The Evolution of Robotics – Comparing Cobots to Industrial Robots

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The evolution of robotics has significantly transformed the manufacturing and industrial landscapes. Two of the most influential types of robots in modern automation are collaborative robots (cobots) and industrial robots, both of which Cyan Tec have experience of integrating into automated solutions. While both technologies aim to enhance productivity, efficiency, and precision, they serve distinct purposes and operate under different principles. This article provides a comprehensive comparison of cobots and industrial robots, focusing on their design, capabilities, use cases, safety, flexibility, and cost.

Cobots are designed to work alongside human workers in a shared workspace, offering collaboration between humans and machines. Their primary advantage lies in their ability to assist in tasks requiring a human touch, while enhancing precision and reducing physical strain on workers. Cobots are used in applications that require dexterity, adaptability, and flexibility, typically in environments with less volume or varying product lines.

Industrial robots are generally used for high-volume, repetitive tasks in manufacturing environments. They are typically larger, more powerful, and operate in isolated environments for safety reasons. These robots excel in applications requiring high speed, strength, and endurance, such as welding, painting, material handling, and assembly.

Cobots are designed with safety and ergonomics as a priority. They often feature lightweight bodies, advanced sensors, and articulated joints, enabling them to be flexible and easily programmable. Key design characteristics include:

  • Force and Torque Sensors: Integrated to detect any potential collision with humans or objects, allowing the cobot to slow down or stop.
  • Smaller Payloads: Cobots generally handle lighter loads (up to 35 kg) compared to industrial robots.
  • Ease of Use: They are designed for quick deployment and can be programmed using intuitive interfaces without requiring deep technical knowledge.
  • Human-friendly Materials: Cobots often feature rounded edges and softer materials to minimize the risk of injury.
Image courtesy of Fanuc Robotics

Industrial robots are designed for high-performance tasks and are typically larger, heavier, and more rigid than cobots. Some key design elements include:

  • High Payload Capacity: Industrial robots are capable of handling heavy loads, with some robots able to lift several hundred kilograms.
  • Speed and Precision: They are built for high-speed operations with extreme accuracy, suitable for repetitive tasks that demand consistency.
  • Dedicated Workspaces: These robots usually require a caged environment or safety barriers to prevent accidental human contact.
  • Complex Programming: Programming industrial robots often requires expertise in specialized robotic languages and software.

One of the primary features of cobots is their inherent focus on safety, a key aspect to machine builders like Cyan Tec. Cobots are built to work safely alongside humans, and several standards govern their design and operation. They incorporate advanced safety features such as:

  • Force Limiting: Cobots automatically reduce their operating speed or stop entirely if they encounter any resistance or collision.
  • Lightweight Frames: Designed with lower mass and rounded structures, cobots minimize the risk of injury.
  • Collaborative Features: Cobots can function at lower speeds or even in “co-mode” where human interaction is directly required for specific tasks.

Safety for industrial robots is ensured through physical separation from humans. Due to their size, speed, and power, industrial robots pose a significant safety risk, and they are typically fenced off or housed in enclosures with interlocking gates. Cyan Tec’s experienced team of engineer’s design and manufacture the majority of guarding enclosures to suit the specific application. Some safety features that are required when integrating industrial robots into automated systems include:

  • Physical Barriers: Guarding or fencing is used to ensure that human workers cannot inadvertently enter the robot’s workspace.
  • Emergency Stop Mechanisms: Industrial robots are equipped with emergency stop systems to halt operations if an unsafe condition arises.
  • Light Curtains and Sensors: Proximity sensors or light curtains are sometimes installed around industrial robots to detect humans entering the workspace.

Cobots are designed to be highly flexible and easily adaptable to different tasks. They are particularly well-suited for environments where production requirements change frequently.

Cobots can often be reprogrammed by non-experts via drag-and-drop interfaces or by physically guiding the robot through the desired motion. Their compact size allows them to be easily moved and redeployed in various locations.

Cobots excel in environments that require frequent product changes or customized operations, such as assembly lines in electronics or consumer goods.

Industrial robots, while powerful and precise, are generally less flexible than collaborative robots. They are typically optimised for repetitive, high-volume tasks and require more effort to reprogram or redeploy.

Industrial robots are ideal for mass production where the same task is repeated over long periods. Re-configuring an industrial robot often requires significant engineering effort, making it less adaptable for tasks that frequently change. Cyan Tec has the vital skills and experience required for the design and manufacture of bespoke and modular tooling systems that are frequently mounted to the end of a robotic arm.

Industrial robots have a rigid structure, allowing them to perform tasks at high speed and with extreme precision, making them ideal for sectors like automotive manufacturing.

As with any investment in capital equipment, the return on investment (ROI) is critical to the end user. The initial investment for cobots is generally lower compared to industrial robots due to their smaller size and lower complexity. Additionally, cobots provide faster ROI due to them not requiring extensive modifications to existing production lines or safety barriers, reducing setup expenses.

Also, due to simpler programming and setup, cobots can be redeployed quickly, minimising operational disruptions and giving the end user flexibility with their production processes. However, it is important to remember that engineering expertise is still required when integrating cobots with certain technologies such as digital inkjet printing. Cyan Tec’s impressive history in this particular field is critical to ensuring a successful project.  

Industrial robots come with a higher initial investment and often require specialised infrastructure. However, they can offer a strong ROI in high-volume environments due to their ability to work at faster speeds and with greater precision. Also, industrial robots are typically built to withstand harsh conditions and continuous operation, contributing to a long operational lifespan. Industrial robots are particularly useful in situations where repetitive, high-force tasks are required, providing the end user efficiency and cost savings over time. With industrial robots being available for many years, Cyan Tec has vast experience in the design and manufacture of bespoke and modular robotic systems.

A list of typical applications where collaborative and industrial robots can be integrated is detailed below.

Cobots:

  • Electronics Assembly: For tasks that require delicate handling and precision.
  • Packaging and Palletising: Assisting workers in repetitive yet low-force operations.
  • Inspection and Quality Control: Where human oversight and cobot precision are required.
  • Pick and Place: Sorting and organizing items in smaller production batches.

Industrial Robots:

  • Laser Manufacturing: Where welding, cutting, marking and cleaning processes are using a laser, the robot is required to be enclosed with a laser safe guard system. Although cobots can be used in laser applications, Cyan Tec’s experience predominantly includes integrating industrial robots in laser applications.
  • Automotive: For tasks like welding, painting, and assembling car parts.
  • Heavy Manufacturing: Material handling, loading/unloading, and machining.
  • Metal Fabrication: High-speed cutting, bending, and welding.
  • Pharmaceuticals: Handling hazardous materials in cleanroom environments.

As robotics technology evolves, the lines between cobots and industrial robots are beginning to blur. Advancements in AI, machine vision, and sensor technology have enabled industrial robots to become more adaptable and safer, while cobots are starting to tackle more complex, high-speed tasks. However, the fundamental differences in safety, flexibility, and collaboration still remain significant.

In conclusion, Cobots and industrial robots are both vital components of modern automation, but they serve distinct purposes. Cobots are the ideal choice for flexible, collaborative environments that are highly likely to require adaptability of the process in the future. Industrial robots, on the other hand, excel in high-volume, repetitive tasks where speed, power, and precision are paramount. The decision to implement one over the other depends on the specific needs of the operation, the nature of the tasks, and the desired level of human-robot interaction.

To discuss your Cobot or industrial robotic applications, please contact our sales team on 01509 815186 or sales@cyan-tec.com.