Optimize factory robots to ensure operator safety

By definition, cobots need to work with humans. They can be installed without the use of safety cages, which both reduces installation costs and reduces the footprint of the factory or warehouse. However, this structure requires additional safety features to ensure operator safety.

95DSS2-1 Advances in torque sensors could make cobots safer and more reliable. Torque sensors are installed on each shaft of the cobot arm to measure the mechanical tension in the shaft motor and gearbox. We can program the torque to stay below a specific threshold so that the cobot automatically shuts down before a possible danger arises, avoiding injury to the operator or damage to the cobot arm itself.

As the use of cobots continues to rise, we expect further improvements in other safety features, such as proximity sensors and absolute position sensors. For example, by using an array of optical sensors and pressure sensors, an invisible fence can be built around a cobot, triggering the machine to slow down or stop immediately once someone enters the cobot’s workspace.

95DSS2-1 Ensures reliability in harsh environments

Reducing downtime and maintenance costs is critical to controlling the cost of cobots, which is one of the challenges designers face because cobots often need to work in environments that are not friendly to electronic components and moving parts. Dust, humidity, oil, heat, vibration and electromagnetic interference are common in factory and warehouse environments.

As a result, TE has designed components such as position and Angle sensors specifically for harsh environments. But designers tend to overlook other components that are critical to the reliability of cobots: cables and connectors.

95DSS2-1 Cables and connectors for axis components such as sensors and motors are usually installed inside the arm of a collaborative robot. Even with this layer of protection, it is still necessary to use specially designed industrial grade cable assemblies. While achieving the required range of motion for each arm joint, any unnecessary movement can be avoided when the arm performs repetitive tasks.

The connection gets trickier when the task involves coordinating changes between arm tools and sensing. Switching between tasks typically requires a new set of tools, including clamps, sensors, cameras, and lights, to be installed at the end of the cobot arm. In addition to the cobot arm protection, each of these components requires a power and data connection.

Since adaptability is one of the main advantages of cobots, we are committed to helping designers reduce the complexity of wiring and connectivity while maintaining functionality. We are developing solutions that combine power and data connections in a single cable, such as single Pair Ethernet (SPE). Such a single cable can provide sufficient power and data transfer rate for any arm peripheral device.

95DSS2-1 Powering the future factory architecture

The rise of cobots, which just a few years ago were either immature or overpriced, has taken automation to a new level. Cobots continue to perform more tasks instead of humans, while also helping manufacturers optimize production processes for greater efficiency and flexibility.

What we will see in the future is a manufacturing shop where modular units are configured, each with the flexibility to switch between discrete tasks or custom processes. In addition, advances in wireless connectivity technology will help factories monitor and analyze the production of each of these semi-automatic units. At the same time, the continuous development of artificial intelligence and machine learning will also help collaborative robots learn new tasks faster.

Increased levels of factory automation can meet manufacturers’ growing demands for speed, efficiency and customization, while also helping them address other challenges, including persistent labor shortages. While the evolution from semi-automatic production to full automation will still take some time, the combination of collaborative robots with seamless connectivity and enhanced intelligence technologies will be the only way to achieve this goal.