Maximum Movement Flexibility
Articulated Robots
Articulated robots, also known as robotic arms, feature multiple rotary axes, most commonly 4-6. This provides an extremely broad range of motion and enables advanced operations across different planes and at almost any angle. As a result, articulated robots are used in many industries, from welding and painting to precision assembly of electronic components.
Why Consider Articulated Robots?
Thanks to their high kinematic flexibility, articulated robots can handle complex shapes and demanding processes that are beyond the capabilities of simpler designs. Their versatility, high precision, and ability to operate in difficult conditions translate into efficiency and reliability across diverse production environments.
Articulated Robots
Design and Operating Principle
Articulated robots feature complex kinematics that enable movement across multiple rotational axes. This design gives them impressive flexibility and the ability to perform a variety of tasks precisely, from simple pick & place operations to complex welding or assembly processes.
Mechanical Design
- Articulated Arms Most articulated robots have 4 to 6 rotary axes, allowing them to move in almost any plane. Each joint is responsible for a specific rotation range, and their combined operation enables complex spatial movements.
- Segments Connected by Joints The robot's elements (arms) are connected by joints containing bearings and gearboxes. This ensures smooth operation and stable movement, even under heavier loads.
- Body and Base A stable body structure, often made from steel or aluminum alloys, forms the robot's foundation. It provides balance and enables precise positioning even under dynamic conditions.
Drive and Control
- Servo Motors and Gearboxes Articulated robots commonly use servo motors that provide precise control of speed and torque. Harmonic or planetary gearboxes transmit power while ensuring high motion accuracy and repeatability.
- PLC Systems and Dedicated Controllers The robot can be controlled by an external system, such as a PLC, or by the manufacturer's integrated controller. The software continuously monitors joint positions and coordinates the movement of all axes.
- Advanced Sensors and Safety Many modern articulated robots use high-resolution encoders as well as safety systems (e.g. light curtains, guarding) to protect operators within the robot's work area.
Movement Method
- Multi-Axis Kinematics An articulated robot can execute complex trajectories by bending and rotating its arm in multiple directions. This makes it possible, for example, to align a gripper with irregularly shaped parts or reach difficult-to-access locations.
- Freedom of Manipulation The robot arm often moves horizontally, vertically, and around its own base, while additional axes control rotation of the wrist or gripper. This provides broad configuration possibilities, from simple assembly to precise welding operations.
- High Number of Degrees of Freedom enables the robot to work at different angles and in multiple planes simultaneously.
- Ability to Adjust Trajectories in real time, for example when welding curved paths.
- Easy Motion Programming even for complex tasks, thanks to intuitive offline systems and teach pendants, panels used to "teach" the robot step by step.
Key Advantages
Key Advantages of Articulated Robots
Articulated robots are valued in industry for their versatility and excellent ability to adapt to different tasks. Below are the key advantages of this design:
- Versatility of Movement Thanks to multi-axis kinematics, the robot can follow almost any motion path. It performs well in applications where flexibility matters, from handling large components and screwdriving or welding to precision painting and polishing.
- High Precision and Repeatability High-resolution servo motors and precise gearboxes enable motion repeatability at the level of hundredths of a millimeter. This is important wherever consistent quality is required (e.g. in the electronics or automotive industries).
- Ability to Handle Different Payloads The market offers both lightweight articulated robots for small assembly tasks and machines with much greater reach and payload for handling heavy components, including loads of several hundred kilograms.
- Use in Difficult Conditions Articulated robots are used in welding, painting and material processing operations where high temperatures, dust or hazardous substances are present. Appropriate covers and anti-corrosion coatings allow them to work in demanding environments.
- Easy Integration with Vision Systems Thanks to movement flexibility and support for multiple degrees of freedom, articulated robots often work with vision cameras, enabling dynamic trajectory correction or object recognition on the production line.
Industrial Applications
Articulated Robots
Articulated robots have been used across a broad range of industries and processes for many years because of their versatility. Their ability to work at different angles and in multiple planes makes them particularly valuable in the following areas:
Welding and Resistance Welding
Arc welding, MIG/MAG, TIG: Articulated robots guide the welding torch precisely along a planned path, minimizing errors and achieving high weld repeatability.
Spot Welding in the Automotive Industry: They perform very well when joining bodywork components, ensuring fast and accurate connections.
Painting and Coating
Painting applications: Multi-axis movements enable even application of paint or coating to hard-to-reach areas.
Applications in the Furniture and Automotive Industries: Through precise motion control, the robot arm ensures optimal material use and consistent finishing quality.
Assembly and Mechanical Processing
Assembly of Components with Complex Geometry: Flexible joint movements make it easier to adapt to non-standard shapes and diverse assembly positions.
Grinding, Polishing and Deburring: The robot can perform these operations repeatedly and with uniform pressure, improving surface quality and extending tool life.
Packaging and Palletizing
Handling Heavier Components: Articulated robots with higher payload capacity are well suited to handling loads ranging from tens to hundreds of kilograms, such as bags of raw material or transport crates.
Diverse Product Shapes: Thanks to rotary joints, the robot can optimally align the gripper with objects that have irregular profiles.
Quality Control and Inspection
Cooperation with vision systems: The articulated robot precisely maneuvers cameras or sensors, enabling inspection of components from different angles in 3D.
Component Testing: A robot arm can feed components to testing stations that detect defects or dimensional nonconformities.
Machine Tending
CNC Loading and Unloading: Articulated robots can easily adapt to the interiors of machining equipment, receiving and transferring materials or finished semi-products.
Injection Molding Machines and Presses: They are highly effective at intercepting molded parts, accelerating the production cycle and protecting the operator from contact with dangerous equipment.
Articulated robots
Industries Where Articulated Robots Are Most Commonly Used
Articulated robots operate in diverse conditions, from small craft facilities to advanced production lines in international corporations. Here are several key sectors:
Welding and spot welding of body components, assembly of mechanical subassemblies, painting, and surface polishing.
Machining, grinding, welding, and handling heavy components.
Robots with higher payload capacity can transport heavy parts without losing precision.
Soldering, assembly of printed circuit boards (PCBs), and handling delicate components that are sensitive to damage.
Packaging products into bulk packages, palletizing bags of raw materials, and dispensing liquid and powdered substances.
Applying labels, packaging small bottles and jars, and automated pharmaceutical packaging lines.
Handling bricks, concrete slabs and other large-format materials.
Ability to use suitable protective covers against dust and moisture.
Regardless of whether you operate an assembly line, welding station, or transshipment warehouse, articulated robots can significantly increase the efficiency and precision of your processes. Thanks to a broad payload range and multiple degrees of freedom, they work well both for delicate tasks and for handling heavy components or intensive processing operations.
Articulated robots
Technical Requirements and Integration
For articulated robots to achieve maximum performance, their operating parameters must be configured appropriately and they must be integrated correctly with the existing production line. Below are the most important aspects to consider:
Operating Parameters
Payload and Reach
The choice of robot model should depend on the weight and dimensions of the handled components and the distance over which they need to be moved. Articulated robots are available with payloads ranging from a few to several hundred kilograms.
Accuracy and Repeatability
In industries requiring high precision, such as electronics and pharmaceuticals, it is worth paying attention to movement repeatability, specified in millimeters or micrometers.
Speed and Dynamics
Excessive acceleration can lead to vibration and loss of precision, so the robot should be selected to provide an optimal balance between speed and operating stability.
Integration with Control Systems
PLC Controllers and HMI Panels
Articulated robots usually support standard industrial protocols such as EtherCAT and Profinet, making communication with PLC systems and visualization of parameters on HMI panels easier.
CAD/CAM Software and Vision Systems
In welding or assembly processes, importing motion paths from CAD/CAM software may be necessary. For quality inspection or precise positioning, integration with vision cameras is worth considering.
IoT and Remote Monitoring
Through cooperation with IoT platforms, robot operating data can be analyzed continuously and potential faults can be diagnosed remotely. Details about connectivity can be found in the Supporting Services/IoT Integration section.
Safety and Standards
Fencing and Light Curtains
Articulated robots can reach high speeds and handle heavy loads, so physical safety barriers are usually required.
ISO 10218 Standards and Risk Assessment
Installing an industrial robot requires compliance with safety standards, including ISO 10218. A risk assessment is carried out before commissioning to prevent collisions and hazards to personnel.
Articulated Robots
Comparison with Other Robot Types
Articulated robots are distinguished by advanced multi-axis kinematics, usually covering 4 to 6 axes, enabling complex trajectories and precise object manipulation. Their high freedom of movement makes them a strong choice for flexible applications such as welding, assembly and machine tending. To determine whether articulated robots best meet your process requirements, it is worth comparing them with other industrial robot types such as Cartesian, SCARA, Delta, cylindrical, collaborative cobots and Gantry systems.
Articulated Robots vs. Cartesian Robots (XYZ)
Kinematics and Range of Motion
Articulated robots can move in multiple planes, making them very effective when working around components with complex shapes. Cartesian (XYZ) robots move along three linear axes, and less commonly four, providing simple perpendicular movements. This design simplifies path programming and provides high stability for pick & place tasks across a large work area.
Applications and Performance
Cartesian robots are highly suitable for 3D printing, machining lightweight materials, or linear palletizing where high positioning accuracy along the X, Y, and Z axes is required. Articulated robots perform better in welding, painting, and applications where parts have unusual shapes or hard-to-reach areas must be accessed.
When to Choose?
If you need high flexibility and work at different angles, choose an articulated robot. If, however, you need long, straight movements (e.g. across a large production area) and simple kinematics, a Cartesian robot may be more cost-effective.
Articulated Robots vs. SCARA
Spatial Motion vs. Planar Motion
SCARA robots typically have 3-4 axes and perform very well in fast assembly operations in the horizontal plane. In contrast, articulated robots provide full freedom across multiple axes, allowing complex 3D movements such as arc welding and painting at different angles.
Applications and Dynamics
SCARA robots achieve exceptionally short cycle times in pick & place tasks, especially with small components. Articulated robots are more versatile and can work with larger payloads and handle tasks requiring complex movements. At the same time, they usually cannot match SCARA speeds in "flat" movements.
When to Choose?
An articulated robot is better when maximum flexibility and multi-plane processing capability are required. SCARA is suitable for fast assembly lines with strictly repeatable motion geometry, such as screwdriving in a single plane.
Articulated Robots vs. Cylindrical Robots
Design and Movement Method
Cylindrical robots combine linear vertical motion along the Z axis with rotation around that axis and often an additional radial reach. This kinematics is simpler than that of articulated robots but provides a more limited motion range, mainly rotation and translation along one axis. Articulated robots, by contrast, can offer up to six rotary axes, giving them substantially greater freedom of movement and the ability to adapt to unusual component shapes.
Applications
Cylindrical designs are well suited to tasks requiring axial work, such as transporting components between circularly arranged stations, dispensing liquids, or retrieving parts from a rotary storage system. Articulated robots are more versatile and can perform many different operations, including assembly and processing tasks such as welding, polishing, and packaging.
When to Choose?
If structural simplicity and exclusively rotary-linear movement are key, a cylindrical robot may be sufficient and will be less expensive and easier to maintain. If the application requires multi-plane processing and access to difficult locations, an articulated robot has a clear advantage.
Articulated Robots vs. Delta
Kinematics Characteristics
Delta robots consist of several arms attached to a common platform usually positioned above the work area. They enable extremely fast pick & place of light objects, although within a limited workspace. Articulated robots offer greater spatial reach and can work with heavier components across multiple planes.
Applications and Key Differences
Delta robots dominate in the food, pharmaceutical, and electronics industries, where ultra-short motion paths and high throughput are required, for example when sorting small products. Articulated robots perform very well in more complex tasks such as welding, machining, and painting, with payload capacities beyond the reach of most Delta robots.
When to Choose?
If your priority is packaging or sorting light components at high speed, choose a Delta robot. When you need flexibility in three-dimensional operations and work with larger loads, an articulated robot will be indispensable.
Articulated Robots vs. Gantry Robots
Reach and Design
Gantry systems are robots based on several linear axes, for example X, Y and Z, where the entire arm moves along guides mounted above the work area. This design can cover a very large area, such as an entire hall, and move heavy loads vertically. An articulated robot has a limited operating radius around its base. Although it offers greater freedom of movement around a part, it cannot cover an area as large as a Gantry system.
Applications and Areas of Advantage
Gantry robots perform very well in high-bay warehouses, when handling heavy components or in the metal industry, where large and massive parts must be moved. An articulated robot is better suited to tasks requiring more complex trajectories, such as welding, painting or multi-plane processing, and when the workpiece is relatively small and fits within the reach of its arms.
When to Choose?
A Gantry system is the best choice when you need to transport large-scale loads or use one robot to serve several distributed workstations across a large area. However, if the objective is versatile manipulation of a component along many axes and angles, for example assembly or welding, an articulated robot will generally be less expensive to install and more flexible.
Articulated Robots vs. Cobots (Collaborative Robots)
Working in a Safety Zone vs. Collaboration with People
Articulated robots usually operate in a separated area protected by fencing or light curtains because they can move quickly and handle significant loads. Cobots, or collaborative robots, are designed to work side by side with people, often without additional guarding. Their built-in force and torque sensors detect contact with an operator and automatically stop movement.
Performance and Application Range
Cobots are ideal for tasks requiring direct interaction with people, such as joint assembly of components or processes where the operator performs part of the work while the robot relieves them of the most demanding activities. Articulated robots, thanks to their higher speed and greater payload, are used in automated mass-production lines where maximum productivity matters and the operator does not need to remain in the robot's work zone.
When to Choose?
If safe human-machine collaboration is essential, for example in a company with low production volumes or frequent product changes, a cobot can be an excellent solution. However, when the priority is high efficiency and handling heavier tasks, such as welding large structures or high-speed packaging, an articulated robot clearly offers greater capability and speed.
Articulated robots are among the most popular solutions in industrial robotics, offering impressive movement flexibility in machining, assembly, and handling tasks. Under specific conditions, however, such as the need to collaborate with an operator, handle large loads across an extensive area, or perform ultra-dynamic planar work, other robot types including cobots, Gantry, Delta, and SCARA may be more effective.
We encourage you to analyze the priorities and requirements of a given application in order to select the technology that is most beneficial in terms of functionality, cost and ease of implementation. If you have any questions, please contact us. Our team will be happy to advise you on selecting the best solution for your needs.
Frequently Asked Questions
Frequently Asked Questions About Articulated Robots
The cost depends on many factors: robot size and payload, drives and gearboxes used, the need for integration with vision systems, and specific operating conditions. Prices for basic models may start at tens of thousands of PLN, while more advanced models with high payload and precision can cost several hundred thousand PLN.
Manufacturers usually recommend periodic inspections based on operating hours, for example every 6 to 12 months, during which joints, bearings, motors, and safety systems are checked. More frequent inspections may be necessary in intensive applications such as welding or machining.
More information in Service and Modernization.
Yes, provided that appropriate seals, protective coatings and ingress protection ratings (IP) are used. Some industries, such as food and chemical processing, also use special corrosion-resistant materials that are easy to clean.
Usually yes. Articulated robots have flexible software, and manufacturers provide ready-made environments for creating and modifying motion paths. Teach pendants and offline CAD/CAM solutions are often used, accelerating the implementation of new processes.
Yes. Many articulated robot models achieve repeatability measured in hundredths of a millimeter. In addition, servo motors and advanced control systems provide smooth movements, which are important when handling delicate components.
Safety fencing, light curtains, emergency stop buttons or vision systems that detect human presence in the work area are typically used. Implementation should always be preceded by a risk assessment and compliance with ISO 10218.
Often yes. Because of its versatility, a single robot can perform many tasks, such as welding, machine tending, and packaging, provided its payload and reach parameters allow it and appropriate motion sequences are programmed.
Yes. Most manufacturers offer a wide range of accessories and modules that can be mounted on the robot wrist. These include pneumatic and electric grippers, welding tools, vision sensors and measurement systems.
Do you have more questions?
Contact us or visit the FAQ section for detailed answers to all questions about articulated robots
- Experience Across Diverse Industries We have completed projects in sectors such as automotive, electronics, food, and metalworking. This enables us to select the right articulated robot model and equipment for the specific process.
- Comprehensive Approach We provide not only robot supply but also integration with existing lines, programming assistance, and employee training. Our engineering team is involved at every stage of implementation, from concept through commissioning and service.
- Innovative Technologies We work with leading manufacturers of servo motors, vision systems and CAD/CAM software, providing access to current standards of quality and performance. We are also prepared for Industry 4.0 challenges, offering IoT integration and remote robot monitoring.
- Reliable Service Support Our support does not end after commissioning. We provide regular inspections, rapid spare parts delivery, and online technical support so your production line can operate continuously and safely.
- Flexibility and Openness to Partnership At NexaRob, we believe in the value of synergy. That is why we cooperate with companies offering complementary solutions, including AI providers, manufacturers of modern grippers, and specialized software integrators. Together, we create advanced automation systems for the market.
Explore the details of our implementations and achievements in the Case Studies section, then contact us to learn how we can help improve processes at your facility.
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Global Reach
We Operate Globally, Support Locally
NexaRob operates in more than 100 countries, providing advanced technologies and service support wherever businesses need reliable and modern robotic solutions. Thanks to a broad network of distributors and regional partners, we can:
- Ensure a Rapid Response Our local specialists ensure smooth implementations and ongoing technical support, minimizing downtime and supporting your production at the highest level.
- Adapt Solutions to Your Market We take regulations, standards, and regional preferences into account, delivering personalized robotic systems across various industrial areas.
- Share Knowledge and Experience Thanks to an international community of experts, we can share best practices and introduce innovations drawn from different industries and business cultures.
Whether your company operates locally or globally, NexaRob will adapt robotic solutions to your business needs, providing timely support and comprehensive after-sales care.
NexaRob
Would you like to become our Partner?
At NexaRob, we are building a community of experts and innovators who jointly bring new automation technologies to market. If you represent a technology company, system integrator, or have your own solutions supporting Industry 4.0, we invite you to cooperate with us!
Why Work with NexaRob?
Collaboration in R&D
Together, we work on new modules, sensors, and industry applications, expanding robot functionality with advanced AI, IoT, and vision system solutions.
Access to a Global Network
Our partners benefit from NexaRob's extensive business contacts and customer base spanning many industries worldwide.
Marketing and Technical Support
We provide training, promotional materials and engineering support to jointly develop projects and effectively reach new audiences.
Who are we looking for?
- Manufacturers of advanced robots and components
- Suppliers of AI, IoT, and vision system technologies
- Companies developing innovative autonomous and fleet-management solutions
- Partners specializing in Industry 4.0
Join NexaRob's Global Network!
Join us and help shape industrial automation worldwide. If you want to become a NexaRob partner, contact us and let us build the future of robotics together!
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