What Are Industrial Robots?
Get to know all the what’s and why’s
Industrial robots are already an integral part of modern industries, helping firms automate processes and enhancing productivity. These mobile industrial machines are designed to execute tasks that are often repetitive, labor-intensive, or even dangerous for human workers to carry out.
In this article we will explore all the what’s and why’s of industrial robots, and dive into how they work, the different types, the benefits and costs of industrial robots. By reading this article, you will learn:
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Understanding industrial robots
Industrial robots are programmable machines capable of performing a wide array of tasks in different industries with precision and consistency. They range from simple robotic arms used in assembly lines to advanced autonomous robots that navigate and operate in dynamic environments. The main goal of deploying industrial robots is to automate tasks that are either too mundane or too risky for human workers, thereby improving operational efficiency and safety.
The definition of industrial robots
Industrial robots are automated machines that perform repetitive tasks like assembly and material handling in manufacturing, logistics, and warehouses.
How do Industrial robots work?
The functioning of industrial robots varies widely depending on their type and purpose. Some industrial robots are highly specialized, with machine learning or vision systems that allow them to handle complex tasks like quality inspections or intricate assembly, while others perform more straightforward, repetitive tasks with little need for complex decision-making. The variety in industrial robots reflects the diversity of industries they serve, from simple pick-and-place operations to dynamic, intelligent systems capable of adapting to unpredictable environments. Later in this article, we will explore the functionalities of the most common types of industrial robots.
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The evolution of industrial robots
The journey of industrial robots began in the 1950s when the first programmable robot, Unimate, was introduced in the automotive industry. These early robots were primarily used for tasks such as welding and material handling. Over the decades, technological advancements have led to the development of more sophisticated robots capable of executing a broader range of functions.
What types of industrial robots are there today?
Industrial robots come in various forms, each designed to cater to specific applications within different industries. Here, we explore the main types of industrial robots:
1. Autonomous mobile robots (AMRs)
AMRs represent the next generation of industrial robots. AMRs use advanced sensors, cameras, and software to navigate autonomously. They can adapt to their surroundings, avoid obstacles, and choose the most efficient path to complete their tasks. This flexibility makes them suitable for dynamic environments where changes are frequent.
At MiR, we specialize in Autonomous Mobile Robots (AMRs) - a type of industrial robot known for its adaptability, flexibility, and efficiency. Our robots not only help streamline operations - our AMRs also enable various industries to operate smarter and safer.
What to know: AMRs do not require extensive infrastructure modifications, making them easier and more cost-effective to implement. They can be programmed for a variety of tasks and can operate in tandem with other robots or human workers, enhancing overall productivity.
2. Automated guided vehicles (AGVs)
AGVs are designed to transport materials from one location to another within a facility. They follow predefined paths using magnetic strips, sensors, or other guiding mechanisms. AGVs are ideal for tasks that require consistency and are performed in a controlled environment with minimal changes. Learn the key differences between AMRs and AGVs to see which type fits you best.
What to know: One of the main limitations of AGVs is their lack of flexibility. Since they rely on fixed paths, any changes to the production layout or tasks require reprogramming and reconfiguring the guiding infrastructure, which can be costly and time-consuming.
3. Robotic arms
Robotic arms are perhaps the most common type of industrial robots. They are widely used in manufacturing for tasks such as welding, painting, assembling, and material handling. A robotic arm mimics the movements of a human arm and can be programmed to perform repetitive tasks with high precision. These robots are typically stationary and operate within a defined workspace.
What to know: Robotic arms can be useful in automotive assembly lines for welding and assembling car parts, in electronics manufacturing for placing components on circuit boards, and in packaging industries for sorting and packing products.
4. Collaborative robots (Cobots)
Cobots are designed to work alongside human workers in a collaborative environment. They are equipped with advanced sensors and safety features that allow them to detect and respond to human presence, ensuring safe operation. Cobots are typically used for tasks that require human-robot interaction, such as assembly, inspection, and packaging.
What to know: Cobots are designed with safety as a priority. They can detect when a human is nearby and either slow down or stop to prevent accidents. This feature makes them ideal for applications where human workers need to interact with the robot frequently.
5. Articulated robots
Articulated robots have multiple rotary joints that provide a greater range of motion. This type of robot is commonly used in tasks that require complex movements, such as welding, painting, and assembly. The flexibility of articulated robots allows them to operate in confined spaces and perform intricate tasks with high precision.
What to know: Their complex design can make them more expensive and challenging to program and maintain compared to simpler robots. They also require precise calibration to ensure accuracy, which can be time-consuming.
6. SCARA robots
Selective Compliance Assembly Robot Arm (SCARA) robots are designed for tasks that require fast, precise movements in a horizontal plane. They are commonly used in assembly, packaging, and material handling applications. SCARA robots have a rigid structure that provides stability, making them suitable for tasks that require high-speed and accuracy.
What to know: The design of SCARAs limits them to tasks on a single plane, restricting their versatility compared to multi-axis robots like articulated arms. This makes them less suitable for operations requiring more complex or three-dimensional movements.
What are the advantages of industrial robots?
The integration of industrial robots into various industries brings numerous advantages, making them indispensable assets for modern businesses. Here’s the 6 key advantages:
1. Increased efficiency
Industrial robots operate at a higher speed and with greater precision than human workers. They can perform tasks continuously without fatigue, leading to increased productivity and shorter production cycles. By automating repetitive tasks, robots free up human workers to focus on more complex and value-added activities.
2. Cost-effectiveness
While the initial investment in industrial robots can be significant, the long-term savings they offer make them a cost-effective solution. By automating tasks, businesses can allocate employees to other important tasks, minimize errors, and increase overall efficiency. Robots also ensure precise handling and production processes, minimizing errors that lead to material waste. By automating tasks, they also streamline workflows, optimizing resource usage and reducing inefficiencies in manufacturing operations.
As you consider the variety of industrial robots available, it's important to note that certain types, like AMRs, offer a particularly fast return on investment (ROI). With their ability to significantly boost productivity and reduce labor costs, the initial investment in AMRs can be quickly recouped, often within just a few months of implementation. We'll explore more on AMR-specific ROI later in this article.
3. Enhanced safety
Safety is a major concern in industries that involve hazardous tasks or environments. Industrial robots are designed to operate in conditions that may be dangerous for human workers. They can handle toxic materials, work in extreme temperatures, and perform tasks that pose a risk of injury. This not only protects workers but also helps companies comply with safety regulations.
Some industrial robots, like AMRs, are equipped with advanced safety features like sensors and cameras to navigate safely around obstacles and avoid collisions in environments with human workers. Additionally, proper training and clear safety protocols are essential to ensure seamless human-robot collaboration while minimizing workplace hazards
4. Scalability
As production demands change due to various factors such as shifts in consumer preferences, market trends, seasonal fluctuations, and technological advancements, industrial robots offer the flexibility to scale operations up or down. They can be reprogrammed for different tasks, adapted to new processes, and integrated with other systems. This scalability allows businesses to respond quickly to market demands and stay competitive.
5. Flexibility
Unlike AGVs, industrial robots like AMRs can be easily reprogrammed and redeployed for different tasks or routes. This flexibility makes them ideal for dynamic environments where production needs may change frequently. They can operate alongside human workers, handle a variety of tasks, and adapt to new requirements without extensive reconfiguration.
With advanced navigation technology, AMRs can map their environment and choose the most efficient path for their tasks. This allows them to adapt to changes in their surroundings, such as the movement of people or equipment.
6. Improved product quality
Industrial robots perform tasks with high precision and consistency, reducing the likelihood of errors and defects. This results in products of higher quality and fewer instances of rework. By maintaining a consistent level of quality, businesses can improve customer satisfaction and reduce warranty claims.
Case story: How manufacturing robots took over repetitive tasks at Honeywell Analytics
Human Collaboration. Perhaps the most significant aspect of AMRs is their ability to collaborate with humans. They can be programmed to work in tandem with human employees, taking over repetitive and physically demanding tasks. This not only enhances productivity but also allows human workers to focus on more complex and creative tasks.
“We wanted staff to get back onto the production line and drive efficiency. By bringing the MiR robots on-site, we freed up six full-time staff members to produce more, and make the line more efficient.” - Timothy Ward, Design Engineer at Honeywell Analytics
By integrating MiR's AMRs into manufacturing and production processes, businesses can achieve a higher level of efficiency, safety, and productivity. The collaborative nature of these robots ensures that human workers are supported, rather than replaced, making them an invaluable asset in the modern manufacturing environment.
What to consider when you are ready to automate internal logistics
While industrial robots offer numerous advantages, there are also several disadvantages to consider when integrating them into your operations. Understanding these limitations can help you make more informed decisions when adopting robotic solutions for your company.
1. Initial investment
Investing in industrial robots requires a substantial upfront commitment. However, this should be seen as a strategic investment rather than a cost. The initial outlay covers not only the acquisition of advanced robotic systems but also their integration into the broader production processes. This investment enables companies to significantly improve productivity, efficiency, and long-term profitability.
2. Maintenance and upkeep
Although industrial robots are designed for long-term use, they still require regular maintenance to ensure optimal performance. This includes routine inspections, software updates, and potential repairs. The cost and effort associated with maintaining a fleet of robots can be considerable. Without proper upkeep, the risk of breakdowns increases, which can lead to costly production downtime.
3. Complexity and learning curve
Implementing industrial robots involves a steep learning curve for many businesses. Operators and technicians need to be trained to program, operate, and maintain the robots, which can be time-consuming and costly. Additionally, programming complex tasks and integrating robots into existing systems require specialized skills and knowledge, which may necessitate hiring or training personnel or rely on a deployment plan.
4. Potential job displacement
One concern often raised regarding industrial robots, is the risk of job displacement. As robots take over routine or hazardous tasks, there is apprehension that the demand for human labor, especially in roles involving repetitive manual work, may decrease. Although this automation leads to significant gains in productivity and efficiency, it also raises debates about its impact on employment and the future of workforce roles in automated environments. However, robots like AMRs are designed to complement human efforts, not replace them. This collaboration allows workers to shift their focus to higher-value tasks that involve strategic thinking, problem-solving, and creativity, fostering a more balanced and efficient workplace where technology and human capabilities enhance each other.
5. Safety risks
Although industrial robots are designed with safety features, they can still pose risks if not properly managed. For example, articulated robots have powerful moving parts that can cause injury if safety protocols are not followed. Additionally, in environments where robots and humans work in close proximity, there is always a risk of accidental collisions. Ensuring safety requires adherence to guidelines, regular training, and the implementation of fail-safes.
6. Dependence on technology
Relying heavily on industrial robots also introduces a dependence on technology. If there are software bugs, power outages, or network issues, production can come to a halt. This dependence makes it crucial to have robust support systems, including backup power sources, regular software updates, and a skilled team to handle technical issues.
Understanding these disadvantages is key to effectively implementing industrial robots. By weighing the benefits against the limitations, businesses can develop strategies to mitigate potential drawbacks, ensuring a more successful integration of robotic automation.
What industries can benefit from using autonomous mobile robots?
Industrial robots are utilized across a multitude of industries, each with unique requirements and challenges. The adaptability of these robots makes them invaluable assets in various sectors.
Automotive industry
In the automotive industry, robots are used extensively to enhance production efficiency and quality. They handle tasks such as welding, painting, and assembly, which are not only repetitive but also require high precision. Mobile robots, like those from MiR, have improved assembly line operations by automating the transportation of heavy components for FORD, Megatech Industries, and more.
Example: In a typical automotive plant, AMRs can transport car parts between different sections of the assembly line, ensuring a seamless flow of materials and reducing the need for manual labor. This not only speeds up production but also minimizes the risk of workplace injuries.
Fast-moving consumer goods (FMCG)
The FMCG industry is characterized by high-speed production and a constant demand for efficiency. Industrial robots play a crucial role in optimizing inventory management, streamlining order processing, and enhancing overall operational agility. By automating these processes, businesses can maintain high standards of safety and quality while meeting the fast-paced demands of the market.
Example: Australian Kinrise Snackfoods invested in four MiR robots to automate the palletizing process, ensuring that products are accurately tracked and transported. This has helped reduce the likelihood of errors and ensures that inventory levels are maintained. By using the AMRs from MiR, Kinrise Snackfood can keep internal logistics running 24 hours a day, six days a week, handling hundreds of pallets and covering 10’s of thousands of kilometers within the facility.
Logistics & 3PL
In the logistics and 3PL sectors, industrial robots are transforming traditional warehousing and distribution processes. They automate tasks such as picking, packing, sorting, and transporting goods, facilitating precise inventory control and efficient space utilization. This automation helps address critical issues such as time management, error reduction, and the need for rapid response to customer demands.
Example: By deploying AMRs in warehouses, TTI and FM Logistics can now significantly reduce the time required to fulfill orders. The MiR robots can navigate autonomously through the warehouse, selecting and transporting items to the packing area, thus speeding up the order fulfillment process.
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Discover real-world use cases from leading companies and learn from their experiences with industrial robots.
Electronics industry
The electronics industry requires meticulous precision in handling delicate components. Industrial robots assist in assembling intricate parts, reducing the margin of human error, and enhancing overall production quality. They also contribute to creating a safer working environment by handling hazardous materials and performing tasks that could pose a risk to human workers.
Example: AMRs equipped with precision tools can assemble small electronic components with high accuracy. This ensures that each product meets the required quality standards, reducing the need for rework and minimizing production costs. Companies like Kimball Electronics and Vestfrost Solutions have already experienced healthier working conditions and fewer bottlenecks.
Healthcare and pharmaceuticals
In healthcare and pharmaceutical industries, robots are used for tasks such as transporting medical supplies, sorting medications, and assisting in laboratory automation. They help ensure the safe and timely delivery of critical items, reduce human contact with hazardous materials, and maintain high levels of hygiene. AMRs can automate the movement of samples and reagents within a laboratory, improving efficiency and reducing the risk of contamination. This is particularly important in environments where precision and cleanliness are paramount.
Example: Transporting packaging materials is a tedious and labor-intensive process. In Novo Nordisk on a typical working day, it took more than five hours for the forklifts to deliver materials, and more than eight hours in extremely busy production times. By investing in five MiR500 AMRs have improved the warehouse logistics within the Chinese plant for Novo Nordisk.
Other industries
Industrial robots are also making an impact in sectors like agriculture, construction, and the textile industry. In agriculture, robots assist in tasks such as planting, harvesting, and sorting crops. In construction, they are used for brick-laying, welding, and material transport. In the textile industry – or any other industry -, robots are being deployed for tasks such as transportation of heavy loads.
Example: Five MiR1000 AMRs at Florisa’s textile plant in Brazil have increased fabric transport capacity by 122%, from 90 to 200 tons daily, improving productivity and safety. This upgrade has also eliminated previous storage issues.
Why choose Mobile Industrial Robots?
We offer a range of advanced AMRs designed to meet the diverse needs of various industries. Our robots are known for their superior navigation capabilities, adaptability, and ease of integration. Here’s why you should consider choosing MiR for your industrial automation needs:
Superior navigation and intelligence
Our AMRs are equipped with state-of-the-art navigation systems that allow them to operate autonomously in dynamic environments. They use a combination of cameras, sensors, and laser scanners to construct maps and navigate safely around obstacles. This ensures that material flow remains uninterrupted, optimizing productivity.
Dynamic routing: Our robots can dynamically adjust their routes based on real-time changes in their environment, such as the presence of obstacles or changes in the production layout. This ability to adapt on the fly makes them ideal for dynamic and complex environments.
User-friendly interface and integration
MiR robots are designed with ease of use in mind. They feature an intuitive interface that allows operators to control and configure the robots with minimal training. The robots can be easily integrated into existing workflows and systems without the need for extensive modifications.
Fleet management: MiR offers a fleet management system that allows businesses to control multiple robots simultaneously. This system can prioritize tasks, assign missions to robots based on their availability and position, and monitor the status of each robot in real-time.
Flexibility and adaptability
One of the key advantages of MiR AMRs is their flexibility. They can be reprogrammed for different tasks and environments, providing a versatile solution for businesses with changing production needs. Whether it's transporting materials, assembling products, or managing inventory, MiR robots can be adapted to a wide range of applications.
Customizable top modules: MiR offers customizable applications that can be added to the robots for specialized tasks. These modules include conveyor shelf carriers, hooks, and lifts, allowing businesses to tailor the robots to their specific needs.
Safety and compliance
Safety is a top priority at MiR. Our robots are equipped with advanced safety features, including sensors and cameras that allow them to detect and navigate around obstacles. They are designed to operate safely in environments with human workers, reducing the risk of accidents and injuries.
Safety certifications: Our AMRs are built to comply with international safety standards and certifications, ensuring that they can be deployed in a wide range of environments. This includes they are built to comply with ISO 3691-4, which sets the safety requirements for driverless industrial trucks.
Rapid ROI and cost-effective investment
Investing in our AMRs offers a rapid return on investment, often within a year. The efficiency gains, labor savings, and reduced operational costs provided by our robots make them a financially sound choice for businesses looking to improve their operations.
Want to know more about your options?
If you're interested in learning more about how MiR's industrial robots can benefit your business, we invite you to contact our team of experts. We are here to answer your questions, provide demonstrations, and guide you through the process of integrating AMRs into your operations. Contact us today to take the first step towards a more automated and efficient future.