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Collaborative robots, or cobots, are transforming workplace safety by working directly with humans in many different settings. These advanced robots reduce risk by taking on repetitive and hazardous tasks, allowing workers to focus on safer, more complex activities in manufacturing, warehousing, healthcare, and many other industries.
Safety in the workplace is a priority across any industry, especially in manufacturing, where workers must achieve high productivity levels in a fast-paced, hazard-filled setting. Collaborative robots, called cobots, have emerged as a viable solution. Unlike traditional robots that work separately from humans, cobots work directly with humans. They are prized for their ability to rapidly perform repetitive tasks and improve overall safety and are swiftly gaining popularity throughout a range of industries.
This article explores cobots more in-depth, examining the evolution of cobots, what sets them apart from robots, their unique features and capabilities, and how they transform safety protocols in manufacturing and beyond.
Cobot is a term that means collaborative robot. It's a robot designed to work directly with humans in a shared workspace. Engineered with advanced protective features, cobots can safely operate alongside humans without extensive safety barricades.
Commonly, cobots perform physically demanding or redundant activities, reducing the risk of strain, injury, or tedium for human workers (International Federation of Robotics, 2022).
While cobots seem like a recent phenomenon, the concept was first introduced in the 1990s when engineers explored ways to make industrial robots safer. The first cobots were developed for direct physical interaction between human workers and machines.
Over the years, many more cobots have been developed and deployed. Kuka Robotics launched its first cobot in 2004, and Universal Robots, one of the world's largest robot suppliers, released its first cobot in 2008 (Wired Workers, n.d.).
Gradual advancements in artificial intelligence (AI), machine learning, and sensor technology have significantly enhanced the capabilities of cobots, making them a staple in modern manufacturing settings.
Cobots are a more collaborative form of robots, but there are significant differences between the two.
Commonly, industrial robots are large, powerful, and dangerous—often requiring physical barriers to keep human workers safe. They are programmed to perform specific tasks with precision, but not with humans nearby.
Equipped with sensors and safety features, cobots can detect and respond to the presence of humans, making them safe for use in more settings (Robotics Business Review, 2021).
Common features and components of cobots include:
Cobots are built with advanced sensors to recognize humans and other objects in their environment to prevent collisions, accidents, and workplace injuries (U.S. Department of Labor, Occupational Safety and Health Administration, 2021).
The tooling or attachments at the end of a cobot's arm can include grippers, welding torchers, paint sprayers, or any other work utensils. This EOAT can be attached to a single-arm or multi-arm configuration (up to 10 joints), far exceeding human capacity, dexterity, and precision (Standard Bots, October 2023).
Cobots usually come with intuitive user interfaces that allow non-programmers to program and control the robot with minimal training, commonly with teaching pendants or guided user interfaces (GUIs).
Teaching pendants rely on haptic feedback. These handheld devices allow users to manually teach desired movements that cobots record and replicate.
A GUI typically has drag-and-drop functionality, simple visual navigation, and easy features for non-programmers to complete tasks through clicks, taps, or simple drag-and-drops. Many GUIs include simulation software, which allows operators to test and refine cobot tasks before deployment.
Cobots are typically smaller, lighter, and more flexible than traditional robots, allowing them to easily integrate into workspaces.
Many modern cobots use AI and machine learning to continuously adapt to changing tasks and environments, which improves their efficiency, safety, and general usefulness over time (National Institute of Standards and Technology, 2022).
Cobots have several advanced safety features that are ideal for working directly with humans (Standard Bots, October 2023).
These include:
Cobots also adhere to safety standards like ISO/TS 15066, which provides guidelines on the safe use of collaborative robots.
Beyond increased productivity and worker safety, cobot technology presents many other advantages.
Cobots are generally less expensive to deploy and maintain than traditional robots, making them a more cost-effective solution for manufacturers. Additionally, cobots bring incredible scalability and versatility as they can be easily reprogrammed for near-endless tasks on the production line.
As technology advances, the role of cobots in manufacturing will likely grow. Future adaptations may include more sophisticated AI, enhanced human-robot cooperation, and broader usage of cobots in even more complex and varied tasks across more industries.
And while workers fear losing their jobs due to this technology, labor shortages are expected to drive market demand for cobots. Some expert analysts predict 20-30% growth in the cobot market from 2025 to 2026 (Tech Target, n.d.).
Industries like automotive, electronics, manufacturing, healthcare, and logistics benefit significantly due to their flexibility and safety features (International Federation of Robotics, 2022). In the future, cobots may be used more widely in other industries, such as agriculture and retail.
While there are significant upfront expenses, cobots are generally more affordable and cost-effective in the long run than ‘traditional’ robots (Robotics Business Review, 2021; PFA Incorporated, February 2024).
Cobots are meant to work alongside humans, not replace them. They’re designed to handle repetitive, dangerous, or hazardous tasks, allowing workers to focus on safer, more complex, and creative aspects of their jobs (Occupational Safety and Health Administration, 2021).
How much are you willing to spend? This is the short answer, but in reality, costs can vary dramatically based on budget and needs. Even one component, such as end-of-arm tooling, can significantly impact total cost.
According to Tech Target, cobots typically cost between $10,000 and $50,000 (Tech Target, August 2023).
Deploying cobots for machine tending and other manufacturing tasks requires a blend of planning, technical understanding, leadership buy-in (and sustained enthusiasm), and strong organizational communication. Experts recommend focusing on tasks that promise quick returns on investment (ROI) and avoiding overly complex projects.
Here are some key planning considerations:
Understanding a cobot’s limitations and safety needs is another crucial step. Cobots improve safety immensely, but they alone aren’t inherently safe. You’ll need to implement safety measures like force limiting and emergency protocols, as well as conduct a thorough risk assessment.
Finally, strong communication and early buy-in from a cross-departmental team are crucial. Beyond leadership, involve engineers, managers, department leads, and operators early in the process to build enthusiasm and avoid surprises down the line. Regular updates, clear goals, and a solid training plan are essential for a successful rollout. Keeping the team engaged—maybe even by letting them name the cobot—can foster ownership and boost morale as you celebrate successes, learn from any setbacks, and continuously improve to ensure long-term cobotic success.
