of tasks, making them versatile tools for manufacturers of all sizes.
Example of a Cobotic Solution: The Modular Robot System (MRS)
One example of a cobotic solution is the Modular Robot System (MRS). This system combines the collaborative nature of cobots with the flexibility and adaptability needed for various manufacturing tasks. The MRS can be quickly reassigned for different post-processing and end-of-line processing functions, such as:
- Packaging automation
- Pick and place robotics
- Machine tending
- Palletizing automation
- Secondary processing automation
The MRS demonstrates how cobots can provide a versatile and cost-effective automation solution for manufacturers, allowing them to adapt to changing production needs and improve their workflows.
Key Features of Cobots
Cobots are packed with features that set them apart from traditional industrial robots and make them ideal for collaborative work environments.
Built-In Safety Mechanisms
Safety is paramount in collaborative robotics. Cobots are equipped with a variety of built-in safety mechanisms to prevent accidents and ensure the well-being of human workers. These mechanisms include:
- Force-Limiting Sensors: These sensors constantly monitor the force exerted by the cobot and immediately stop its movement if it comes into contact with a person or object.
- Collision Detection: Cobots use sophisticated sensors to detect potential collisions and take evasive action to avoid them.
- Safety-Rated Monitored Stop: Automated machine stops allow cobots to pause their operation when a human enters their workspace, resuming once the person has moved to a safe distance.
- Power and force limiting (PFL): This technology restricts the amount of power and force a cobot can exert, further minimizing the risk of injury.
Ease of Programming And Reprogramming
Cobots are designed with user-friendliness in mind. They can be easily programmed and reprogrammed by operators with minimal technical expertise. That flexibility allows businesses to quickly adapt their cobot applications to changing production needs without the need for extensive programming knowledge.
Smaller Footprint And Lighter Weight Compared To Industrial Robots
Compared to industrial robots, cobots are typically smaller and lighter. So they’re much easier to install and redeploy in different areas of a manufacturing facility. Their compact size also allows them to be integrated into existing production lines without requiring major modifications.
Cobots in Manufacturing
The use of cobots in manufacturing is rapidly growing. Their flexibility, safety features, and ease of use make them ideal for a wide range of applications, including:
- Assembly: Cobots excel at supporting human workers in repetitive assembly tasks, enhancing both efficiency and precision while minimizing the risk of human error.
- Machine Tending: By automating machine tending processes, cobots free up valuable human resources to focus on more intricate and strategic tasks, optimizing overall productivity.
- Pick and Place: With their precision and accuracy, cobots streamline pick and place operations, boosting throughput while safeguarding against product damage.
- Quality Inspection: Cobots bring consistency and reliability to quality inspections, ensuring product conformity and reducing the likelihood of defects slipping through.
- Packaging and Palletizing: Cobots lend a helping hand in packaging and palletizing, accelerating these processes while alleviating the physical strain often associated with these repetitive tasks.
Cobots vs. Industrial Robots: Key Differences
While both cobots and industrial robots play crucial roles in automation, they have distinct characteristics that make them suitable for different applications. Understanding these key differences is essential when choosing the right solution for your manufacturing needs. Let’s break down the difference between cobots vs industrial robots.
Safety
When considering cobots vs industrial robots, safety is a paramount concern. A critical distinction between cobots and industrial robots lies in their safety features and operational requirements:
- Cobots: Designed with safety as a top priority, cobots are equipped with force-limiting sensors, collision detection, and other safety mechanisms that enable them to work collaboratively with humans without the need for safety cages. This allows for greater flexibility and interaction in the workspace.
- Industrial Robots: Due to their high speed and power, industrial robots typically operate within designed safe areas to protect human workers. This limits their ability to collaborate directly with humans and requires additional safety measures to be implemented.
Flexibility and Ease of Operation
For manufacturers, both flexibility and ease of operation are paramount. The adaptability of your automation solution directly influences your ability to respond to shifting production demands, while its operational simplicity impacts training time, efficiency, and overall adoption.
- Cobots: Cobots excel in adaptability, being easily reprogrammed and redeployed for diverse tasks. This makes them a perfect fit for agile manufacturing environments where product lines or processes change frequently. Their user-friendly interfaces and simplified programming methods allow operators with minimal technical expertise to adapt the cobot to new tasks, further enhancing their flexibility.
- Industrial Robots: While industrial robots are often designed for specific, high-volume applications, they can offer unparalleled ease of operation once programmed and integrated into a production line. Their turnkey nature means that operators can often initiate complex automated sequences with the simple press of a button, minimizing training requirements and maximizing uptime. However, reprogramming or adapting an industrial robot to new tasks can be time-consuming and may require specialized expertise.
Cost: Balancing Upfront Investment with Long-Term Growth
When considering automation solutions, the initial cost is often a major factor. However, it’s crucial to weigh the upfront investment against the potential long-term return on investment (ROI) and the impact on your business’s growth potential.
- Cobots: Cobots generally have a lower upfront capital investment compared to industrial robots. Their smaller size, simpler design, and reduced power requirements contribute to their cost-effectiveness. This lower initial cost can translate to a faster payback period, making cobots an attractive option for businesses prioritizing immediate cost savings or those with limited budgets. However, it’s important to recognize that cobots, often operating at human speeds, may have limitations in terms of maximizing production output and revenue generation compared to industrial robots.
- Industrial Robots: While industrial robots typically come with a higher initial price tag due to their complexity and potential need for additional safety infrastructure, they offer the potential for greater long-term financial gains. Their ability to operate at higher speeds and handle heavier payloads can significantly increase production capacity, potentially leading to new sales opportunities, reduced scrap rates, and a smaller warehouse footprint. Over time, these advantages can translate to a higher ROI and substantial revenue growth compared to cobots.
The choice between cobots and industrial robots ultimately depends on your business priorities and risk tolerance. If your primary focus is on cost containment and achieving a quick ROI, cobots may be the ideal solution. However, if you’re aiming for significant growth and long-term profitability, investing in industrial robots might be the more strategic choice, despite the higher upfront cost.
By carefully considering your budget, desired ROI, and growth aspirations, you can make an informed decision that aligns with your business goals and sets you on the path to success.
Speed and Payload
The speed and payload capacity required for your specific manufacturing tasks play a crucial role in determining the right automation solution.
- Cobots: Cobots are engineered to operate at speeds that allow safe and efficient collaboration with human workers. This collaborative design often results in speeds that match or closely mirror those of a human performing the same task. While this may limit their suitability for high-speed, heavy-duty applications, it makes them ideal for tasks requiring precision, dexterity, and seamless human-robot interaction. Attempting to exceed these collaborative speeds would compromise safety protocols and negate the core purpose of a cobot.
- Industrial Robots: If your application requires high-speed operations and the ability to handle substantial payloads, industrial robots are the optimal choice. Their superior speed and payload capacity allow them to perform repetitive tasks with exceptional efficiency and accuracy, making them well-suited for mass production and applications where human safety might be a concern due to the rapid movements or heavy loads involved.
By carefully evaluating the speed and payload requirements of your manufacturing tasks, you can ensure that the chosen automation solution aligns seamlessly with your operational needs and safety considerations. Remember, choosing the right tool for the job is key to maximizing productivity and efficiency while maintaining a safe working environment.
How to Choose Between a Cobot and an Industrial Robot
Choosing the first automation project for your manufacturing processes is a critical decision that can significantly impact your productivity, efficiency, ROI, and bottom line. Whether a cobot or an industrial robot is the better fit for your business depends on various factors. To make an informed choice, consider the following key points.
Assess Your Needs
Begin by thoroughly assessing your specific requirements and manufacturing goals. Consider the following questions:
- Task Complexity: How complex are the tasks you need to automate? Cobots are well-suited for repetitive, predictable tasks, while industrial robots can handle more complex operations.
- Required Speed and Precision: What level of speed and precision do you need? Industrial robots typically excel in high-speed, high-precision applications, while cobots prioritize safety and collaboration over raw speed.
- Safety Concerns: Do you need a robot that can work safely alongside humans? Cobots are designed for collaborative workspaces, while industrial robots usually require safety barriers.
- Budget and ROI: Consider both your automation budget and desired return on investment (ROI). While cobots offer lower upfront costs and faster payback, a strategic investment in industrial robots, despite a higher initial cost, can yield significantly higher long-term ROI and profit generation through increased production capacity and efficiency gains. Conduct an automation opportunity assessment to identify areas where automation can have the greatest impact and deliver the fastest ROI, ensuring your investment aligns with your long-term business goals.
- Available Floor Space: How much space do you have available for a robot? Cobots have a smaller footprint than industrial robots, making them a good option for facilities with limited space.
Consider Collaboration
If human-robot collaboration is a priority for your manufacturing processes, cobots are the clear choice. Their inherent safety features and collaborative design allow them to work side-by-side with human workers, enhancing productivity and efficiency. However, if the tasks are primarily high-speed or require minimal human interaction, industrial robots may be more suitable.
Evaluate Flexibility Requirements
The flexibility of your automation solution is another crucial factor to consider. If your production needs are likely to change frequently, or if you require a robot that can be easily redeployed for different tasks, cobots offer greater adaptability. Industrial robots, on the other hand, are often optimized for specific applications and may be less flexible in changing environments.
Consult with Experts
Choosing between a cobot and an industrial robot can be a complex decision with various trade-offs to consider. Seeking guidance from automation integrators like DEVELOP LLC can help you tackle these complexities and determine the best solution for your unique needs. Our team of experts can assess your manufacturing processes, analyze your requirements, and recommend the most suitable automation technology to help you achieve your goals.
Cobots in Manufacturing for Agility and Efficiency
Cobots, with their inherent flexibility and safety features, are reshaping traditional assembly lines, transforming machine tending, and redefining the entire process of pick-and-place operations. Let’s look at the many ways they’re helping manufacturers achieve unprecedented levels of efficiency.
Assembly
In assembly lines, cobots work alongside human operators to perform repetitive and precise tasks, such as fastening screws, inserting components, and dispensing adhesives. Their ability to handle delicate parts and work in close proximity to humans without compromising safety makes them invaluable in this application. By automating repetitive tasks, cobots not only increase productivity but also reduce the risk of human errors and injuries.
Machine Tending
Cobots are increasingly used for machine tending, which involves loading and unloading materials into machines, such as CNC machines, injection molding machines, and presses. Cobots can work tirelessly around the clock, optimizing machine use and ensuring consistent production flow. Their ability to handle hazardous materials or operate in harsh environments only improves workplace safety.
Pick and Place
Pick and place operations are common in manufacturing. Cobots excel at these tasks due to their precision, speed, and ability to work in confined spaces. They can be easily programmed to handle different objects and adapt to varying production requirements, making them versatile tools for pick and place applications.
Quality Inspection
Maintaining product quality is paramount in manufacturing. Cobots equipped with vision systems and other sensors can perform quality inspections with high accuracy and consistency. They can identify defects, measure dimensions, and verify product integrity, ensuring that only high-quality products leave the factory. No more risk of costly recalls while also enhancing customer satisfaction.
Packaging and Palletizing
Packaging and palletizing are areas where cobots are transforming manufacturing. They can handle a wide range of packaging tasks, including filling containers, sealing packages, labeling products, and palletizing finished goods. Cobots can adapt to different package sizes and shapes, making them suitable for both low-volume and high-volume production runs. By automating packaging and palletizing, businesses can improve throughput, reduce labor costs, and enhance the overall efficiency of their packaging lines.
Benefits of Collaborative Robots in Manufacturing
The integration of collaborative robots into manufacturing processes is delivering a variety of benefits for businesses across various industries. Let’s explore some of the key advantages that cobots bring to the manufacturing floor.
Increased Productivity
Cobots are proven to significantly boost productivity in manufacturing environments. By automating repetitive, time-consuming tasks, cobots free up human workers to focus on more complex and value-added activities. Studies have shown that 95% of manufacturing leaders report improved production speed after implementing cobots. This increase in speed not only translates to higher output but also improves overall operational efficiency.
Improved Quality
Cobots are known for their precision and consistency, which can significantly enhance product quality. By reducing the risk of human error, which accounts for 80% of manufacturing defects, cobots help ensure that products meet stringent quality standards.
Enhanced Safety
Safety is a vital concern in manufacturing, and cobots are playing a crucial role in improving workplace safety. By taking over hazardous tasks, such as those involving heavy lifting, repetitive motions, or exposure to harmful substances, cobots reduce the risk of worker injuries.
This not only protects employees but also saves companies significant costs associated with workplace accidents. On average, a single workplace injury can cost a company over $100,000, including direct costs like workers’ compensation claims and indirect costs like lost production and administrative expenses.
Reduced Costs
Cobots are a cost-effective automation solution for manufacturers of all sizes. While the initial investment in a cobot may seem significant, the long-term cost savings can be substantial. By increasing productivity, improving quality, and reducing the risk of workplace accidents, cobots can generate a significant return on investment. Their flexibility also allows them to be redeployed for different tasks as production needs change, further maximizing their value.
Low Volume Manufacturing vs. High Volume Manufacturing: Finding the Right Fit
Low-volume manufacturing and high-volume manufacturing can determine whether a cobot or an industrial robot is the best automation solution for your business. Each production model presents unique challenges and opportunities, and choosing the right robotic technology can significantly impact your efficiency and bottom line.
Low-Volume Production
In low-volume manufacturing environments, characterized by smaller production runs, frequent product changes, and customization, cobots shine due to their inherent flexibility and adaptability. Their ease of reprogramming and redeployment allows manufacturers to quickly switch between tasks and product lines, minimizing downtime and maximizing productivity.
Cobots can be seamlessly integrated into existing workflows, collaborating with human workers to augment their capabilities and address fluctuating production demands. The affordability of cobots only enhances their appeal in low-volume manufacturing, where budgets may be more constrained.
High-Volume Production
High-volume manufacturing, with its emphasis on large-scale production, standardized processes, and consistent output, often calls for the speed and precision of industrial robots. These robots are designed to perform repetitive tasks with exceptional accuracy and speed, making them ideal for mass production lines. While they may lack the flexibility of cobots, their unwavering performance and ability to handle heavy payloads make them indispensable in scenarios where maximizing throughput is paramount.
Hybrid Solutions
In many cases, a hybrid approach that combines cobots and industrial robots may offer the ideal solution. By strategically integrating both technologies, manufacturers can leverage the strengths of each to optimize their production processes. Cobots can be deployed for tasks that require flexibility and collaboration with humans, while industrial robots can handle high-speed, heavy-duty operations. This hybrid model enables businesses to achieve a balance between agility and efficiency, catering to both low-volume and high-volume manufacturing needs.
Can Cobots Work Alongside Humans?
Absolutely! In fact, the defining characteristic of cobots is their ability to work safely and efficiently alongside human workers. Unlike traditional industrial robots that operate in isolation behind safety systems or cages, cobots are designed with in-built safety features that enable them to interact directly with humans in a shared workspace.
What are the Limitations of Cobots?
While cobots offer numerous advantages for manufacturers, it’s important to acknowledge their limitations to make informed decisions about their implementation. Here are some key areas where cobots may fall short compared to traditional industrial robots.
Speed and Payload
Cobots are generally slower and have lower payload capacity than industrial robots. This is due to their design, which prioritizes safety and collaboration over raw speed and power. While cobots can handle a wide range of tasks, they may not be suitable for high-speed, heavy-duty applications that require rapid, repetitive movements or the ability to lift and manipulate heavy objects.
Complex Tasks
Cobots excel at repetitive, predictable tasks, but they may struggle with more complex operations that require advanced dexterity, intricate movements, or sophisticated decision-making. Industrial robots typically have greater processing power and specialized tooling, so are often better equipped to handle such tasks. However, advancements in cobot technology are constantly expanding their capabilities, and some cobots are now able to perform increasingly complex tasks.
Cost
While cobots are generally more affordable than industrial robots, they still represent a significant investment. The initial cost of purchasing and installing a cobot, as well as the ongoing costs of maintenance and programming, can be substantial. However, the long-term benefits of increased productivity, improved quality, enhanced safety and faster ROI can often outweigh these initial costs.
A Note on Cobots and Reshoring
Cobots are playing a significant role in the resurgence of manufacturing in the US, a phenomenon known as reshoring. By automating repetitive and labor-intensive tasks, cobots are helping to reduce labor costs and increase efficiency, making US manufacturing more competitive on the global stage. This has led to a growing trend of companies bringing manufacturing operations back to the US from overseas, creating new jobs and revitalizing local economies.
In the past, the biggest threat to manufacturing jobs in the US was offshoring, where companies relocated production to countries with lower labor costs. However, the advent of collaborative robots is changing this dynamic. Cobots are not only helping to create new jobs in manufacturing but also bringing back jobs that were previously lost to offshoring. This is because cobots can perform tasks that were once considered too expensive to automate in the US, making domestic production more viable.
Cobots and Industrial Robots – Your Path to Automation
While both technologies offer valuable automation solutions, their ideal use cases vary based on factors like task complexity, required speed, payload capacity, collaboration needs, and preferred ROI timescales.
As manufacturing continues to evolve, the role of both cobots and industrial robots will only become more prominent. With advancements in artificial intelligence, machine learning, and sensor technologies, these robotic systems will become even more intelligent, versatile, and integrated into the manufacturing ecosystem.
Ready to Start Your Automation Journey?
DEVELOP LLC is your partner in tackling the complexities of automation. We offer a range of resources and services to help you identify the right automation solution for your unique needs.
First, take our free Automation Assessment Questionnaire. Quickly assess your specific requirements and get guidance on personalized automation solutions. We’ll help you explore various strategies and pinpoint your ideal automation targets. With the support of a dedicated expert, you’ll be equipped to make informed decisions and maximize your return on investment.
Alternatively, download the free eBook written by the DEVELOP team, Automate to Elevate: Your Automation Assessment Guide. This comprehensive resource will arm you with the knowledge and tools you need to transform your manufacturing operations. Learn about the DIY assessment process, explore DEVELOP’s proven methodologies, and unlock the secrets of automation.
Don’t miss out on the opportunity to transform your manufacturing with automation. Contact DEVELOP LLC today or use our free resources to start your journey to a more efficient, productive, and competitive future.
About the Authors:
Matt Moseman leads as President of DEVELOP, with a strong foundation from the Milwaukee School of Engineering, where he earned both a Bachelor’s and a Master’s in New Product Management. Moseman’s career highlights include his pivotal role in founding NodeUDesign, innovating in automation hardware, and driving DEVELOP LLC to the forefront of industrial robotics with a focus on enhancing productivity and efficiency.
Sean McKittrick, as Project Program Coordinator at DEVELOP LLC, brings a multifaceted background from Knox College. McKittrick’s first year at DEVELOP LLC has been marked by significant team growth and zero turnover, showcasing his ability to build a collaborative and effective work environment. His experience spans quality management in healthcare software to managing production for a million pounds of material monthly, highlighting his diverse expertise in project coordination and manufacturing excellence.