Robot-based Automation: 3 Tips for a Time and Cost-efficient Implementation

Silke Glasstetter, Head of Marketing | ArtiMinds Robotics GmbH

05/24/23, 05:39 AM

Using robots is almost always worthwhile for companies. They can reduce labor costs, relieve
employees, and make production more flexible - because the required batch sizes are becoming
smaller and production processes more individual. In addition, a robot or cobot offers another
major advantage: it can work without breaks and fatigue, thereby increasing product quality and
reducing scrap. 

With modern robot systems, almost all processes can now be automated. Usually, robots take
over simple, dirty, monotonous, physically demanding, or even dangerous tasks. However, with
the right hardware and, above all, software, very complex or particularly demanding tasks, so-
called "Advanced Robotics" applications, can also be solved. Examples of this include the
assembly of flexible and bendable components such as cables, wires, or hoses or force-controlled
surface processing. 

Following the no-code/low-code trend, there are various software solutions on the market that
enable graphical and therefore simplified and faster programming. The advantage is that no
special programming skills are required. The portfolio ranges from manufacturer-specific
solutions to independent offerings that can be used to program robots from different
manufacturers with one single software. Especially in the latter case, experts recommend using
tools that automatically generate native robot code for the particular robot controller instead of
controlling the robot arm via a separate IPC. 

No-code/
low-code tools simplify and speed up robot programming thanks to their template-based
approach; Source: ArtiMinds Robotics GmbH
In the first case, users remain flexible when it comes to adjustments or optimizations during
operation and avoid a lock-in effect, as they can continue to program the robot in the traditional
way using line code even without using the software. 

Whether with external engineering tools or line code, there are factors on the path to robot-based
automation that users often underestimate and therefore do not pay enough attention to. How to
avoid three of the most important stumbling blocks will be briefly explained below.

Advanced robotics applications such as the assembly of flexible cables pose a major challenge
for classical robot programming; Source: ArtiMinds Robotics GmbH

FACTOR 1: PROGRAMMING EFFORT 

The time required for programming an application is usually not underestimated, but there are
other pitfalls in this phase: for example, process tolerances and variances that have not been
taken into account or the increased complexity when incorporating sensors or establishing a
communication between the robot and a PLC. In addition, programming a system is often a
tailor-made and complex solution that is difficult to adapt. Moreover, programmers often have
their own style, which can make the resulting code or program difficult to understand and modify
for other programmers. At this point, the market supports the user with the aforementioned no-
code/low-code solutions. For example, with pre-defined function blocks, programs can be
constructed and structured in a clear and understandable manner for others. Process tolerances
and variances can also be automatically compensated, analyzed, and optimized by using the right
software. If the corresponding interfaces are already integrated, the effort required to connect
sensors or set up a PLC communication is also immensely reduced. 
 

FACTOR 2: EFFORT DURING COMMISSIONING 

A rule of thumb states that the cost of the robot itself is only about one-third of the initial cost of
the cell, and experience shows that around 45 percent of the typical costs are incurred during
ramp-up. This is because users often underestimate the time required for commissioning.
Although the system is programmed offline and simulated throughout in advance, differences
between theory and practice often become apparent during commissioning. 

Thus, despite good preparation, the process can take significantly longer than planned, and
adjustments and changes can quickly become expensive In addition, factors that were not
apparent during digital preparation now need to be addressed on-site during commissioning. This
makes this phase difficult to calculate. With consistent tools, the ramp-up can be implemented in
a controlled manner and without great loss of time, so that this phase does not become a cost
driver. It is important to combine simulation, programming, sensors, and data analysis in one
single software package. This way, the engineering chain becomes consistent without the user
having to compromise on functionality. 

This makes changes and adjustments faster, more flexible and easier. With ideally automatically
generated robot code and the ability to transfer teach points back from the real robot into the
software, such a solution integrates seamlessly and optimally into existing commissioning and
maintenance processes. This also offers the greatest flexibility in terms of online and offline
programming, allowing the user to choose the best option and easiest way for the respective task.
 Programs can be structured and made traceable using pre-defined function blocks. Before
commissioning, the process can be simulated as realistically as possible in a 3D simulation
environment and tested; Source: ArtiMinds Robotics GmbH

FACTOR 3: CHANGES DURING THE LIFECYCLE OF THE CELL

Even when the robot is running, there is still a danger that is often not considered: Over the
system runtime, numerous changes in general conditions can occur that require adaptation of the
programming. 

These can be vibrations and shocks, for example caused from forklifts or other machines, wear
and tear of tools, replacement parts that react differently than the previous components, changes
in workpiece batches, and the space available in the hall or a change of the operating personnel.
Changed lighting conditions and temperature conditions or the difference between a cold-started
and warmed-up robot can also have an impact. 

Software that standardizes and simplifies programming allows the user to react simply, quickly,
and flexibly to these and many other changes and to make necessary adjustments in the program
itself. If the worker uses a tool that also makes changes or the resulting consequences visible
early on in terms of forces, cycle times, or defects and quality, it becomes easier to analyze and
derive possible optimizations, which makes the user best prepared.

αSTEP Electric Gripper EH Series - AZ Series Equipped

The EH Series is a electric gripper based on a rack-and-pinion mechanism equipped with an AZ
Series motor. Its delicate grip, like that of a human hand, assists in automation and labor-saving.

 Provides Delicate, Human-like Grip for Robotic Applications

 Built-In battery-free absolute sensor, for constant monitoring of motor position information
without an external sensor
 High reliability with closed loop control
 High efficiency technology reduces motor heat generation and saves energy
 AZ Series Driver (DC Input) required*

Mechanical Absolute Encoder

Max.
Max. Push
Grip Stroke Backlash
Actuator Size Speed Speed
Force (mm) (mm)
(mm/s) (mm/s)
(N)
Electric Gripper
EH3

15 156 20
0.2
36 mm 7 (7.5 each (78 each (10 each
(each side)
side) side) side)
 25 156 20
0.1
46 mm 25 (12.5 each (78 each (10 each
(each side)
side) side) side)

Electric Gripper
EH4

Study Course Logistics: EduArt - Your Tutor 4.0

Robot Platform

Industry 4.0 and Intralogistics 4.0 are changing the production environment long term. The need
for autonomous guided vehicles (AGVs) and autonomous mobile robots (AMRs) as well as the
requirements on them are becoming more and more complex. In order to enable the industry to
keep up with the latest trends by means of quick and cost-efficient development, Markus Fenn
and Prof. Dr. Stefan May have developed "EduArt," a learning and prototyping platform that
relies on FAULHABER motors for drives.

How did your robot platform come about?

It started as a result of an inquiry from a company to Prof. Stefan May. The company needed a
platform to educate and train their employees on mobile robotics. Subsequently, we developed
“EduArt” together. In addition to the robot platform, EduArt Robotik GmbH provides a range of
teaching and service offerings for testing and optimization.

What makes your robot platform unique?

The robot is about 40 x 40 x 15 cm in size and weighs almost 8 kg. The platform offers simple
rubber tires as well as mecanum wheels. These allow the robot to turn on the spot, drive
sideways or diagonally. This enables exact positioning and navigation in very tight spaces. The
rubber tires are mainly used for testing in outdoor areas or in rescue robotics, but only in pretend
scenarios. The use of high-quality FAULHABER motors is ideal for both applications.
Interview with Markus Fenn

Furthermore, the platform has open interfaces, an integrated sensor concept with integrated
distance and inertial measuring devices, and an integrated battery management system (BMS).
This basic equipment can be expanded at the customer's request, either by us or the customer
himself. This allows the customer to, e.g., select the gear ratio of the drive, whether 72:1 or 89:1,
depending on the speed or torque required. This enables the customer to cost-efficiently test his
new concepts. But we are also helping with the implementation of application solutions.

How relevant is the use of EduArt in the industry?

AGV and AMR are becoming more and more important for automation, but unfortunately
companies are largely uninformed. The robot platform, for example, makes it possible to quickly
and easily test a new sensor system. And because the platform can virtually be expanded as
needed, it can bring the relevant knowledge into production.
The trends for AGVs and AMRs are towards more autonomy. They are becoming a
production component and work with production modules instead of conveyor belts. So
AGVs and AMRs work together out of necessity. Are they able to understand each other?

AGVs and AMRs have the VDA5050 standard interface and can thus also communicate with the
control center. Customers can easily test new software using a platform like EduArt, and the
results can be transferred 1:1 to large AGVs and AMRs. Applications can thus be evaluated
without much simulation, because the software essentially remains the same, whether with
EduArt or with a large system. A digital twin helps with the planning and expansion, this is
available with the platform on request.

EduArt's drive systems also have to meet the future requirements of AGV and AMR
concepts. Which drive systems do you use for the platform and why?

For our training and PoC platform we are using DC-micromotors with precious metal
commutation from FAULHABER. They are capable of generating high torques despite their
small size and are particularly power efficient. They are also easy to control and are suitable for
high-precision control loops.

For larger platforms, we use large DC-motors from the same manufacturer to enable a quick
proof of concept, e.g., easy controllability with own electronics. Where necessary and depending
on the application, we have replaced these with BLDC motors, because they are maintenance-
free and durable.

For a long time, production has been characterized by decreasing lot sizes and a greater
number of variants. What effects does this have on logistics and on the functionality of
AGVs and AMRs?

In this context robots are needed for smaller loads, i.e., smaller robots with smaller but more
powerful drives, like the high-quality drives from FAULHABER. These autonomous industrial
trucks have fewer electronics and smaller batteries, which means lower weight and decreased
energy consumption. If the loads get higher again at any time, it is easy to scale up and work as a
unit, as the robots are able to work together collision-free thanks to high-precision drives.

More functionality requires more complexity in AGVs and AMRs: What is feasible and
what makes sense in this regard?

When it comes to AGVs and AMRs, only the software is complex. What is important is the
planning, so that AGVs can work together seamlessly. To ensure that it not only recognizes
pallets, but also sees whether these are full or empty or perhaps tilted, the AGV must be as
intelligent as possible. This is where AI (Artificial Intelligence) comes into play. The complexity
will increase due to the use of AI. Our small robot is suitable for testing this efficiently.
Another trend is towards larger automated fleets. For that you need fleet management.

For this the robots have to interact with each other, “think” themselves, exchange information via
standard interfaces and, if necessary, cooperate. Whether these are small or large AGVs/AMRs
only has a small impact on the software. Short of a few different lines in the program, they are
essentially the same. The software only needs little information about the AMR. It only has to
calculate where the robot is located on the hall plan. The navigation, which is one of the few
components that knows the dimensions of the robot, then searches for the appropriate path. But
testing remains an important factor, because mobile robotics is still in its infancy and has few
standards.

In order to reach the required speed, the motor controller calculates the number of wheel
revolutions required. Adjusting this requires three lines in the program code or a configuration
file. FAULHABER supplies motors with high-precision gearheads and encoders for precise
positioning for this, which together provide optimum performance and safety.

Intralogistics 4.0/Industry 4.0 require networked AGVs and AMRs: Does the networking
take place via the cloud or is it better via the edge? And what about security and protection
from hackers?

Depending on the manufacturer, the systems can be made "unhackable" to a certain extent by
separating the hardware from the Internet. Robots have safety scanners with distance sensors so
they don't hit the wall. This means that even if hacked, no dangerous movements can be triggered
on the robot. And the process data is as secure in the network as the company network itself.  

One of the goals of the Industry 4.0 are self-organizing, heterogeneous, multimodal
systems. These require the exchange of data between AGVs and AMRs, and AI also
requires data. What are the requirements for FAULHABER components, as they also have
to collect and forward data?

This takes place via 5G or via the company's internal WLAN. The systems do not need the data
in real time because the data from the planning phase is already available. For example, the
routes and speeds are available in the system in the route planning and do not change
continuously. If the robot moves from one point to the next, a sign of life every few seconds is
all it takes. This means less data traffic and the networks are not overloaded. The available data
are compiled and evaluated on the AMR. Encoders record what is happening and ensure safe
control with the controllers. 

How safe are AGVs and AMRs?

Very safe. If one of four motors fails, the motor controller recognizes it and stops the drive. If a
person enters the driving area, this is recognized by the laser scanner and the system brakes.
These two safety levels are sufficient.

Where is research still needed for the development of future AGVs and AMRs, and how
does that impact the requirements on your test platform? At the same time, the demands
on drives are also increasing. What about the drive of the future?

Robots still have to be better networked with each other. For example, if four small robots
instead of one large robot are working on a transport task together, you need small motors that
work very precisely. Otherwise, the robot swarm will stumble or lose its synchronization. In
order to improve reliability, encoders must be absolutely immune to interference so that the robot
is not influenced by external interferences. For this reason, FAULHABER sometimes uses two
encoders on each motor.

When you combine the different motor variants from FAULHABER with gearheads, encoders,
controllers etc., you theoretically get 25 million combinations. A considerable percentage of
which has already be realized by FAULHABER. This enables every company to find the optimal
drives for current and future uses.

Products

FAULHABER SR

Powerful rare-earth magnet

Wide operating temperature range: -30 °C to +85 °C (optional to +125 °C)

All-steel housing with corrosion-resistant coating

No cogging torque, highly dynamic performance, precise speed control

Low current and starting voltage

Extremely compact and lightweight design with integrated encoder

Details

Further information

EduArt Robotik GmbH

Industry 4.0

Industry 4.0 refers to the current trend of automation and data exchange in manufacturing
technologies. It represents the fourth industrial revolution, building upon the previous three
revolutions that brought about mechanization, mass production, and digitalization.

Industry 4.0 combines various technologies such as the Internet of Things (IoT), artificial
intelligence (AI), big data analytics, cloud computing, and robotics to create a connected and
intelligent manufacturing ecosystem. It aims to transform traditional factories into smart factories
that are more efficient, flexible, and capable of making data-driven decisions.

Key aspects of Industry 4.0 include:

1. Cyber-Physical Systems (CPS): Physical machines and devices are connected to digital
systems through sensors, allowing real-time monitoring and control.
2. Internet of Things (IoT): Devices, sensors, and machines are interconnected and can
communicate with each other, enabling seamless data exchange and coordination.
3. Big Data Analytics: Large amounts of data collected from various sources are analyzed to
derive insights, optimize processes, and support decision-making.
4. Artificial Intelligence (AI): Intelligent algorithms and machine learning techniques are
employed to automate processes, optimize performance, and enable predictive
maintenance.
5. Cloud Computing: Manufacturing data is stored and processed in the cloud, providing
scalability, accessibility, and collaboration capabilities.
6. Additive Manufacturing (3D Printing): Enables the production of complex designs and
customized products with reduced waste and faster prototyping.
7. Human-Machine Interaction: Collaboration between humans and machines through
intuitive interfaces, augmented reality (AR), virtual reality (VR), and wearable
technologies.

The goal of Industry 4.0 is to improve productivity, increase operational efficiency, enhance
product quality, and enable more flexible and customized manufacturing processes. It has the
potential to revolutionize industries across sectors, including manufacturing, logistics,
healthcare, and energy.
Integrating Industry 4.0 into robots involves incorporating digital technologies, connectivity, and
data-driven capabilities into robotic systems. Here are steps to integrate Industry 4.0 into robots
effectively:

1. Assess your current robotic systems: Evaluate your existing robotic infrastructure to
identify areas where Industry 4.0 integration can bring the most value. Determine the
functionalities, limitations, and potential areas for improvement in terms of connectivity,
data collection, and automation.
2. Enable connectivity: Ensure that your robots are capable of connecting to the internet and
other devices within your manufacturing ecosystem. This can involve equipping robots
with appropriate communication protocols, network interfaces, and software integration
capabilities.
3. Implement sensors and data collection: Install various sensors on your robots to capture
data about the environment, production processes, and product quality. Sensors such as
vision systems, proximity sensors, temperature sensors, or pressure sensors can provide
valuable information. Integrate these sensors with the robotic control system to collect
and transmit data in real-time.
4. Utilize data analytics and AI: Leverage the collected data to derive insights and optimize
robotic operations. Apply data analytics techniques and AI algorithms to analyze the data
and identify patterns, anomalies, or areas for improvement. This can include using
machine learning algorithms for predictive maintenance, process optimization, or quality
control.
5. Implement cloud or edge computing: Determine whether your robotic systems can
benefit from cloud computing or edge computing capabilities. Cloud computing can
provide scalable storage and computing resources for large-scale data analysis, while
edge computing allows for faster processing and real-time decision-making by
performing computations closer to the robots.
6. Establish a communication framework: Develop a communication framework that allows
robots to exchange data and collaborate with other robots, machines, and systems. This
can involve using industrial communication protocols such as OPC UA, MQTT, or
RESTful APIs to facilitate seamless data exchange and interoperability.
7. Implement real-time monitoring and control: Set up a monitoring and control system that
provides real-time visibility into the status of robots, production metrics, and
performance indicators. This can involve centralized dashboards or control systems that
enable operators to monitor and control robots remotely, make informed decisions, and
intervene when necessary.
8. Ensure cybersecurity measures: Implement robust cybersecurity measures to protect your
robotic systems, networks, and data from potential threats. This includes setting up
firewalls, access controls, encryption mechanisms, and regular security audits. Stay
updated with the latest security practices and address vulnerabilities promptly.
9. Foster human-robot collaboration: Enable humans to work alongside robots in a
collaborative and safe manner. Implement safety measures such as sensor-based collision
detection, force limiting, or safety-rated monitored stop to ensure the well-being of
human operators. Design robotic systems that can adapt to human presence, receive input
from humans, and collaborate on complex tasks.
 10. Provide training and upskilling: Offer training programs to educate and upskill your
workforce on Industry 4.0 concepts and the integration of robotics. Provide training on
operating, maintaining, and programming the interconnected robotic systems. Ensure that
your employees can effectively utilize the new capabilities offered by Industry 4.0
integrated robots.

By following these steps, you can successfully integrate Industry 4.0 principles into your robotic
systems, enabling them to operate as connected, data-driven, and intelligent components within
your manufacturing ecosystem.