A New Dimension of Safe Automation
Collaborative Robots (Cobots)
Collaborative robots, commonly known as cobots, are innovative industrial-automation solutions specifically designed to work safely with people in the same workspace. Unlike traditional industrial robots, which often require robust fencing or safety curtains, cobots are equipped with advanced force and torque detection systems and intelligent collision-detection algorithms. This allows them to stop or slow down within a fraction of a second as soon as they detect a person nearby.
Why Consider Collaborative Robots?
Safe Coexistence with the Operator
Cobots are designed to minimize accident risk as much as possible. Low initial speeds, smooth shapes, rounded edges, and sensitive force sensors mean that potential collisions are less likely to cause serious injuries.
Ease of Reprogramming and Setup
Unlike typical industrial robots, cobots can often be reprogrammed in as little as several minutes by moving them to another workstation and teaching them new tasks. This makes them an ideal tool for low-volume production and frequently changing assembly lines.
Minimal Fencing or No Fencing
Thanks to their integrated safety functions, cobots do not require extensive protected zones. A risk assessment and basic protective measures are sufficient for operators to work side by side with the robot in the same area.
Lower Costs and Improved Ergonomics
Collaborative robots relieve people of monotonous or hazardous tasks such as moving heavy components, tightening screws, or repetitive packaging. This helps reduce injuries and human errors while increasing productivity.
What Makes Cobots Different from Other Robots?
Compliance with stringent safety standards such as ISO 10218 and ISO/TS 15066.
Many models offer simple programming interfaces based on the “teach and repeat” method, enabling rapid deployment even by non-specialist engineers.
A broad range of grippers, vision sensors, and accessories can be installed, turning the cobot into a multifunctional assistant for virtually any process.
The Future of Automation - Humans and Robots on One Team
Modern factories face a growing need for production flexibility, frequent changeovers, and rapid response to changing market demands. Collaborative robots address these challenges by combining machine precision and repeatability with human creativity and intuition. As a result, cobots help companies increase efficiency without extensive expansion of safety infrastructure and without eliminating human involvement in critical areas of quality control or manual work.
Collaborative Robots (Cobots)
Design and Operating Principle
Cobots, or collaborative robots, were created to enable safe and efficient coexistence of people and machines within the same work area. Their design and operating principles are subject to strict safety standards to provide maximum operator protection while preserving the functionality and efficiency of typical industrial robots.
Mechanical Design
- Rounded Shapes and No Sharp Edges Cobots usually have rounded housings and smooth arm contours, which help prevent serious injuries in the event of accidental contact with an operator.
- Suitable Materials Some models use parts made of lightweight alloys and covers made of soft plastics to further minimize the effects of potential collisions with people.
- Built-in Force and Torque Sensors Advanced sensors are often installed in cobot joints, enabling detection of even small resistance or torque changes. When configured values are exceeded, the robot automatically stops or switches to a reduced-speed mode.
Operating Principle and Control
- Collaborative Mode A cobot can work side by side with a person, responding to physical contact or the operator's presence in its work area. When it detects resistance or a force impulse exceeding the programmed limit, it stops or slows to a safe speed.
- Simple Programming Interfaces Many cobots support teach by demonstration. The operator holds the robot arm and guides it along the desired path. The system records these movements and reproduces them in a later production cycle. In addition, modern software, for example with graphical interfaces, makes it easy to modify trajectories or motion parameters.
- Communication and Integration Cobots work smoothly with typical PLC controllers, vision systems, and sensors. They use standard industrial protocols such as EtherCAT and Profinet and integrate with IoT platforms, enabling remote monitoring and analysis of operating data.
Safety Functions
- Speed and Torque Limitation Cobot factory settings already include speed and force limits that can be modified based on the risk assessment for a given process.
- E-stop and Safe Stop Functions Emergency stop buttons are usually located on cobot arms, while the software provides functions for stopping in a safe position, such as Safe Torque Off, if a collision is detected or guards are opened.
- Zone Visualization Systems Some cobots use additional vision sensors or 3D scanners to detect the presence of people. This allows them to slow down automatically when an operator approaches the work area.
Thanks to built-in force and torque sensors, advanced control algorithms, and limits on speed and payload, collaborative robots can operate in a shared space with people without requiring extensive guarding. This considered design and the ability to detect even minor collisions are key reasons cobots are transforming assembly and handling processes in factories around the world.
Key Advantages
Key Benefits of Collaborative Robots
With the growing need for flexible and safe automation, collaborative robots are becoming a foundation of innovation for many companies. They can directly support operators in tasks requiring precision, endurance, or repeatability.
- Safe Human-Robot Collaboration Cobots comply with stringent ISO standards, and their design, both mechanical and electronic, reduces the risk of injury if the robot arm comes into contact with the operator's body. This allows many processes to be automated without removing people from the immediate production area.
- Easy Adaptation to Changes With frequent production line modifications (e.g. a change of product model or assembly sequence), traditional robots require time-consuming reconfiguration and programming. Cobots can be adapted quickly using intuitive drag-and-drop tools, touch panels or by teaching the arm a new movement trajectory directly "by hand".
- Reduction of Occupational Health and Safety and Infrastructure Costs Because cobots operate without fencing, or with minimal fencing, there is no need to invest in expensive safety cages, barriers, or gates. Operators can perform their work freely while cooperating with the robot, for example by supplying it with the next parts to be assembled.
- Versatility and Scalability Depending on the manufacturer, cobots are available with a wide range of payload parameters, from 0.5 to several dozen kilograms, different numbers of axes, most commonly 6, and varying arm reaches. This makes it possible to select a model for tasks ranging from delicate electronics handling to moving medium-sized components.
- Improving Ergonomics and Working Conditions Cobots can take over tedious, monotonous, or physically demanding activities from operators, helping prevent occupational illnesses and injuries. This allows people to focus on more creative and supervisory tasks while the process gains precision and stability.
- Easy Integration with Vision Systems and IoT Collaborative robots are well suited to Industry 4.0 environments. They can be equipped with cameras, vision sensors, or wireless communication modules to collect cloud data and support remote analysis. This provides greater quality control and faster response to unexpected production events.
Industrial Applications
Collaborative Robots (Cobots)
Collaborative robots, or cobots, perform very well across many industries, from automotive to food processing and pharmaceuticals, wherever people and machines need to work together smoothly. Their ability to operate in changing conditions, flexible software, and advanced safety features mean they are increasingly replacing traditional robots that require costly guarding and isolation.
Assembly and Quality Control
Collaborative Component Assembly
In applications where the operator performs some manual activities, for example inserting delicate electronic components, while the robot performs repetitive movements, such as tightening screws or pressing clips into place.
Assembly Verification
Thanks to force sensors or vision systems, cobots can support operators in quality inspection, for example by testing the smooth operation of a mechanism or checking the tightness of latches.
Packaging and Palletizing
Compact Packaging Lines
In small and medium-sized facilities where there is not enough space to install large industrial robots with safety cages, cobots work particularly well alongside operators when packing products into boxes or stacking them on pallets.
Direct Feeding by the Operator
It is enough for a person to place the product within reach of the cobot's arm, and the cobot will safely and repeatedly transfer it into the packaging without requiring the process to be stopped to remove safety guards.
Machine Tending and Component Feeding
Cooperation with CNC Machines
A cobot can load and unload parts into a machine tool while the operator supervises the process and makes minor parameter adjustments. This minimizes downtime and reduces risk to the employee from contact with moving or sharp components.
Moving Parts Between Workstations
Collaborative robots work well on low- and medium-volume lines where a fully automated production line is not yet economically justified.
Applications in the Food and Pharmaceutical Industries
Small Packaging Tasks
Applying labels and tightening caps on jars or bottles, tasks that previously burdened employees with monotonous work, can be taken over by cobots.
Improved Hygiene and Safety
Suitable coatings and smooth enclosures make cleanliness easy to maintain, which is important in food processing or pharmaceutical packaging.
Assisted Manual Work
Collaborative Soldering, Gluing or Painting
An operator can begin the assembly process or apply a preparation, and the cobot can finish or standardize the task, for example filling a gap with adhesive precisely along an edge, ensuring repeatability.
Support for Assembly Teams
In some locations, one cobot is enough to support several employees by moving heavy components to a workstation or assisting in hard-to-reach parts of a structure.
Collaborative Robots
Industries Where Collaborative Robots Are Most Commonly Used
Although cobots have become extremely popular in recent years, their applications continue to grow into new sectors of the economy. Below is an overview of industries in which collaborative robots have transformed production and assembly processes:
Assistance in assembling delicate electronic parts, such as sensors and wiring harnesses, and jointly handling heavier vehicle body components.
Precision soldering, handling small components, and tightening screws in device housings.
Collaboration with people during visual inspections and measurements.
Safe feeding of raw materials, packing products into bulk packaging, or operating filling lines.
Flexibility for frequent changes in product ranges and packaging.
Gentle handling of ampoules, vials, and tablets under sterile conditions.
Assisting employees with packaging and quality control of medicines, bandages and medical equipment.
Picking e-commerce parcels, handling small shipments, or sorting letters in smaller logistics centers.
Supporting workers who pack a variety of goods into non-standard packaging.
In most of these industries, the key benefits of cobots are: safety, flexibility i ease of programming. With growing pressure for shorter production runs, changing consumer needs, and shortages of qualified staff, collaborative robots address the challenges of modern automation by combining the potential of machines and people in one harmonious process.
Collaborative Robots (Cobots)
Technical Requirements and Integration
Collaborative robots, or cobots, despite simplified operation and built-in safety layers provided by manufacturers, still require proper preparation of the environment and integration with the existing production line. Below are the key elements worth considering before deploying a cobot.
Operating Parameters
Payload and Reach
Most cobots have payloads ranging from several to a dozen kilograms. There are also models capable of lifting several dozen kilograms, but higher payloads usually mean larger arms and higher costs. Arm reach, from about 0.5 m to as much as 1.5-2 m, should be selected according to application requirements so that the robot can freely reach the entire work area.
Accuracy and Repeatability
For precision assembly, packaging, or screw tightening, accuracy within hundredths of a millimeter is crucial. Most cobots provide repeatability of ±0.05-0.1 mm, which is fully sufficient in many cases.
Speed and Safety Modes
Depending on the operating mode, such as human collaboration or a partially fenced area, maximum movement speeds can be set. In full collaborative mode, speeds are limited so that any collisions do not cause injury.
Integration with Control Systems
PLC Controllers and HMI Panels
Cobots support popular industrial protocols such as Profinet, EtherCAT, and OPC UA. They can be easily integrated into a line architecture to receive and send signals to a supervisory controller, including start and stop sequences and cycle-time data.
Vision Systems and Sensors
In many tasks, especially pick and place or assembly, integration with 2D or 3D vision cameras is essential. By analyzing camera data, a cobot can modify its trajectory on the fly. Additional force/torque sensors, either built in or mounted on the gripper, allow it to respond to changing part geometry or unexpected obstacles.
Software and Cloud (IoT)
Cobots increasingly support IoT platforms, enabling remote monitoring, for example analysis of key productivity indicators and early detection of failure symptoms. This makes it possible to respond quickly to changing conditions and optimize work schedules.
Risk Assessment and Safety
Hazard Assessment (Risk Assessment)
Despite built-in safety functions, every process involving a cobot should be analyzed for real hazards. Factors to verify include the weight of transported parts, operating movements, the presence of sharp edges, and high temperatures.
Safety Fencing - Is It Always Necessary?
In a fully collaborative operating mode with limited speeds, safety cages are usually not required. However, if the robot operates at higher speed or handles heavier objects during certain phases, a buffer zone or light curtains should be considered.
Maintenance and Service
Although cobots are designed to work safely with people, they still require inspections and periodic checks of force sensors. Regular equipment checks in accordance with the manufacturer's guidelines are recommended to maintain a consistently high level of safety.
Environmental Conditions
Temperature and Humidity
Make sure the cobot is suitable for the conditions in the facility (e.g. cold storage, high humidity, or proximity to heat sources).
Contact with Chemical Substances
In the pharmaceutical or chemical industry, anti-corrosion coatings and material certificates may be required.
Cleanliness and Sterility
In sterile areas such as cleanrooms, models must be selected that meet specific standards and are equipped with covers that limit particle emissions.
Collaborative Robots (Cobots)
Comparison with Other Robot Types
Collaborative robots, or cobots, are solutions designed to work with people and are distinguished by advanced safety functions and intuitive operation. Thanks to their flexibility, they can be used in many industries, from assembly to packaging. To help select the most suitable solution, below we compare cobots with six other robot types. The following sections provide detailed comparisons and recommendations.
Cobots vs. Cartesian Robots (XYZ)
Human Collaboration Concept vs. Linear Axis Motion
Cobots are designed to work safely with an operator in the same workspace, without requiring safety fencing or with fencing kept to a minimum. They have collision sensors and usually operate at lower speeds and payloads to reduce risk. Cartesian robots, or XYZ robots, move along three linear axes, often within a separated safety zone, and in the traditional setup are not intended to operate with a person close to moving components.
Applications
Cartesian robots are well suited to processes requiring regular, linear movements, such as 3D printing, machining lightweight materials, or pick and place over a large area. Cobots excel in tasks where the operator and robot complement each other, for example, the robot precisely tightens a screw while the employee manually aligns the component.
When to Choose?
If the priority is human-robot collaboration, safety, and rapid workstation changeover, cobots are an excellent choice. When a large working area along the X, Y, and Z axes must be covered and direct interaction with people is not required, a Cartesian robot may prove simpler and more cost-effective.
Cobots vs. SCARA
Safety and Dynamics
Cobots are designed to limit force and speed so that contact with a person does not cause injury. SCARA robots specialize in ultra-fast pick & place or assembly operations in the horizontal plane but do not normally include functions for safe human collaboration and therefore most often require guarding or safety curtains.
Applications and Advantages
SCARA robots are attractive for applications such as assembly of small electronics, screwdriving, or fast transfer of lightweight components between production cells. Cobots, on the other hand, perform well where a worker and robot must share a space and assist each other, for example when the robot holds a component while the worker performs quality inspection or manual finishing.
When to Choose?
If short cycle times and high speeds in "2D plus Z axis" movements are important, a SCARA robot will be more efficient. When human-robot collaboration is essential, for example in low-volume production with frequent product changes, cobots have an advantage in flexibility and safety.
Cobots vs. Articulated (Arm) Robots
Collaboration vs. Power and Freedom of Movement
Articulated, or robotic arm, systems are a classic industrial solution, often offering high payload capacity and a wide range of motion with 4 to 6 axes. They operate in a separated work zone, usually without people in the immediate vicinity. Cobots, by contrast, are designed for safe interaction with operators. They typically have lower speed and payload, but include collision sensors and can brake within a fraction of a second.
Applications
Articulated robots dominate processes involving heavy components, multi-plane welding, painting, or CNC machine tending. Cobots perform very well when working with people at the same workstation, for example in final assembly stages, quality testing, or packaging lightweight products.
When to Choose?
If the priority is high productivity, processing larger components and full automation, an articulated robot is difficult to replace. In applications with frequent product changes and a need for direct human-machine interaction, cobots have a clear advantage thanks to their safety functions and easy reprogramming.
Cobots vs. Cylindrical Robots
The Concept of Collaboration and Safety vs. Simple Axial Kinematics
Cylindrical robots move around a vertical axis (rotation) and along that axis (up-down movement), sometimes with additional reach. Cobots focus on safe collaboration with people: low speeds, collision sensors, and limited force/torque so that contact does not pose a hazard.
Applications
Cylindrical robots are highly effective in applications where rotary and vertical movement is sufficient, for example rotating parts around a single axis or transferring them between two stations arranged radially. Cobots can work together with an operator at a shared workstation, for example by supplying components, tightening screws or holding a part being assembled by a person.
When to Choose?
If the workstation does not require human interaction and simple movements (rotation + Z axis) are sufficient, a cylindrical robot may be less expensive and easier to maintain. If human collaboration and safety are essential and the movement requires more freedom than rotation + Z, a cobot will be the more versatile solution.
Cobots vs. Delta Robots
Direct Cooperation vs. Ultra-Fast Pick and Place
Delta robots specialize in extremely fast cycles for handling small products, particularly in the food and electronics industries, but they usually operate in separated zones and at high speeds. Cobots, designed to work alongside people, move more slowly and generally have lower payloads, depending on the model, with safety during operator contact as the priority.
Applications
Delta robots are excellent for high-volume production lines where continuous human involvement in the immediate vicinity is unnecessary. Cobots work well in areas where humans and robots need to assist each other, such as hybrid assembly, where some steps are performed by the machine and others by the operator.
When to Choose?
If you need extremely high pick-and-place speeds, with hundreds of cycles per minute, choose a Delta robot. If you value flexibility and safety when working with people and the ability to reassign a robot easily to different tasks, cobots offer a more versatile and user-friendly implementation.
Cobots vs. Gantry Systems
Collaboration Concept vs. Large Reach and Payload
Gantry systems are often massive structures with X and Y axes, and sometimes Z, that can cover a very large work area, for example an entire warehouse hall or production line. Cobots focus on safety and direct cooperation with an operator, usually within a smaller area. They do not achieve the same reach or payload as Gantry systems.
Applications
Gantry systems are a solution for transporting oversized or heavy loads between multiple stations or racks. Cobots are most often used for precision tasks, light assembly, testing or packaging, where people frequently need automated assistance but can also step in at any time and work together with the robot.
When to Choose?
Choose Gantry if you need to cover significant horizontal distances and/or handle substantial payloads, for example several hundred kilograms. If human-robot cooperation and operation within a limited area are the priorities, but tasks change frequently, a cobot will make full use of its safe and flexible nature.
Collaborative robots, or cobots, prioritize safety and easy operator interaction, making them ideal for processes where people perform part of the operation. They do not achieve the high speeds of Delta robots, the reach of Gantry systems, or the simple kinematics of cylindrical robots. However, when fast changeovers, flexibility, and readiness for changing assembly tasks are important, cobots excel.
Frequently Asked Questions
Frequently Asked Questions
Collaborative Robots (Cobots)
Cobots are designed for close coexistence with people. They are equipped with sensors that detect collisions and limit speed or force when resistance is detected. They also comply with ISO standards, including ISO 10218 and ISO/TS 15066, so potential impacts are gentler and the risk of injury is significantly lower than with conventional robots.
Not necessarily. Under a risk assessment approach, if the robot operates in collaborative mode, with limited speed and torque, marking the area or using basic light curtains is usually sufficient. Full guarding is needed when the robot reaches higher speeds during certain operations or carries hazardous objects.
Yes, this is one of the greatest advantages. Many models allow the arm to be "taught" by physically guiding it along a specified path, known as hand guiding. Changing the application and adapting to a new line therefore takes significantly less time than with traditional industrial robots.
Most modern models provide repeatability of approximately ±0.05-0.1 mm, which is sufficient for many assembly, packaging, and quality control tasks. More precise applications (for example, microassembly) may require specially adapted grippers or sensors.
Although the main cobot market focuses on payloads of around 5-15 kg, there are also models capable of carrying 20-35 kg or even more. The choice depends on application needs, but increasing payload also increases the mass and size of the arm itself, and collaborative operation may require reviewing additional safety measures.
Yes. Cobots typically support major communication protocols such as EtherCAT, Profinet, and OPC UA, and they can be equipped with 2D/3D cameras to identify component positions or verify quality. In addition, many manufacturers offer IoT platforms that enable remote monitoring and cloud-based data analytics.
Usually up to 1 m/s, sometimes faster, but in collaborative mode speeds are often limited to approximately 0.25-0.5 m/s depending on the risk assessment and safety settings. If the application requires very fast cycles, SCARA, Delta, or articulated robots in a fenced area are worth considering.
Thanks to built-in force sensors, a cobot detects a collision and stops or significantly reduces its speed. This helps eliminate the risk of serious injury. The operator can usually resume the process after a brief safety confirmation procedure.
In theory, yes, provided appropriate service and maintenance breaks are carried out in accordance with the manufacturer's recommendations. Frequent stoppages may result more from changeovers or the need to supply the line with new raw materials than from limitations of the robot itself.
Many companies offer short courses or online tutorials that are sufficient for independently programming basic tasks. For more advanced applications, it is worth using full manufacturer training or integrator services to learn how to make the most of human-robot collaboration.
Do you have more questions?
Contact us or visit the FAQ section for detailed answers to all questions about collaborative robots..
- Experience Across Diverse Industries From electronics and automotive to food and pharmaceuticals, our portfolio includes numerous implementations in which cobots work alongside people, supporting assembly, packaging, and inspection tasks. This allows us to select the right robot model for the specifics of your process.
- Individual Consulting and Needs Analysis Before recommending specific solutions, we conduct a thorough audit of processes and requirements. Only after understanding the business objective and production-line characteristics can we select an appropriate cobot and equipment, such as grippers and cameras.
- Comprehensive Integration and Training We provide full implementation support, from cobot selection and installation through communication protocol configuration to staff training and production testing. This minimizes downtime risk and accelerates return on investment.
- Latest Industry 4.0 Technologies The solutions we provide can be easily integrated with IoT systems, Big Data analytics, or remote monitoring. We focus on innovation so you can continuously improve processes and keep pace with a dynamically changing market.
- Various Forms of Financing We understand that investing in a cobot can be challenging for smaller companies, so we offer flexible financing options, including leasing, long-term rental, and even Robot-as-a-Service, where you pay only for actual equipment use.
If you want to see how NexaRob helps with real projects, visit our Case Studies. See how collaborative robots have accelerated production and improved quality in companies with diverse profiles.
Automate Your Business with NexaRob - Contact Us!
Global Reach
We Operate Globally, Support Locally
At NexaRob, we combine broad expertise in robotics and automation with international experience. Our presence in many markets allows us to effectively adapt solutions to different legal, cultural, and business requirements.
- Regional Expert Teams Thanks to an extensive network of offices and partners, we offer technical and service support in more than 100 countries. This means our engineers and consultants can respond quickly and help maintain production continuity.
- Knowledge of Local Standards Each market has its own occupational safety standards, certification guidelines, and customer preferences. We understand the specifics of local industries and can design an implementation to meet all applicable requirements.
- Innovation Transfer We work with clients from different sectors and regions, enabling us to transfer best practices and innovative solutions between different parts of the world. As a result, your project benefits from NexaRob's global experience.
Whether you operate a small manufacturing facility in Europe or manage a factory in Asia, NexaRob will provide high implementation standards for collaborative robots, adapted to the local realities and priorities of your business.
NexaRob
Would you like to become our Partner?
At NexaRob, we believe that developing the robotics and automation industry requires cooperation among many organizations, from component manufacturers and software suppliers to integrators and consulting companies. If you have technology or services that can complement the collaborative robot solutions we integrate, we encourage you to establish a partnership.
Why Work with NexaRob?
Creating New Solutions
Together with our partners, we develop dedicated grippers, tools, vision interfaces, and AI systems that expand cobot functionality and open the way to innovative applications.
Training and Technical Support
We offer recurring webinars, educational materials, and engineering sessions for our partners. This helps you develop expertise in collaborative robotics and implement new ideas more quickly.
Joint Business Development
Our global network allows us to promote partner solutions among customers from different industries and regions of the world. Together, we participate in trade fairs, conferences and events, increasing visibility and reaching potential customers more effectively.
Who is cooperation with NexaRob for?
- Companies developing accessories for cobots, such as specialized grippers, vision systems, and AI software
- Manufacturers of IoT and production analytics solutions
- Integrators of extensive industrial lines that need support in collaborative robotics
- Innovators and start-ups seeking an experienced partner for prototype development and product market entry
Join the global NexaRob community!
Contact us and together we can discuss how to enrich our respective offerings and develop solutions that are not only innovative but also genuinely improve comfort and productivity in production facilities around the world.
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