Cobots are a significant asset in production, bridging the gap between fully manual processes and complete automation. 

But, the huge variety and complexity of cobots can leave you feeling a bit lost. This guide aims to provide a thorough understanding of these robo-assets.

Here, we’ll learn about: 

• Cobots: what are they? 
• A brief historic overview of cobots
• Key features of cobots
• 6 functionalities of cobots 
• Types of cobots
• cobots across industries
• How to use a cobot

Let’s dive right in!

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What is a cobot?

Collaborative robots, commonly known as cobots, are meant to work alongside human employees without the need for safety barriers — assuming proper risk assessment, of course. 

They are built with safety and flexibility in mind, which lets them perform a variety of tasks ranging from simple to complex while being intuitive enough for non-experts to program and handle.

Cobots have not always been as accessible as they are today. They came from industrial robots, which were often large, expensive, and confined to safety cages. 

However, the real innovation of cobots started with the idea of creating more approachable robots that could safely interact side-by-side with humans.

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A brief history of cobots

For many years, large companies and manufacturers had to use traditional robots in their warehouses and factories. 

These expensive and complex robots were specifically created for high-volume and repetitive production tasks. 

Conversely, smaller and medium companies had a clear need for low-volume, high-precision tasks performed by smaller robots. 

• The very first cobot was created in 1996 by Michael Peshkin and J. Edward Colgate. Their original cobot definition was "a device and method for direct physical interaction between a person and a computer-controlled manipulator". 
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• Since then, the cobot has been transformed into a precision machine that can perform jobs next to people.
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• KUKA Robotics released its first commercial cobot in 2004. 
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• Today, cobots have become cost-effective, user-friendly, and very versatile. They allow a variety of companies of any size and almost any industry to improve their production processes, become more efficient, and improve the quality of their products.

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Components and essential features of a cobot

1. Arms and joints

The arm of a cobot is typically what people notice first — it's the most prominent feature and signifies the reach and capability of the robot. 

Some cobots have single-arm designs, with a streamlined structure designed for tasks in confined spaces. 

Others have multiple-arm configurations for complex tasks that mimic the human coordination of using both hands.

But what truly brings a cobot’s arm to life are its joints (also known as the axis), the points that allow the arm to bend, rotate, and extend. 

These are the different types of joints in a cobot:

• Rotary joints let a cobot arm twist and turn, which is pretty much required for tasks that need rotation, like screw-driving or polishing.
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• Linear joints allow the arm to extend or retract in a straight line, vital for precision placement tasks in assembly operations.

Cobots can have between 4 and 10 joints on an arm – far exceeding the capabilities of a human.

2. End-effectors

End-effectors are the tools that allow cobots to interact with objects. They are the point of contact between the cobot and the workpiece or product, essentially the robot’s “hand”. 

The nature of the material being handled — its weight, fragility, and size — dictates the type of end-effector needed. 

Here are some types of end-effectors:

• Grippers allow cobots to pick up, carry, and put down objects. They can be customized for specific materials, shapes, and sensitivity requirements.
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• End-of-arm tooling (EOAT) lets users mount a variety of different tools on cobots, like welding torches, screwdrivers, or painting nozzles.
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• Tool changers are a new technology enabling cobots to autonomously change their tools as needed for the specific task they are working on.
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• Range extenders can be used to increase the range of a cobot along the X- or Y-axis.
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• Vision systems are becoming increasingly common and are used to scan barcodes or identify things.
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• Feeding systems are mostly used in assembly lines. Cobots use these systems to supply screws or other objects required for operations.

End-effectors change depending on the task and the robot’s payload and compatibility. 

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Sensors and safety features

Since cobots operate alongside people, safety features are necessary. 

These components serve as the cobot's sensory organs, allowing it to detect people and objects in their vicinity and ensuring safe interactions.

Most cobots are designed with ergonomics in mind, using lightweight materials, and have rounded edges. If they come in contact with a person, there’s usually less risk of injury. 

These are some of the sensors and safety measures in cobots:

• Collision avoidance sensors prevent cobots from crashing into people — they will stop when a person (or object) is near. 
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• Force and torque sensors detect and measure the force and torque applied by or to the cobot, enabling it to regulate its strength and respond to unexpected resistance or obstacles.
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• Proximity sensors use various technologies such as ultrasonic or infrared, to detect the presence of objects or people close to the cobot without physical contact.
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• Vision systems like cameras and advanced imaging sensors provide spatial awareness, allowing cobots to perform complex tasks like quality inspection or object recognition.
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• Emergency stop buttons to halt operations immediately if a hazardous situation is detected.
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• Pressure-sensitive, responsive skins that detect contact and stop movement to prevent injury.

Safety standards like ISO/TS 15066, provide guidelines on collaborative robot operation, focusing on safety measures.

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User interfaces

User interfaces are the touchpoints where human operators communicate with cobots. 

The ease of use of these UIs significantly affects the efficiency with which workers can program, monitor, and interact with the robo-system. 

Two major interfaces for cobots are teach pendants and graphical user interfaces (GUI):

• Teach pendants are handheld devices that allow operators to manually lead a cobot through desired movements, which the cobot then records and replicates. They’re typically ergonomic, with a clear display and responsive controls, ensuring that the precision of programming is not lost in translation between human and robot. 
  
  Now, a lot of modern teach pendants include touchscreens and can provide haptic feedback to guide users through programming sequences.

• GUIs with drag-and-drop functionality and visual programming languages simplify the programming process, making it accessible to users without advanced training. Some systems include simulation software that allows operators to test and refine cobot tasks virtually before deploying them in the real-world environment. 

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Software and control systems

These systems serve as the brain of a cobot, and they determine how effectively a cobot can perform tasks, respond to changes, and integrate with other digital systems in a smart factory environment. 

These are the core elements of a cobot’s control system: 

• The Operating System (OS) is the foundation on which all other software functions operate, managing the cobot's hardware resources and ensuring stable, real-time responses.
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• The programming environment provides tools for coding the cobot’s tasks, which can range from text-based languages for complex instructions to graphical interfaces for simple drag-and-drop programming. 
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• The motion control software dictates how the cobot moves, with algorithms that calculate trajectories, ensure smooth acceleration and deceleration, and correct for deviations.
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• Advanced software systems equip cobots with learning algorithms that enable them to improve their performance over time through machine learning. They are also designed with connectivity in mind to allow cobots to communicate with other machines and software systems, such as MES (Manufacturing Execution Systems) or ERP (Enterprise Resource Planning) systems.

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6 functionalities and capabilities of cobots

Getting a grip on what cobots can and can’t do is essential for deploying them successfully. 

Here are the basic cobot capabilities to keep in mind before you buy:

1. Payload

Payload capacity is the maximum weight a cobot can lift and manipulate safely. 

It's very important for tasks such as material handling, machine tending, or assembly operations where weight plays a role. 

Generally, most cobots can lift payloads to the weight of 10-20kg.

The higher the payload, the sturdier the cobot’s build must be, which can influence its size and range of motion.

Remember: You want a robot with a slightly higher payload than what you need — you need to account for the tooling and end-effector when considering the total payload a task will require. 

2. Reach

Reach is the maximum horizontal extension of the cobot arm from the base to its furthest point of extension. 

It dictates how far the cobot can access and is critical in layout planning. 

There's often a trade-off between reach and payload. A long reach may reduce payload capacity due to the increased force on the cobot's joints and motors.

3. Precision

Precision refers to the cobot’s ability to reach a point within a certain tolerance and is necessary for tasks that need a high accuracy, such as assembly or intricate welding.

Also, environmental factors, such as vibrations or thermal expansion, can affect precision. Cobots are designed with feedback systems to correct these issues and maintain consistent accuracy.

4. Speed

Speed is how fast the arm can move from point A to point B. It's measured in terms of cycle times for repetitive tasks or in degrees per second for joint movements.

While it's beneficial to have cobots work quickly to increase throughput, their speed must be regulated when sharing space with humans to avoid serious accidents. 

Speed settings can be tailored within the cobot's control software, allowing for different speeds for various phases of an operation. For example, a cobot may move quickly between tasks but slow down during precise operations or when a human coworker is nearby.

Keep in mind: Maximizing speed can increase the possibility of errors, thus lowering repeatability. Damping vibrations and controlling acceleration/deceleration is crucial.

5. Repeatability

Repeatability is the cobot’s ability to return to the same position multiple times with a high degree of accuracy, often measured in millimeters — a crucial factor for tasks that demand consistency. 

It's important to differentiate repeatability from accuracy. A cobot can be highly repeatable even if it’s not accurate to a target position, as long as it consistently hits the same incorrect spot. Both factors are essential for different aspects of task performance.

6. Adaptability

Adaptability refers to a cobot's ability to switch between different tasks without extensive downtime for reprogramming. Quick-change end-effectors and user-friendly programming interfaces facilitate this.

As operations scale or change, cobots can be reconfigured with new software, tools, or tasks. This is often as simple as updating the software or selecting new modes on the cobot’s interface. 

Cobots can also adjust to changes in the working environment, such as lighting variations, or to new positions of objects due to their advanced vision systems and high-end sensory inputs.

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Types of collaborative robots

These are the different types of collaborative robots based on how safe they are to work with humans:

• Power and force-limiting cobots: These cobots aim to be inherently safe, equipped with sensors that detect contact and either stop or limit force to minimize injury risk. They allow humans and robots to share a workspace without barriers, but task nature and environment should be considered for optimal safety and efficiency.
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• Safety-monitored stop cobots: Integrated safety sensors halt these cobots if a human enters their workspace. While effective in preventing collisions, they require a system reset to resume operation, so workflow mapping is crucial to minimize stoppages.
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• Speed and separation monitoring cobots: These cobots adjust their speed based on human proximity, slowing down or stopping as needed. This requires reliable sensors and predictive software to maintain a safe working environment.
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• Hand-guiding cobots: Operators can manually guide these cobots, making them easy to teach new tasks without complex programming. Training in manual handling and basic programming is recommended for optimal use.
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• Specialized customization (Industrial CNC machines): These machines offer high customization to meet specific manufacturing needs, unlike standard CNC machines with limited options. For example, a wind turbine blade manufacturer might need a custom industrial CNC machine with specialized tooling and software for optimal production.

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Use cases of cobots in different industries

Collaborative robots are incredibly versatile and are becoming more and more affordable, which means they are used in a range of industries. 

Below are some industries that most commonly make use of cobots today:

Cobots in manufacturing

Robots have commonly been used in the automotive industry, but they can be death traps when operating alongside people.

The built-in safety features of cobots mean they can navigate human workspaces safely without causing harm. 

For example, in the automotive industry, a cobot carrying a heavy load with sharp edges will move around slowly, completely aware of the people around it.

In the manufacturing industry, cobots are used for:

• Quality control and inspection
• Assembly
• Machine tending
• Dispensing

They can also be customized much more easily than regular bots. 

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Healthcare

Hospitals have started to turn to cobots for repetitive administrative tasks. These bots can also perform different jobs in the medical manufacturing industry, like creating prosthetics. 

Here are some common medical automation solutions:

• Lab testing
• Data entry
• Patient intake
• Billing
• Creating prescriptions
• Inventory management
• Client management
• Insurance claim processing
• Scheduling appointments
• Track vitals
• Sending out emergency alerts

A specific niche of robots in healthcare is those used in surgeries and physical therapy. Cobots can work alongside medical professionals to increase precision during operations or aid in the rehab of post-op patients. 

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Electronics

The electronics industry and tech companies have used collaborative robots for several years. These cobots are used mostly for repetitive tasks requiring precision work. 

Some examples include:

• Labeling products
• Screw driving
• Insertion of components
• Dispensing

By automating these processes, skilled workers can apply their "human-only" abilities, like strategic thinking and problem-solving, without having to focus on these tasks. 

Smaller tech companies that use cobots are able to see a total ROI in less than a year thanks to the versatility and ease of programming to customize the bots. By using cobots, they are much more productive, with lower production costs, while meeting customer demands.

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Metal fabrication

Companies working with metals make use of cobots for a variety of applications, including:

• Machine tending
• Welding
• CNC
• Press brakes
• Die-casting
• Dial tables

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Polymers and plastics

Companies in the plastics and polymers industry have to inject molds repeatedly and work with materials at melting points or consisting of harmful chemicals. 

This work is not only dangerous for human workers, but it can also be quite stressful due to the precision involved.

Cobots are used in this industry for: 

• Palletizing
• Polishing
• Injecting molds
• 3D printing
• Loading and unloading

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Food and drink

The food and beverage industry often uses cobots in harsh working environments, like humid greenhouses or freezers. 

Cobots can also work around the clock, which is helpful if there is a high production volume.

In the food industry, cobots can further be used for:

• Labeling
• Packaging
• Machine tending

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Science

The scientific research community is often at the forefront of new discoveries, so it should come as no surprise that this industry has wholeheartedly embraced the use of collaborative robots. 

Cobots are also used in laboratories to automate experiments. This is especially useful in dangerous labs where there is the risk of harmful contamination.

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Other industries

As is clear from the above, collaborative robots can be used in various industries, and also in various ways within each industry. As cobot technology continues to advance, so does cobot application.

Some other industries that are starting to use cobots include:

• General manufacturing
• Packaging
• Agriculture
• Furniture and equipment
• Chemical

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How to implement a cobot

Implementing collaborative robots (cobots) into a production line or workplace involves strategic planning and consideration of various factors.

First, go through this checklist: 

1. Assess and define: Review and document current processes to identify repetitive, labor-intensive, or precision-dependent tasks suitable for cobot automation.
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2. Optimize before automating: Streamline existing processes to eliminate inefficiencies before automation. Automation should enhance an already optimized process, not complicate an inefficient one.
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3. Choose the right cobot: Use the detailed jobs and requirements to choose a cobot with the appropriate payload, reach, precision, speed, and repeatability. The right cobot company is going to make all the difference here. 
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4. Test before you invest: Consider a trial period with a demo unit to test the cobot's performance in real-world conditions and ensure it meets operational needs before full integration.
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5. Design a cobot-friendly workspace: Design the workspace to accommodate the cobot, considering factors like the reach of the cobot arm and the safety of human workers.
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6. Prioritize safety: Implement necessary safety measures, including sensors and programmable safety zones, to prevent accidents and ensure compliance with regulatory standards.
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7. Train your team: Develop comprehensive training programs to educate staff on how to operate, interact with, and troubleshoot cobots. Some cobot manufacturers, like FANUC, offer their own training — at a price. 
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8. Engage with employees early: Address concerns and highlight the benefits of cobots, such as reducing the strain of manual labor and upskilling opportunities.
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9. Make sure you get good integration: Make sure the chosen cobot can be integrated with existing machinery and software systems, minimizing disruption to current operations.
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10. Set up data infrastructure: Set up the necessary data infrastructure to support cobot functionality, including machine learning capabilities and data analytics for continuous improvement.
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11. Set KPIs: Establish key performance indicators (KPIs) to measure the impact of cobot implementation on productivity, quality, and ROI.

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Summing up

The integration of collaborative robots into various industries marks a significant stride toward a more efficient, flexible, and productive future. 

Cobots stand as major catalysts for growth, not merely through their operational contributions but also by fostering an environment of continuous learning and adaptation. 

But remember: They are not a replacement for the human workforce but a complement that can drive innovation.

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Next steps

Looking to scale your operations with a high-end cobot? Enter RO1 from Standard Bots — the top choice for both burgeoning startups and established industrial giants alike.

• Affordable and reliable: RO1 leads its class of robotic arms, delivering unparalleled value at half the cost of its nearest competition.‍

• Fast & robust: Despite sporting a best-in-class payload of 18 kg, RO1 outpaces rivals in both speed and precision.‍
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• Intelligent adaptability: With learning AI-powered capabilities (on par with GPT-4), RO1 outshines the competition in both brains and brawn. No programming knowledge required, thanks to its intuitive no-code framework. 

• Built-in safety: Equipped with safety sensors and collision detection, RO1 ensures secure and dependable operations right on your shop floor.

Get in touch with our expert teamnow to initiate a complimentary, 30-day onsite trial and get tailored guidance for a seamless RO1 deployment.