Integration of cobot into production line - collaborative robots (cobots) step by step

Estimated reading time: approx. 10 minutes

TL;DR

• Collaborative robots (cobots) allow humans to co-operate safely in a shared space.
• Careful preparation is important: analysing processes, resources and choosing the right cobot model.
• Phased implementation, including installation, configuration and training, minimises the risk of downtime.
• Cobots help reduce labour costs, improve safety and increase repeatability.
• Once in place, regular maintenance, updates and ongoing optimisation of the duty cycle are required.

Table of contents

• Why collaborative robots are the future of automation
• Preparation for cobot implementation
• Step by step: cobot integration into the production line
• The most common challenges and how to solve them
• Examples of collaborative robot applications
• After launch: maintenance and optimisation
• Summary and next steps

Introduction

Collaborative robots, often referred to as cobots, are revolutionising the approach to automating production lines. Their flexibility and safety make more and more companies decide to implement such a solution. In this article, we will explain why integrating cobots into an existing production line is becoming a key step for companies looking to streamline work, increase productivity and reduce costs. We will show you step by step what to pay attention to and how to carry out the entire process effectively. You will also learn what specific benefits you can achieve by opting for collaborative robots in your company.

Why collaborative robots are the future of automation

Collaborative robots, also known as cobots, are devices designed to work side-by-side with humans. Thanks to advanced safety systems and sensors, cobots can effectively share space with an operator, dynamically reacting to the operator's presence. Unlike classic industrial robots operating in separate protective zones, collaborative robots do not usually require extensive barriers and fences.

Among other reasons, this technology is growing in popularity:

• Reduces accidents at work thanks to built-in collision sensors.
• It is highly flexible and can be quickly rearmed for new tasks.
• It promotes optimum use of space in the production facility.
• Thanks to its modular design, it is easy to expand with additional functionalities (e.g. video systems).

At Michale Automatyka, we implement collaborative robots from SIASUN (we are its official distributor). In our experience, cobots easily find their way into various industries. It all depends on the specific needs of the plant, the anticipated number of pieces produced and the quality control requirements.

Preparation for cobot implementation

A key element prior to cobot implementation is proper preparation. Many companies skip this step or implement it very superficially, resulting in unnecessary downtime and additional costs in the future.

Preliminary demand analysis

As a starting point, assess which processes in your company are the most time-consuming, have a high incidence of human error or pose a potential risk to employees. Use data from cycle time measurements, job performance information or the number of quality defects. This is where a cobot will bring the greatest benefit and improve the efficiency of operations.

Determining available resources

The next point is to verify the resources within the company - this is about technical competence, space conditions on the production line and budget. Check whether you have employees with basic robot programming knowledge or whether training and support from an external integrator will be needed.

Step by step: cobot integration into the production line

Process analysis and goal setting

At this stage, you assess which specific jobs or processes are best automated first. For example, in a manufacturing company, this might be:

• Assembly of small components such as screws and nuts.
• Packaging of products into cartons.
• CNC machine operation (feeding and receiving of workpieces).

It is important to strike a balance - it does not always pay to fully automate every step. Sometimes a single workstation is enough to reduce bottlenecks and significantly increase overall productivity.

Choosing the right cobot model

You will find many types of collaborative robots on the market, differing among other things:

• Maximum load capacity.
• Arm's reach.
• Adaptability (additional axes, vision systems, safety certificates).

Michale Automation, through its partnership with SIASUN, helps you select the right cobot model for your specific task. For example, if your company needs to move a 10 kg workpiece over a distance of 1 metre, it makes sense to choose a machine with a slightly longer reach and lifting capacity to provide functional backup.

Assembly and configuration of the robotic workstation

Once the right model has been chosen, the time comes for detailed design. A lot depends here on the current infrastructure:

• Does the production line have enough space for new 'collaborators'?
• What additional equipment is required (e.g. grippers, rotary tables, vision system)?
• How do you secure the position so that people can move safely around the cobot?

The installation itself then proceeds. At this stage, it is also worth taking into account infrastructural connections such as the power supply or possible integration into the control system (PLC).

Programming and testing in a production environment

Once the cobot is physically installed, it is time to programme its movements and check that it behaves as intended. The basis for success will be to match the sequence of movements to the production line cycle.

• A basic programme is first created to handle key tasks, e.g. picking a workpiece from a conveyor and placing it in a designated area.
• Adjustments are then made and the performance of the cobot is tested in various scenarios: increasing the speed, checking the reaction to a collision or shutting down in the event of unexpected contact with a worker.
• Finally, performance tests are carried out to assess whether the robot meets the requirements of the production line and does not create additional downtime.

The most common challenges and how to solve them

Safety and adaptation of posts

One of the key concerns surrounding the deployment of robots, including cobots, is worker safety. Many companies are used to safety cages and barriers. Cobots have a sophisticated sensor system that should sense an approaching barrier or human limb. Nevertheless, during the design phase, it needs to be carefully established:

• What are the speed and torque limits of the cobot?
• Should additional barriers or security zones be introduced, such as traffic lights or RFID tags to detect human presence?

Team training and staff resistance

Workers are sometimes concerned that cobots may threaten their jobs in the future. Therefore, it is crucial to conduct workshops and training sessions that explain the real benefits of human-robot cooperation and identify new career opportunities (e.g. in robot programming and control).

Integration with IT systems (ERP, MES)

Today's production lines often run on sophisticated production planning (ERP) and process monitoring (MES) systems. In order to fully exploit the potential of cobots, it is worth integrating them with these solutions. This will make it possible, among other things, to:

• Automatic transfer of job performance information to the ERP system.
• Real-time monitoring of cobot performance and downtime.
• Predictive maintenance planning when the MES system sees dips in performance.

Examples of collaborative robot applications

Collaborative robots are suitable for a variety of tasks: from simple assembly to more complex processes such as welding, painting or packaging. For example:

• In the food industry, the cobot can sort and stack products in cartons, increasing hygiene and reducing human contact with food.
• In metalworking companies, such robots often help to operate grinding or polishing machines.
• In the furniture industry, collaborative robots can flexibly select tools and precisely mill wooden components.

If you want to find out more about the full range of robotisation services, it is worth visiting our robotisation services.

After launch: maintenance and optimisation

After the testing phase and the official launch of the cobot, the process is by no means over. Collaborative robots - just like classic industrial robots - require regular inspection and maintenance. This will ensure stable operation and minimise unplanned downtime.

• Regular maintenance: Checking the wear and tear of moving parts, cables and wires, as well as assessing the performance of safety systems.
• Software updates: Often, cobot manufacturers release new firmware versions that improve the robot's operation or add important functionality.
• Modifications and redevelopment of posts: Over time, a company's process may change. The Cobot should be easy to reprogram and refit to support new tasks.

To ensure top performance and trouble-free operation over a long period of time, it is worth taking a look at our range: service and maintenance of robot workstations.

Summary and next steps

Key tips and recommendations

- Define the areas in the factory that most need to be automated - the most complex process will not always be the first choice.
- Carefully verify human resources and competences. Plan training so that staff know how to use cobots to their full potential.
- When choosing a specific solution, pay attention to the lifting capacity, arm reach and compatibility with additional modules (e.g. vision systems).
- Carry out comprehensive tests in a production environment. Don't forget safety: set appropriate speed and torque limits, especially at the initial stage.
- Ensure seamless integration with existing systems (ERP, MES) to benefit from full analytics and predictive maintenance planning.

How to get started?

If you are just considering investing in collaborative robots, try to estimate the potential return on investment first and analyse which areas of production will generate the most profit. In the case of welding, it is worth visiting ROI calculator for welding robotisation.

If, on the other hand, you are thinking about complete and comprehensive automation or building new workplaces, you may also be interested in services such as robotisation of welding.

The use of collaborative robots (cobots) provides the company with tangible benefits in terms of reducing labour costs, reducing errors and standardising quality, among other things. At Michale Automatika, we develop and implement modern robotic workstations that support employees and relieve them of monotonous or potentially dangerous tasks. This allows them to concentrate on more creative and demanding activities.

Encouragement for further action

After reading the article:

• Assess whether collaborative robots will help your specific process.
• Discuss implementation options with decision-makers in the company.
• Contact a professional integrator such as Michale Automation for support at every stage of your investment.

If you have any further questions, please do not hesitate to contact us. You can also visit our other articles, which will introduce you to the topic of automation and show you the benefits of implementing modern robotics in your company.

Summary

The integration of collaborative robots into the production line is one of the most disruptive developments in modern industry. Although it requires a well-thought-out strategy, from demand analysis to phased implementation and service, it brings real results in terms of increased productivity, increased safety and significant cost reductions.

With their ability to work closely with humans, cobots combine the advantages of classic automation (precision and repeatability) with human experience and the ability to react quickly to unplanned events. In order to make this process step by step and as painless as possible, it is advisable to work with an experienced partner who not only provides the right equipment, but also takes care of comprehensive implementation and after-sales support.

We encourage you to subscribe to our news, where we share our knowledge on the latest trends in automation and robotics. We would also appreciate your comments, questions and suggestions to help us respond even better to the challenges of today's industry.

Thank you for your time and we wish you the best of luck in planning and implementing your collaborative robot projects!

FAQ

How long does it take to integrate a cobot into an existing production line?
Integration time depends on the complexity of the processes and the degree of automation. In practice, it can range from a few weeks to several months for more advanced projects.

Are cobots safe for workers?
Yes, cobots have a range of sensors and safety features. This allows them to share space with humans, sensing possible collisions and reacting immediately, for example by stopping movement.

What competences do staff need to operate a cobot?
In most cases, the basics of robot operation and programming are sufficient. Many companies offer training, and the manufacturers themselves provide intuitive software that makes configuration and modification of settings significantly easier.