Whether you’re a seasoned automation expert or a business owner exploring robotics for the first time, understanding the different types of industrial robots is key to choosing the right tools for your specific needs.
This guide will explain seven essential types of industrial robots (also referred to as manufacturing robots), their applications, strengths, limitations, and how to determine which one is the perfect fit for your operations. We’ll also explore the three core principles of industrial robots and provide insights to help you start on your automation journey.
The 7 Essential Types of Industrial Robots
Industrial robots have revolutionized manufacturing and automation across various industries. They come in various forms, each with unique capabilities and applications. Here are the details on the seven essential types of manufacturing robots, shedding light on their characteristics, functions, and the industries they serve.
1. Collaborative Robots (Cobots)
Cobots, short for collaborative robots, are designed to work safely alongside humans in shared workspaces. Equipped with advanced sensors and safety features, cobots can detect human presence and adjust their movements accordingly, minimizing the risk of accidents. This collaborative nature opens up many applications where humans and robots can work together to achieve greater efficiency and productivity.
Applications of Cobots
Cobots, a type of industrial robot, find applications in various industries, including:
- Manufacturing: Assisting with assembly tasks, machine tending, and quality inspection.
- Logistics: Helping with packaging, palletizing, and material handling.
- Healthcare: Supporting medical procedures, dispensing medication, and assisting with rehabilitation.
- Agriculture: Performing tasks like picking, sorting, and packaging produce.
Strengths of Collaborative Robots
Prioritize safety, allowing them to work alongside humans without the need for extensive safety barriers.
Often, they have intuitive interfaces and simplified programming methods, making them accessible even to those with limited robotics experience.
Adaptable to various tasks, making them valuable assets in dynamic production environments.
Generally more affordable than traditional industrial robots, making them accessible to small and medium-sized businesses.
Limitations of Collaborative Robots
Factors like slower cycle times, lower payload capacity, and potential need for additional tooling or safety measures can impact the overall cost-effectiveness of a cobot solution.
Typically designed for lighter payloads compared to other types of manufacturing robots.
May operate at slower speeds to ensure safety in collaborative settings.
Cobots are best for: Companies seeking to enhance human-robot collaboration and improve workplace ergonomics, particularly in tasks requiring precision and dexterity.
Related Reading: Cobots vs. Robots: What’s Right For You?
2. Robotic Arms
Robotic arms, or articulated robots, are perhaps the most recognizable type of industrial robot. These versatile machines mimic the movements of a human arm, with multiple joints and axes of motion. This flexibility allows them to perform a wide range of tasks, from simple pick and place operations to complex assembly processes.
Applications of Robotic Arms
Robotic arms, a versatile type of manufacturing robot, have been widely adopted in various sectors, but these examples have seen widespread adoption:
- Manufacturing: Assembling products, handling materials, loading and unloading machines.
- Packaging: Filling containers, labeling products, placing items into boxes, and palletizing goods for shipping.
- Electronics: Soldering components, inspecting circuit boards, and assembling electronic devices.
Strengths of Robotic Arms
Capable of precise movements and positioning, ensuring accuracy in repetitive tasks.
Perform tasks quickly and consistently, improving production efficiency.
Can be equipped with various end-effectors (grippers, tools) to handle different materials and objects.
Offer 5, 6, or more axes of motion, allowing for complex movements and access to tight spaces.
The Limitations of Robotic Arms
While the initial investment for robotic arms can be significant, it’s important to remember they offer extremely long-term value through high uptime, consistent yields, and increased profitability.
Safety measures like fencing or light curtains are required when operating near humans.
Robotic arms are best for: High-volume production lines, tasks requiring intricate movements, and applications where flexibility is essential.
Related Reading: Robotics Safety and Innovation in the Workplace
3. Delta Robots
Delta robots (parallel robots) are used for their speed and precision. Their unique parallel arm design allows for rapid movement and accurate positioning, making them ideal for high-speed pick and place operations. These robots typically have three arms connected to a single base, forming a triangular configuration. This design enables them to reach down into a workspace from above with exceptional agility.
Applications of Delta Robots
Delta robots are versatile machines that excel in a wide range of settings, particularly those requiring high-speed and precise movements for lightweight objects.
- Food Processing: Sorting, packaging, and handling delicate food items.
- Pharmaceuticals: High-speed packaging, sorting, and inspection of pharmaceutical products.
- Electronics: Pick and place of small electronic components, and the assembly of electronic devices.
- Packaging: High-speed packaging of various products, including consumer goods and industrial parts.
Strengths of Delta Robots
Often equipped with vision systems for object recognition and tracking.
Designed to handle lightweight objects with speed and precision.
Offer exceptional accuracy and repeatability in positioning.
Can perform hundreds of pick and place operations per minute.
Limitations of Delta Robots
Can be more complex to integrate into existing production lines.
Can have a relatively small working envelope compared to other robot types.
Primarily designed for handling lightweight objects.
Delta robots are best for: Industries demanding rapid, precise automation, such as food processing and product assembly.
Related Free eBook: Boosting the Bottom Line: The Transformative Impact of Automation for Manufacturers
4. Cartesian Robots
Cartesian robots, also known as gantry robots or linear robots, are simple and cost-effective. They operate along three linear axes (X, Y, and Z), moving in straight lines to perform tasks. This linear motion makes them ideal for roles requiring precise positioning and repetitive tasks.
Applications of Cartesian Robots
Cartesian robots are ideal for a variety of applications that require precise linear motion.
- Pick and Place: Picking and placing objects in manufacturing and packaging lines.
- Adhesive Dispensing: DEVELOP LLC has extensive experience using Cartesian robots for precise and controlled adhesive dispensing applications, ensuring accurate and reliable bonding in a wide range of products.
- Assembly: Performing simple assembly tasks in various industries.
- PCB Routing: Cartesian robots are also well-suited for PCB routing tasks, offering the accuracy and speed required for cutting and shaping circuit boards with intricate patterns.
Strengths of Cartesian Robots
Excel at tasks requiring precise linear movements.
Easy to understand and maintain due to their straightforward mechanical structure.
Require minimal programming expertise compared to more complex robot types.
Often more affordable than articulated or SCARA robots.
Limitations of Cartesian Robots
Their workspace is typically limited by the size of their gantry structure.
Not ideal for tasks requiring intricate or complex movements.
Less versatile than robots with rotational joints, as their movement is restricted to linear axes.
Cartesian robots are best for: Applications requiring linear movement, precise positioning, and repetitive tasks, especially in industries where cost-effectiveness is a priority.
Related Reading: How to Maximize Automation ROI: A Manufacturer’s Guide
5. SCARA Robots (Selective Compliance Articulated Robot Arm)
SCARA robots are characterized by their unique arm design, which offers compliance in the horizontal plane while maintaining rigidity in the vertical plane. This design makes them well-suited for assembly tasks that require both speed and precision. SCARA robots typically have four axes of motion, allowing for complex movements within their working envelope.
Applications of SCARA Robots
SCARA robots, an extremely popular type of manufacturing robot, are highly sought-after for a diverse range of settings that demand both speed and precision in assembly and handling tasks.
- Assembly: SCARA robots excel in assembling intricate components in industries like electronics (circuit boards, smartphones), medical devices (prosthetics, implants), and consumer goods (toys, appliances).
- Pick and Place: These manufacturing robots efficiently pick and place objects in various processes, such as placing components on circuit boards, transferring products between conveyor belts, or sorting items for packaging.
- Packaging: SCARA robots play a crucial role in packaging operations, particularly for products that require precise placement into boxes, trays, or other containers. They can also handle tasks like labeling, sealing, and capping.
- Inspection: With their accuracy and repeatability, SCARA robots are ideal for quality control inspections. They can quickly and reliably check products for defects, ensuring consistent quality standards.
Strengths of SCARA Robots
Require minimal floor space, making them suitable for tight production environments.
Their design is particularly well-suited for horizontal assembly tasks.
Offer excellent accuracy and repeatability in positioning and movement.
Can execute tasks quickly, increasing production throughput.
Limitations of SCARA Robots
Less suited for tasks requiring intricate three-dimensional movements.
Their vertical reach is typically limited compared to other robot types.
SCARA robots are best for: Applications requiring fast, precise assembly of small components, especially in industries like electronics and consumer goods manufacturing.
Related Reading: 7 Ways Automation Improves Efficiency and Reduces Costs
6. Palletizing Robots
Palletizing robots are, as you might have guessed, specifically designed for the task of palletizing, which involves stacking and organizing products onto pallets for storage or transportation. These robots typically have high payload capacities and long reach, allowing them to handle heavy boxes and bags efficiently.
Applications of Palletizing Robots
Palletizing robots are specifically engineered to improve the palletizing process, making them indispensable in various industries where efficient material handling and packaging are crucial.
- Palletizing: Stacking products onto pallets in various industries, including food and beverage, consumer goods, and industrial manufacturing.
- Depalletizing: Unloading products from pallets.
- Material Handling: Moving heavy boxes, bags, and other materials within a warehouse or production facility.
Strengths of Palletizing Robots
Ensure consistent and accurate palletizing, reducing the risk of product damage.
Efficiently stack products onto pallets, maximizing space utilization.
Automate the labor-intensive task of palletizing, reducing the need for manual labor.
Can palletize products much faster than human workers, increasing production output.
Limitations of Palletizing Robots
Can be a significant upfront investment for smaller businesses.
Primarily designed for palletizing and related tasks.
Palletizing robots are best for: High-volume palletizing operations where speed, efficiency, and consistency are critical, especially in industries like food and beverage, consumer goods, and logistics.
Related Reading: Robotic Palletizing Systems: Automating Your End-of-Line Processes for Increased Productivity
7. Autonomous Mobile Robots (AMRs)
AMR) are a rapidly evolving category of manufacturing robots that are revolutionizing the way materials are transported and handled within factories and warehouses. These manufacturing robots are designed to navigate complex environments autonomously, without the need for fixed infrastructure or human guidance. This flexibility makes AMRs an ideal solution for a wide range of applications.
Types of Autonomous Mobile Robots
- Flying Robots (Aerial Drones): These industrial robots utilize aerial mobility to transport goods, inspect infrastructure, or perform surveillance tasks in environments that are difficult or dangerous for humans to access.
- Wheeled Carts: Wheeled AMRs are commonly used for material handling in warehouses and factories. They can transport goods over long distances, autonomously avoiding obstacles and optimizing routes.
- Autonomously Guided Vehicles (AGVs): AGVs follow predefined paths or markers, making them well-suited for repetitive tasks like material transportation in structured environments.
- AMRs with Robot Arms: By combining mobility with robotic manipulation, these AMRs can perform tasks like picking, sorting, and packing, offering a versatile solution for warehouse automation.
- Legged Robots: Legged AMRs are designed to tackle uneven terrain and obstacles, making them suitable for applications in challenging environments like construction sites or disaster zones.
- Spherical AMRs: These unique robots can roll in any direction, providing exceptional maneuverability and flexibility in confined spaces.
- Underwater Robots: Underwater AMRs are used for inspection, maintenance, and exploration tasks in underwater environments, such as pipelines, oil rigs, and ship hulls.
Applications of AMRs
The versatility and adaptability of AMRs have made them a game-changer across a wide range of industries. From streamlining operations in warehouses and factories to revolutionizing delivery and transportation, AMRs are proving their value in numerous applications.
- Material Handling: AMRs are widely used for transporting materials within warehouses and factories, optimizing workflows, and reducing labor costs.
- Logistics and Warehousing: AMRs can automate various tasks in warehouses, including picking, sorting, packing, and palletizing, improving efficiency and accuracy.
- Inspection and Surveillance: Aerial drones and other types of AMRs can be used to inspect infrastructure, monitor crops, or survey hazardous environments, providing valuable data and insights.
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Delivery and Transportation: AMRs are increasingly being used for last-mile delivery of goods, reducing delivery times and costs.
Strengths of AMRs
AMRs can be easily scaled up or down to meet changing production demands, providing businesses with greater flexibility.
AMRs can operate continuously, optimizing workflows and increasing throughput, leading to significant productivity gains.
By automating dangerous or repetitive tasks, AMRs can improve workplace safety and reduce the risk of injuries for human workers.
AMRs can navigate dynamic environments and adapt to changing conditions, making them well-suited for complex and unpredictable tasks.
Limitations of AMRs
The use of AMRs, particularly aerial drones, may be subject to regulations and restrictions in certain areas.
AMRs can be expensive to purchase and implement, making them a significant investment for some businesses.
Implementing and integrating AMRs into existing workflows can be complex, requiring careful planning and expertise.
AMRs are best for: Businesses that need flexible automation solutions for material handling, logistics, inspection, and other tasks that require mobility and adaptability.
The 3 Pivotal Principles of Industrial Robots
Industrial robots, regardless of their specific type, operate on three fundamental principles that define their capabilities and impact on various industries:
- Autonomy: Industrial robots possess a degree of autonomy, meaning they can operate independently without constant human intervention. Equipped with sensors, programming, and decision-making algorithms, these factory robots can perceive their environment, make decisions based on that input, and execute tasks accordingly. This autonomy enhances efficiency, reduces the need for human supervision, and enables robots to adapt to changing conditions.
- Programmability: One of the key advantages of manufacturing robots is their programmability. These machines can be programmed to perform a wide array of tasks, from simple repetitive actions to complex sequences of movements. This flexibility allows businesses to customize robot behavior to match their specific production needs. Advancements in programming interfaces have made it easier than ever to teach robots new tasks, expanding their versatility.
- Automation: At the heart of industrial robots lies the concept of automation. These machines are designed to automate tasks that were traditionally performed by humans. This automation can lead to several benefits, including:
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- Increased Productivity: Robots can work tirelessly, 24/7, without breaks or fatigue, significantly increasing production output.
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- Improved Quality: Robots perform tasks with high precision and consistency, reducing errors and ensuring consistent product quality.
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- Enhanced Safety: Robots can be used to perform hazardous tasks, protecting human workers from dangerous environments or repetitive strain injuries.
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- Reduced Costs: Automation can lead to cost savings in the long run due to increased productivity, reduced labor costs, and minimized material waste.
Related Reading: How You Should (and Shouldn’t) Calculate Your Return on Investment with Your Integrator
Choosing the Right Industrial Robot: Key Considerations
Selecting the right manufacturing robot for your specific needs requires careful consideration of several factors:
- Task Requirements: Analyze the tasks you want to automate. Consider factors like payload capacity (the weight the robot can lift), speed, precision, and reach. Match these requirements with the capabilities of different robot types.
- Expected Return on Investment (ROI): Evaluate your automation project’s potential return on investment (ROI). Calculate the cost savings associated with increased productivity, reduced labor costs, and improved product quality. Use the Automation ROI Calculator to get some initial insights, compare these savings with the initial investment and ongoing maintenance costs of the robot.
- Safety: Prioritize safety features, especially if the robot will work alongside humans (as is the case with collaborative robots). Ensure the robot complies with safety standards and regulations. You can find out more about the basics of robotic safety in our guide, “Robotics Safety and Innovation in the Workplace”.
- Integration: Consider how easily the robot can be integrated into your existing production lines and systems. Compatibility with your current infrastructure and software is crucial for a smooth implementation.
- Future Needs: Consider your long-term goals and how your automation needs might evolve. Choose a robot that can adapt to future changes in your production processes.
Related Reading: Choosing the Right Automation Partner for Manufacturing
Insights for Your Automation Journey
Automation can be a transformative experience for your business. Here are some insights to help guide you:
- Start Small: If you’re new to robotics, consider starting with a pilot project to test the waters. This allows you to assess the benefits of automation in a controlled environment before scaling up.
- Partner with Experts: Consult with automation specialists like DEVELOP LLC. We can provide expert guidance on selecting the right robot, integrating it into your operations, and training your workforce.
- Focus on ROI: Continuously monitor the performance of your industrial robot and track the ROI. This data will help you make informed decisions about future automation investments.
- Choose the Right Opportunity for Automation: Identify repetitive, time-consuming, ergonomically challenging, or hazardous tasks for human workers. These tasks are often the best candidates for robotic automation.
Related Reading: Choosing Your First Automation Project
Unlocking Business Growth with Industrial Robots
The world of industrial robots is rapidly evolving, and the possibilities for automation are almost limitless. By understanding the different types of manufacturing robots and their applications, you can make informed decisions to optimize your operations, enhance productivity, and drive growth.
Are you ready to transform your business with the power of automation? Take the first step towards a more efficient and profitable future by taking our Automation Assessment Questionnaire. This will provide you with valuable insights into your automation potential and help you identify the ideal robot solution for your unique needs.
To further arm yourself with the knowledge and tools necessary for successful automation, you can also download our free eBook, “Automate to Grow Your Business: A Guide to Automation Assessments.” This will allow you to make informed decisions and begin your automation journey with confidence.
Don’t miss out on this opportunity to get the full potential of industrial robots and take your business to new heights. Embrace automation today and witness the transformative impact it can have on your operations.
Have questions? Get in touch and let’s talk through your ideas.
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.