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Robotics is developing at breakneck speed. While more and more robot manufacturers and models are entering the market, the presence of topics such as Artificial Intelligence (AI) and voice control is increasing at the same pace. Robots are becoming increasingly indispensable tools in a wide range of industries. A decisive factor in immensely expanding the range of applications for industrial robots is the integration of robotics with highly developed sensors and intelligent software solutions, which enable data processing and evaluation.
In this blog post, we will look at how and why sensors unleash the full potential of advanced robotic systems, also known as advanced robotics, and the many possibilities they open up.
While humans can see and feel thanks to their eyes and hands, robots do not have these abilities per se. Sensors act as the robot’s sensory organs and enable it to perceive its environment and react to it (in real time). Classic robots, without sensors, are limited to pre-programmed (hard-taught) sequences and cannot react flexibly to unforeseen events.
Advanced robotics systems with advanced sensor technology such as cameras and force-torque sensors enable robots to react visually and tactilely to their environment and adapt themselves or the processes to dynamic production conditions.
The use of precision sensors significantly improves the accuracy of robots. In industrial production, robots with vision sensors can recognize the position and orientation of objects and calculate the optimum pick-up position. For example, force-torque sensors enable robots to carry out force-controlled processing and assembly processes.
This also enables delicate and tactile work steps, such as the insertion of sensitive or flexible components like thin connectors or cables. This leads to shorter cycle times, higher production quality, less waste and more efficient utilization of resources.
The use of advanced sensors enables safe collaboration between humans and robots. With tactile sensors, robots can sense pressure and touch, thus controlling their forces and working collaboratively with humans. This technology opens new horizons in the manufacturing industry, allowing humans and cobots to work side by side without safety risks.
The versatility and application of industrial robots are greatly enhanced by sensors, enabling adaptation to a wide variety of tasks and complex work steps.
Tactile sensors can be used to detect forces and friction, compensating for possible tolerances. Intelligent software is required to process and analyze the data, forming the robot’s brain. Recorded sensor data also provides important information about possible causes of process errors. Slight deviations, often imperceptible to the naked eye, can quickly lead to serious production errors or slower cycle times.
Data-driven analysis is thus a crucial advantage for ensuring cost-effectiveness and efficiency in complex production processes.
By using sensors, robots in production can identify and rectify the smallest defects or irregularities in components or compensate for tolerances. For example, force control is used during end-of-line testing to ensure a correct fit by performing a tensile test.
Grinding, polishing, deburring, or painting surfaces require high precision and consistent quality. With camera systems and force-torque sensors, robots can detect defects or material differences and process the surface with force-control. Sensor-adaptive robotics enables the exact control of applied forces and the measurement of pressure or vibrations to prevent damage and achieve a uniform surface finish.
Sensors allow robots to perform assembly tasks with precision and tactile sensitivity. This is particularly crucial in the manufacturing of complex products with tolerances or numerous component variants, such as in electronic manufacturing or wiring harness assembly.
The integration of sensors is essential to fully and efficiently utilize robots for automation. Sensors not only give robots enhanced perception and the necessary finesse but also enable safe collaboration with humans.
The numerous application areas of advanced robotics in industry, from quality control to surface processing and precise assembly tasks, are driven by sensor-adaptive technologies, leading to more flexible, precise, and sustainable industrial production.
Moreover, to fully exploit the potential of sensor data, such as for detailed process analysis, optimized process flows, or automatic adjustment of motion paths, the use of the appropriate intelligent software is crucial.
With this white paper, we want to provide you with guidance for your automation plans. To help you to avoid typical pitfalls when using robots, we highlight the top 5 underestimated challenges and stumbling blocks when getting started in robotics and provide you with helpful tips and interactive checklists.
In order to maintain high repeatability and process stability even for large quantities, Primus Präzisionstechnik automated the assembly of a gear unit using a flexible robot cell. The vision- and force-controlled application was programmed with ArtiMinds RPS.
MUCH MORE THAN JUST SIMPLE ROBOT PROGRAMMING: With RPS you create cross-process standardization – from planning and programming to maintenance.
