Maximum Range of Motion
Articulated Robots
Articulated robots, also known as robotic arms, are characterized by multiple rotational axes (most often 4-6). This allows for an extremely wide range of movements, enabling the performance of advanced operations in various planes and at almost any angle. As a result, articulated robots find application in many branches of industry - from welding and painting to precise 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 inaccessible to simpler designs. Their versatility, high precision and ability to work in difficult conditions translate into efficiency and reliability in various production environments.
Articulated Robots
Construction and Operating Principle
Articulated robots are characterized by a complex kinematics, enabling movement in multiple rotational axes. This design gives them impressive flexibility and the ability to perform various tasks precisely - from simple pick & place to complex welding or assembly operations.
Mechanical Design
- Articulated Arms Most articulated robots have between 4 and 6 axes of rotation, which allows them to move in almost any plane. Each joint is responsible for a specific range of motion, and their interaction enables complex spatial movements.
- Segments Connected by Joints The elements (arms) of the robot are connected by joints, which contain bearings and gears. This ensures smooth operation and stability of movement, even under higher loads.
- Body and Base A stable body structure, often made of steel or aluminum alloys, forms the foundation of the robot. It provides balance and allows for accurate positioning even in dynamic conditions.
Drive and Control
- Servo Motors and Gears Articulated robots commonly use servo motors, which guarantee precise control of speed and torque. Harmonic or planetary gears transmit power, ensuring high accuracy and repeatability of movement.
- PLC Systems and Dedicated Controllers The robot can be controlled by an external system (e.g., PLC) or an integrated controller from the manufacturer. The software continuously monitors the position of the joints and coordinates the movements of all axes.
- Advanced Sensors and Safety Many modern articulated robots use high-resolution encoders, as well as safety systems (e.g., light curtains, enclosures) to protect operators in the robot's work area.
Type of Movement
- Multi-Axis Kinematics An articulated robot can perform complex trajectories by bending and rotating its arm in multiple directions. This makes it possible, for example, to adapt a gripper to elements with irregular shapes or to reach hard-to-reach places.
- Freedom of Manipulation The robot arm often moves in the horizontal, vertical axis and around its own base, and additional axes are responsible for rotating the wrist or gripper. This provides wide configuration possibilities - from simple assembly to precise welding operations.
- Large number of degrees of freedom allows the robot to work at various angles and in many planes simultaneously.
- Ability to adjust trajectories in real time (e.g., when welding curvilinear paths).
- Easy programming of movements even for complex tasks, thanks to intuitive offline systems and teach pendants (panels for "teaching" 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 various tasks. Below are the most important advantages of this design:
- Versatile Movement Thanks to multi-axis kinematics, the robot is able to perform almost any movement path. It works well in applications where flexibility is important - from moving large parts, through screwing and welding, to precise painting or polishing.
- High Precision and Repeatability Servo motors with high resolution and precise gears allow achieving repeatability of movements at the level of hundredths of a millimeter. This is important everywhere where uniform quality is required (e.g., in the electronics or automotive industry).
- Ability to Handle Various Loads The market offers both light articulated robots for small assembly tasks, as well as machines with much larger reach and load capacity, designed for handling heavy elements (even several hundred kilograms).
- Application in Harsh Conditions Articulated robots are used in welding, painting or material processing processes where high temperatures, dust or hazardous substances occur. Appropriate shields and anti-corrosion coatings allow them to work in a demanding environment.
- Easy Integration with Vision Systems Thanks to their flexible movement and ability to handle multiple degrees of freedom, articulated robots often work with vision cameras, which enables dynamic trajectory correction or object recognition on the production line.
Applications in Industry
Articulated robots
Articulated robots, thanks to their versatility, have been used in a wide range of industries and processes for years. Their ability to work at different angles and in multiple planes makes them indispensable in the following areas:
Welding and Soldering
Arc welding, MIG/MAG, TIG: Articulated robots precisely guide the torch along the planned path, minimizing errors and achieving high weld repeatability.
Spot welding in the automotive industry: They are ideal for joining body parts, ensuring fast and accurate connections.
Painting and Coating
Paint application: Multi-axis movements allow for even application of paint or varnish, even on hard-to-reach areas.
Applications in the furniture or automotive industry: Thanks to precise motion control, the robot arm ensures optimal material consumption and consistent finish quality.
Assembly and Mechanical Machining
Assembling components with complex geometry: Flexible joint movements make it easier to adapt to non-standard shapes and various mounting positions.
Grinding, polishing, deburring: The robot can perform these operations repeatedly and with uniform pressure, which translates into surface quality and extends the life cycle of tools.
Packaging and Palletizing
Handling heavier elements: Articulated robots with a higher payload capacity are suitable for handling loads from several dozen to several hundred kilograms, e.g., bags of raw materials or transport boxes.
Diverse product shapes: Thanks to the rotary joints, the robot can optimally adapt the gripper to objects with an irregular profile.
Quality Control and Inspection
Cooperation with vision systems: The articulated robot precisely maneuvers cameras or sensors, enabling inspection of parts from various angles in 3D.
Component testing: The robot arm can feed components to testing stations that detect defects or dimensional discrepancies.
Machine Operation
CNC loading and unloading: Articulated robots easily adapt to the interior of machining centers, picking up and transferring materials or finished semi-finished products.
Injection molding machines and presses: They are excellent at capturing molded parts, which speeds up the production cycle and protects the operator from contact with dangerous equipment.
Articulated robots
Industries Where Articulated Robots Are Most Often Used
Articulated robots operate in diverse environments, from small craft workshops to advanced production lines in international corporations. Here are some key sectors:
Welding and joining of body elements, assembly of mechanical components, painting and polishing surfaces.
Machining, grinding, welding and transferring heavy parts.
Robots with greater lifting capacity can transport massive parts without losing precision.
Soldering, printed circuit board (PCB) assembly, handling delicate and damage-sensitive components.
Packing products in bulk packaging, palletizing bags of raw materials, dispensing liquid and granular substances.
Labeling, packing small bottles and jars, as well as automated drug packaging lines.
Transferring bricks, concrete slabs or other large-sized materials.
The possibility of using appropriate covers to protect against dust and moisture.
Automatic order fulfillment, sorting parcels and arranging loads on pallets.
Whether you run an assembly line, a welding station or a transshipment warehouse, articulated robots they can significantly increase the efficiency and precision of your processes. Thanks to a wide range of lifting capacities and many degrees of freedom, they are suitable for both delicate operations and handling heavy parts or intensive machining operations.
Articulated robots
Technical Requirements and Integration
In order for articulated robots to achieve maximum efficiency, it is necessary to properly adjust their operating parameters and integrate them correctly with the existing production line. Below we present the most important aspects that should be taken into account:
Operating Parameters
Load Capacity and Range
The choice of robot model should depend on the weight and dimensions of the handled parts, as well as the distance to which they need to be moved. Articulated robots with a lifting capacity from a few to several hundred kilograms are available.
Accuracy and Repeatability
In industries requiring high precision (e.g., electronics, pharmaceuticals), it is worth paying attention to the repeatability parameter, given in millimeters or micrometers.
Speed and Dynamics
Excessive acceleration can lead to vibrations and loss of precision; therefore, the robot should be selected with an optimal balance between speed and stability.
Integration with Control Systems
PLC Controllers and HMI Panels
Articulated robots usually support standard industrial protocols (e.g., EtherCAT, Profinet), which facilitates communication with PLC systems and visualization of parameters on HMI panels.
CAD/CAM Software and Vision Systems
In welding or assembly processes, it may be necessary to import motion paths from CAD/CAM programs. In the case of quality control or precise positioning, consider integrating with vision cameras.
IoT and Remote Monitoring
Thanks to cooperation with IoT platforms, data from robot operation can be analyzed in real time and potential failures diagnosed remotely. Details regarding 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; therefore, physical safety barriers are usually required.
ISO 10218 Standards and Risk Assessment
Installing an industrial robot requires adherence to safety. ISO 10218). Before starting operations, a risk analysis is performed to prevent collisions or hazards to personnel.
Articulated Robots
Comparison with Other Types of Robots
Articulated robots stand out with their advanced multi-axis kinematics, typically including from 4 to 6 axes, which allows them to perform complex trajectories and precisely manipulate objects. Thanks to their high freedom of movement, they are an excellent choice for applications requiring flexibility, such as welding, assembly or machine handling. To determine whether articulated robots best meet the needs of your process, it is worth comparing them with other types of industrial robots, such as Cartesian, SCARA, Delta, cylindrical, collaborative robots (cobots) or Gantry.
Articulated Robots vs. Cartesian (XYZ)
Kinematics and Range of Motion
Articulated robots can move in multiple planes, making them ideal for working around elements with complex shapes. Cartesian (XYZ) robots move in three linear axes (less often four), which provides simple, "perpendicular" movements. This design simplifies path programming and ensures high stability in pick & place tasks over a large work area.
Applications and Performance
Cartesian robots are excellent for 3D printing, milling light materials, or linear palletizing, where high positioning accuracy along the X, Y, Z axes is required. Articulated robots excel in welding, painting, and anywhere else where parts have unusual shapes or access to hard-to-reach areas is needed.
When to Choose?
If you prioritize high flexibility and working at various angles, choose an articulated robot. However, if you need long, straight movements (e.g., in a large production area) and simple kinematics, a Cartesian robot may be more cost-effective.
Articulated Robots vs. SCARA
Movement in Space vs. Movement in a Plane
SCARA robots typically have 3-4 axes and are excellent at fast assembly operations in the horizontal plane. In contrast, articulated robots have complete freedom of movement in multiple axes, allowing them to perform complex 3D movements (e.g., arc welding, painting at various angles).
Applications and Dynamics
SCARA robots achieve record short cycle times in pick & place applications, especially with small parts. Articulated robots are more versatile - they can work with larger loads and handle tasks requiring complex movements. At the same time, they usually do not achieve such high speeds in "planar" movements as SCARA robots.
When to Choose?
An articulated robot will be better when you need maximum flexibility and the ability to process multiple planes. A SCARA robot will perform well in fast assembly lines with strictly repetitive motion geometry (e.g., screwing screws in one plane).
Articulated Robots vs. Cylindrical
Construction and Method of Movement
Cylindrical robots combine linear motion in the vertical axis (Z) with rotation around this axis, and often with additional reach (radius). This type of kinematics is simpler in construction than articulated robots, but allows for a limited range of motion - mainly rotation and movement along one axis. Articulated robots, on the other hand, offer up to 6 axes of rotation, which gives them much greater freedom of movement and the ability to adapt to unusual shapes of parts.
Applications
Cylindrical designs are found in tasks where "axial" operation is required - for example, transporting parts between circularly arranged workstations, dispensing liquids, or picking up items from a rotating magazine. Articulated robots are more versatile and can perform many different operations, both assembly and machining (welding, polishing, packaging).
When to Choose?
If simplicity of construction and purely rotational-linear motion are key, a cylindrical robot will suffice, which will be cheaper and easier to maintain. However, if the application requires multi-plane processing and access to difficult areas, an articulated robot is unmatched.
Articulated Robots vs. Delta Robots
Kinematics Characteristics
Delta robots consist of several arms attached to a common platform, usually placed above the work area. They enable lightning-fast pick & place of light objects at high speed, although in a limited working area. Articulated robots offer greater spatial reach and can work with heavier elements in many planes.
Applications and Main Differences
Delta robots dominate in the food, pharmaceutical, and electronics industries, where ultra-short motion paths and high efficiency are required (e.g., sorting small products). Articulated robots perform well in more complex tasks (welding, machining, painting), with a lifting capacity unattainable for most Delta robots.
When to Choose?
If your priority is the speed of packing or sorting light items, choose a Delta robot. However, if you need flexibility in three-dimensional operations and working with a larger load, an articulated robot will be indispensable.
Articulated Robots vs. Gantry (Bridge) Robots
Reach and Construction
Gantry systems are robots based on several linear axes (e.g., in the X, Y, Z system), where the entire "arm" moves along guides mounted above the work area. This design allows for handling a very large area (e.g., an entire hall) and moving heavy loads vertically. An articulated robot has a limited range of motion around its base - although it offers greater freedom of movement around the part, it does not cover as much space as a Gantry system.
Applications and Area of Advantage
Gantry systems perform very well in high-bay warehouses, when handling heavy components, or in the metal industry, where large and massive parts need to be moved. An articulated robot excels in tasks requiring more complex trajectories (e.g., welding, painting, machining in multiple planes), as well as when the object is relatively small and fits within the reach of its arms.
When to Choose?
The Gantry system is best when you are dealing with the transport of large-size loads or want to use a single robot to handle several distributed workstations over a large area. However, if the goal is versatile manipulation of a part in many axes and angles (e.g., assembly, welding), an articulated robot will be cheaper to install and more flexible.
Articulated Robots vs. Cobots (Collaborative Robots)
Working in a Safety Zone vs. Collaboration with Humans
Articulated robots usually work in a dedicated zone, protected by enclosures or light curtains, because they can move quickly and carry significant loads. Cobots (collaborative robots) are designed to work side-by-side with humans, often without additional enclosures - their built-in force and torque sensors detect contact with the operator, automatically stopping movement.
Performance and Application Range
Cobots are ideal for tasks requiring direct human interaction, such as collaborative assembly or processes where the operator performs part of the work and the robot assists with the most strenuous activities. Articulated robots, thanks to their higher speed and greater payload capacity, are used in automated mass production lines where maximum efficiency and the absence of an operator in the work area are essential.
When to Choose?
If safety in human-machine collaboration is key (e.g., in a small-scale production company or with frequent product changes), a cobot can be an excellent solution. However, if high performance and handling heavier tasks are priorities (welding large structures, fast packaging), an articulated robot clearly wins in terms of capabilities and work pace.
Articulated robots are one of the most popular solutions in industrial robotics, offering impressive flexibility in machining, assembly, and manipulation tasks. However, under certain conditions - such as the need for collaboration with an operator, handling large loads over a wide area, or ultra-dynamic operation in a plane - other types of robots (cobots, Gantry, Delta, SCARA, etc.) may prove more effective.
We encourage you to analyze the priorities and requirements of a given application in order to choose the technology that is most beneficial in terms of functionality, cost, and ease of implementation. If you have any doubts, 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: the size and payload of the robot, the drives and gearboxes used, the need for integration with vision systems, or specific working conditions. The price of basic models can start from several tens of thousands of zlotys, while more advanced models with a large payload and precision can cost several hundred thousand zlotys.
Manufacturers usually recommend periodic inspections based on the number of operating hours (e.g., every 6-12 months), during which the condition of joints, bearings, motors and safety systems is checked. In the case of intensive applications (e.g., welding, machining), more frequent checks may be necessary.
More information can be found in Service and Modernization.
Yes, provided that appropriate seals, protective coatings and ingress protection (IP) class are used. In some industries (e.g., food, chemical), special corrosion-resistant and easy-to-clean materials are also used.
Usually yes. Articulated robots have flexible software, and manufacturers provide ready-made environments for creating and modifying motion paths. Teach pendants or offline solutions (CAD/CAM) are often used, which speeds up the implementation of new processes.
Yes. Many articulated models achieve repeatability at the level of hundredths of a millimeter. In addition, servo motors and advanced control systems provide smooth movements, which is important for delicate components.
Usually, fences, light curtains, emergency stop buttons or vision systems that recognize the presence of a person in the work area are used. Implementation should always be preceded by a risk analysis and compliance with ISO 10218 standards.
Often yes - due to its versatility, one robot can perform many tasks (e.g., welding, machine operation and packaging), provided that the lifting capacity and reach parameters allow it and appropriately programmed motion sequences are used.
Yes. Most manufacturers offer a wide range of accessories and modules that can be mounted on the robot's wrist. This includes pneumatic grippers, electric grippers, welding tools, vision sensors, or measurement systems.
Do you have more questions?
Contact us or visit the FAQ section to get detailed answers to all your questions about articulated robots.
- Experience in Various Industries We have implemented projects in sectors such as automotive, electronics, food processing, and metalworking. Thanks to this, we can adapt the appropriate model of articulated robot and accessories to the specifics of a given process.
- Comprehensive Approach We offer not only the delivery of robots but also integration with existing lines, assistance with programming, and training for employees. Our team of engineers is involved at every stage of implementation, from concept to commissioning and service.
- Innovative Technologies We cooperate with leading manufacturers of servo motors, vision systems, and CAD/CAM software, which guarantees the latest standards of quality and performance. We are also ready for the challenges of Industry 4.0, offering integrations with IoT or remote robot monitoring.
- Reliable Service Support Our support does not end after commissioning. We provide regular inspections, fast delivery of spare parts, and online technical support so that 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 that offer complementary solutions - AI providers, manufacturers of modern grippers, or integrators of specialized software. Together, we create leading automation systems on the market.
Learn more about our implementations and achievements in the Case Studies section, and then contact us to find out how we can help improve processes in your plant.
Automate Your Business with NexaRob - Contact Us!
Global Reach
We operate globally, support locally
NexaRob is present in over 100 countries, providing advanced technologies and service support wherever entrepreneurs need reliable and modern robotic solutions. Thanks to our extensive network of distributors and regional partners, we can:
- Ensure a Quick Response Our local specialists guarantee efficient implementation and ongoing technical support, minimizing downtime and supporting your production at the highest level.
- Adapt Solutions to Your Market We take into account regulations, standards, and regional preferences, providing customized robotic systems in various industrial sectors.
- Share Knowledge and Experience Thanks to our international community of experts, we can share best practices and introduce innovations drawn from different industries and business cultures.
Regardless of whether your company operates locally or globally, NexaRob will adapt robotic solutions to the needs of your business, guaranteeing timely support and full after-sales service.
NexaRob
Do you want to become our Partner?
At NexaRob, we create a community of experts and innovators who jointly introduce innovative automation technologies to the market. If you represent a technology company, system integrator, or have your own solutions supporting Industry 4.0, we encourage you to collaborate!
Why is it worth cooperating with NexaRob?
Collaboration in R&D
Together, we work on new modules, sensors, and industry applications, expanding the functionality of our robots with advanced AI, IoT, and vision systems.
Access to a Global Network
Our partners benefit from NexaRob's extensive business contacts and customer base covering many industrial sectors worldwide.
Marketing and Technical Support
We offer training, promotional materials, and engineering support to jointly develop projects and effectively reach new customers.
Who are we looking for?
- Manufacturers of advanced robots and components
- Suppliers of AI, IoT and vision system technologies
- Companies developing innovative autonomous solutions and fleet management systems
- Partners specializing in Industry 4.0
Join the global NexaRob network!
Join us and together let's change the face of industrial automation worldwide. If you want to become a NexaRob partner, contact us and let's create the future of robotics together!
Interesting facts from around the world
Cruzr Y1: a new industrial humanoid robot from UBTECH with an autonomous agent.
UBTECH presented a new model of an industrial humanoid called Cruzr Y1, which is to be used in...
How are robots changing industry and services in 2022? Five key trends.
In 2022, the global stock of industrial robots exceeded 3 million units, and the growth rate...
The UK is losing ground in global automation - robot sales fell by 3% in 2018.
In 2018, installations of industrial robots in the UK fell by 3 percent - for the first time.
Humanoid robots: between vision and reality - a new report from IFR.
The International Federation of Robotics (IFR) has published a new position paper that analyzes the real prospects for the development of humanoid robots.
Robots help achieve the UN's sustainable development goals.
Robots are not only changing the way products are manufactured, but also contributing to the achievement of sustainable development goals.