A New Dimension of Safe Automation
Collaborative Robots (Cobots)
Collaborative robots, commonly known as cobots, are innovative solutions in the field of industrial automation, designed specifically for safe interaction with humans in the same workspace. Unlike traditional industrial robots, which often require solid enclosures 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 when they detect a human presence in their immediate vicinity.
Why Consider Collaborative Robots?
Safe Coexistence with the Operator
Cobots are designed to minimize the risk of accidents - low initial speeds, smooth shapes, rounded edges, and sensitive force sensors ensure that any collisions do not lead to serious injuries.
Easy Reprogramming and Setup
Unlike typical industrial robots, cobots can often be reprogrammed in as little as a few minutes, moved to another workstation, and taught new tasks. This makes them an ideal tool for low-volume production and frequently changing assembly lines.
Minimal or No Enclosures
Thanks to their built-in safety features, cobots do not require extensive protective zones. A risk assessment and basic safety measures are sufficient for operators to work side by side with the robot in one area.
Reduced Costs and Increased Ergonomics
Collaborative robots relieve people from monotonous or dangerous tasks - such as moving heavy parts, tightening screws, or repetitive packaging. This helps reduce the number of injuries and human errors and increase productivity.
What Distinguishes Cobots 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, which facilitates rapid implementation even by non-specialized engineers.
The ability to mount a wide range of grippers, vision sensors, and accessories makes the cobot a multifunctional assistant in virtually any process.
The Future of Automation - Humans and Robots as One Team
Modern factories are seeing a growing need for production flexibility, frequent retooling, and rapid response to changing market needs. Collaborative robots meet these challenges by combining the precision and repeatability of machines with the creativity and intuition of the human mind. As a result, cobots help companies increase efficiency without the need to expand safety infrastructure or eliminate human involvement in critical areas such as quality control or manual work.
Collaborative Robots (Cobots)
Construction and Operating Principle
Cobots, i.e., collaborative robots, were created with the idea of enabling safe and efficient coexistence of humans and machines in one workspace. Their design and operating principle are subject to strict safety standards to ensure maximum protection for operators while maintaining the functionality and efficiency of typical industrial robots.
Mechanical Design
- Rounded Shapes and No Sharp Edges Cobots usually have rounded housings and smooth arm lines, which prevents serious injuries in case of accidental contact with an operator.
- Appropriate Materials In some models, parts made of lightweight alloys and covers made of soft plastics are used to further minimize the effects of a possible collision with a human.
- Built-in Force and Torque Sensors Advanced sensors are often mounted in the joints of cobots, which enable the detection of even slight resistance or a change in torque. When the set values are exceeded, the robot automatically stops moving or switches to a slower mode.
Operating Principle and Control
- Cooperation Mode The cobot can work side by side with a human, reacting to physical contact or the presence of an operator in its working area. When it detects resistance or a force impulse (exceeding the programmed limit), it stops or slows down to a safe speed.
- Simple Programming Interfaces Many cobots enable so-called teach by demonstration - the operator grabs the robot arm and guides it along the desired path. The system remembers these movements and reproduces them in a later production cycle. In addition, modern software (e.g., with graphical interfaces) allows easy modification of trajectories or movement parameters.
- Communication and Integration Cobots work seamlessly with typical PLC controllers, vision systems, or sensors. They use standard industrial protocols (EtherCAT, Profinet) and integrate with IoT platforms, which enables remote monitoring and data analysis.
Safety Features
- Speed and Torque Limitation Even in the factory settings of cobots, speed and force limits are introduced, which can be modified based on a risk assessment in a given process.
- E-stop and Safe Stop Functions The robot arm usually has emergency stop buttons, and the software offers functions for stopping in a safe position (e.g., Safe Torque Off) in case of collision detection or opening of guards.
- Zone Visualization Systems Some cobots use additional vision sensors or 3D scanners to detect the presence of a human. Thanks to this, they can automatically slow down when an operator approaches the operating area.
Thanks to built-in force and torque sensors, advanced control algorithms, and speed and payload limitations, collaborative robots can work in a shared space with humans without the need for massive fencing. It is this well-thought-out design and the principle of detecting even minor collisions that make cobots revolutionize assembly and manipulation processes in factories around the world.
Key Advantages
Key Advantages of Collaborative Robots
In the face of growing demand for flexible and safe automation, collaborative robots are becoming a cornerstone of innovation for many companies. They enable direct support for operators in tasks requiring precision, endurance or repeatability.
- Safe Human-Robot Collaboration Cobots meet stringent ISO standards, and their design (both mechanical and electronic) reduces the risk of injury in the event of contact between the robot arm and the operator's body. This allows many processes to be automated without sacrificing human presence in the immediate production area.
- Easy Adaptation to Changes With frequent modifications to the production line (e.g., changing a product model, different assembly sequence), traditional robots require time-consuming reconfiguration and programming. Cobots can be quickly adapted using intuitive tools such as "drag & drop", touch panels, or by teaching the arm a new trajectory of movement directly "by hand".
- Reduction of Occupational Safety and Health Costs and Infrastructure Because cobots work without (or with minimal) fencing, there is no need to invest in expensive safety cages, barriers or gates. Operators can freely perform their tasks while working together with the robot - e.g., by providing it with the next parts to be assembled.
- Versatility and Scalability Depending on the manufacturer, cobots with very different payload parameters (from 0.5 to even several dozen kilograms), number of axes (most often 6) or arm reach are available on the market. This makes it possible to select a model for tasks requiring both delicate manipulation of electronics and the transfer of medium-sized components.
- Improved Ergonomics and Working Conditions Cobots can take over tedious, monotonous or physically demanding tasks from operators, helping to prevent occupational diseases and injuries. As a result, people can focus on more creative and supervisory tasks, while the process itself becomes more precise and stable.
- Easy Integration with Vision Systems and IoT Collaborative robots are perfectly suited for the Industry 4.0 environment. They can be equipped with cameras, vision sensors or wireless communication modules to collect data in the cloud and perform remote analysis. This translates into greater quality control and a quick response to unexpected events in production.
Applications in Industry
Collaborative robots (cobots)
Collaborative robots (cobots) work well in many industries - from automotive to food and pharmaceuticals - wherever humans and machines need to interact seamlessly. Their ability to work in variable conditions, flexible software and advanced safety features mean that they are increasingly replacing traditional robots that require costly enclosures and isolation.
Assembly and Quality Control
Cooperative Assembly of Components
In applications where the operator performs some manual operations (e.g., inserting delicate electronic components), and the robot performs repetitive movements (e.g., tightening screws, pressing latches).
Verification of Correctness of Assembly
Thanks to force sensors or vision systems, cobots can support the operator in quality control (e.g., testing the smoothness of a mechanism or checking the tightness of latches).
Packaging and Palletizing
Compact Packaging Lines
In small and medium-sized plants, where there is no space for installing large industrial robots with safety cages, cobots work perfectly, cooperating with the operator in packing products into boxes or stacking them on pallets.
Direct Feeding by Operator
All that needs to be done is for a person to deliver the product within the reach of the cobot's arm, and it will safely and repeatedly transfer it to the packaging, without requiring the process to be interrupted in order to remove safety features.
Machine Tending and Component Feeding
Cooperation with CNC Machines
The cobot can load and unload parts to the machine tool while the operator supervises the process and makes minor adjustments to the parameters. This minimizes downtime and reduces the risk to the employee (contact with moving or sharp elements).
Transferring Parts Between Workstations
Collaborative robots are ideal for low- and medium-volume production lines, where a fully automated production line is not yet economically justified.
Applications in the Food and Pharmaceutical Industries
Small Packaging Tasks
Labeling, closing lids on jars or bottles - tasks that previously burdened employees with monotonous work can now be taken over by cobots.
Increased Hygiene and Safety
Appropriate coatings and smooth housings make it easy to maintain cleanliness, which is important in food processing or when packaging medicines.
Manual Tasks Assisted
Cooperative Soldering, Gluing or Painting
The operator can start the assembly process or apply a preparation, and the cobot will complete or standardize the task (e.g., fill a gap with glue precisely along the edge), ensuring repeatability.
Assistance in Assembly Teams
In some places, one cobot is enough to support several employees by moving heavy elements to the workstation or helping with hard-to-reach parts of the structure.
Collaborative Robots
Industries Where Collaborative Robots Are Most Commonly Used
Although collaborative robots have gained immense popularity in recent years, their applications continue to grow, encompassing ever newer sectors of the economy. Below is a list of industries where collaborative robots have revolutionized production and assembly processes:
Assistance in assembling delicate electronic components (sensors, wiring harnesses), joint handling of heavier body parts.
Precise soldering, transferring small components, tightening screws in device housings.
Collaboration with humans in visual and measurement inspections.
Safe dispensing of raw materials, packaging products in bulk containers, or operating filling lines.
Flexibility in frequent changes of assortment and packaging.
Gentle handling of ampoules, vials, tablets in sterile conditions.
Assisting employees in packing and quality control of medicines, bandages, and medical equipment.
Assembling packages in e-commerce, transferring small shipments, or sorting letters in small logistics centers.
Facilitating the work of people packing various goods in non-standard packaging.
In most of these industrial sectors, the key values of collaborative robots are: safety, flexibility i ease of programming. In the age of increasing pressure for shorter production runs, changing consumer needs and a shortage of skilled workers, collaborative robots are an answer to the challenges of modern automation, combining the potential of machines and humans in one harmonious process.
Collaborative Robots (cobots)
Technical Requirements and Integration
Collaborative robots (cobots) - despite simplified operation and the built-in safety layer provided by manufacturers - still require proper preparation of the environment and integration with the existing production line. Below are the key elements to keep in mind before implementing a cobot.
Operating Parameters
Load Capacity and Range
Most cobots have a lifting capacity of several to a dozen kilograms. There are also models capable of lifting several dozen kilograms, but as the lifting capacity increases, so do the size of the arm and the costs. The reach of the arm (from 0.5 m to even 1.5-2 m) should be selected according to the application requirements, so that the robot can freely reach within the working area.
Accuracy and Repeatability
For precise assembly, packaging or screwing, it is crucial to maintain accuracy within hundredths of a millimeter. Most cobots provide repeatability at the level of ±0.05-0.1 mm, which in many cases is fully sufficient.
Speed and Safety Modes
Depending on the operating mode (collaboration with humans, partially fenced area), maximum movement speeds can be set. In full collaboration mode, speeds are limited so that any collisions do not cause injuries.
Integration with Control Systems
PLC Controllers and HMI Panels
Cobots work with popular industrial protocols (Profinet, EtherCAT, OPC UA). They can be easily connected to the line architecture to receive and send signals to a higher-level controller (e.g., start/stop sequences, cycle times).
Vision Systems and Sensors
In many tasks, especially pick & place or assembly, integration with vision cameras (2D or 3D) proves crucial. The cobot, analyzing data from the camera, can modify the trajectory on the fly. Additional force/moment sensors, built-in or mounted on the gripper, allow reacting to variable geometry of parts or unexpected obstacles.
Software and Cloud (IoT)
Cobots are increasingly supporting IoT platforms, enabling remote monitoring (e.g., analysis of key productivity indicators, early detection of failure signs). This allows for quick response to changing conditions and optimization of the work plan.
Risk Assessment and Safety
Hazard Assessment
Despite the built-in safety features, every process involving a cobot should be analyzed for potential hazards. It is necessary to verify: m.in- the weight of transported parts, operational movements, the presence of sharp edges, or high temperatures.
Fencing - Is It Always Necessary?
Usually, when operating in a fully collaborative mode (with limited speeds), there is no need to install safety fences. However, if the robot operates at higher speeds or handles heavier objects during certain phases, it is worth considering a buffer zone or light curtains.
Maintenance and Service
Cobots, although designed for safe operation with humans, still require inspections and periodic checks of force sensors. Regular equipment checks are recommended in accordance with the manufacturer's guidelines to maintain a consistently high level of safety.
Environmental Conditions
Temperature and Humidity
It is necessary to ensure that the cobot is adapted to the conditions prevailing in the hall (e.g., in a cold storage facility, in high humidity or near heat sources).
Contact with Chemicals
In the pharmaceutical or chemical industry, anti-corrosion coatings and material certificates are often required.
Cleanliness and Sterility
In sterile areas (e.g., cleanroom), models that meet specific standards and are equipped with covers to limit particle emissions should be selected.
Collaborative Robots (Cobots)
Comparison with Other Types of Robots
Collaborative robots (cobots) are solutions designed for collaboration with humans, distinguished by advanced safety features and intuitive operation. Thanks to their flexibility, they can be used in many industries, from assembly to packaging. To help you choose the best solution, we have prepared a comparison of cobots with six other types of robots below - in subsequent parts you will find detailed comparisons and recommendations.
Cobots vs. Cartesian (XYZ)
The Idea of Collaboration with Humans vs. Linear Motion in Axes
Cobots are designed to safely interact with an operator in the same workspace, without the need for enclosures (or with a minimum requirement). They have collision sensors and usually operate at lower speeds and with less payload to avoid posing a hazard. Cartesian robots (XYZ) move in three linear axes, often in a dedicated safety zone, which in the classic approach does not assume the presence of a person near moving elements.
Applications
Cartesian robots are suitable for processes requiring regular, linear movements - e.g., 3D printing, milling of light materials, pick & place on a large plane. Cobots aim at tasks where the operator and robot complement each other, e.g., the robot precisely tightens a screw, and the employee manually adjusts the part.
When to Choose?
If the priority is human-robot cooperation, safety, and quick changeover of the workstation, cobots are an excellent choice. In the case of handling a large area of movement along the X, Y, Z axes and no need for direct interaction with a person, a Cartesian robot may turn out to be simpler and more cost-effective.
Cobots vs. SCARA
Safety and Dynamics
Cobots are designed to limit force and speed so that in the event of contact with a person, they do not cause injuries. SCARA robots specialize in ultra-fast pick & place or assembly operations in a horizontal plane, but do not have standard functions for safe collaboration with humans (they most often require enclosures or safety curtains).
Applications and Advantages
SCARAs attract applications in the assembly of small electronics, screwing screws, or quickly transferring light elements between production nests. Cobots, on the other hand, are suitable where the employee and robot must share space and help each other (e.g., the robot holds an element, the employee performs quality control or manual finishing).
When to Choose?
If short cycle time and high speeds in "2D plus Z-axis" movements are important, a SCARA robot will be more efficient. When human-robot collaboration is key (e.g., in the case of small-batch production with frequent product changes), cobots will have an advantage in flexibility and safety.
Cobots vs. Articulated (Robotic Arm) Robots
Cooperation vs. Power and Freedom
Articulated (robotic arm) robots are the "classic" industrial type, often with a large payload and wide range of motion (4-6 axes). They operate in a dedicated area, usually without human involvement in the immediate vicinity. Cobots, on the other hand, are designed for safe contact with the operator - they have lower speed and payload, but collision sensors and the ability to stop within a fraction of a second.
Applications
Articulated robots dominate processes requiring work with heavy parts, welding in multiple planes, painting, or operating CNC machines. Cobots excel in collaborating with humans at a single workstation, e.g., in the final stages of assembly, quality testing, or packaging light products.
When to Choose?
If high efficiency, processing larger parts, and full automation are priorities, an articulated robot will be indispensable. In applications with frequent product changes and the need for direct human-machine interaction, cobots clearly win thanks to their safety features and easy reprogramming.
Cobots vs. Cylindrical Robots
The Idea of Cooperation 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 humans: low speeds, collision sensors, and limited force/torque, so that in the event of contact, they do not pose a hazard.
Applications
Cylindrical robots work well in applications where only rotary and vertical motion is needed, e.g., rotating parts around one axis, transferring between two stations arranged radially. Cobots can work together with an operator at a common workstation - for example, by supplying components, screwing screws, or supporting an element being assembled by a human.
When to Choose?
If a workstation does not require human interaction and simple movements are sufficient (rotation + Z-axis), a cylindrical robot may be cheaper and easier to maintain. However, if collaboration with humans and safety are key, and the movement requires more freedom than rotation + Z, a cobot will be a more versatile solution.
Cobots vs. Delta
Direct Cooperation vs. Ultra-Fast Pick & Place
Delta robots specialize in lightning-fast cycles for transferring small products, especially in the food or electronics industries, but they usually operate in a separate zone and at high speeds. Cobots, designed to work with humans, move more slowly, have less payload capacity (although this depends on the model), and safety during contact with the operator is a priority.
Applications
Deltas are great for mass production lines where there is no need for constant human involvement in close proximity. Cobots perform well in areas where humans and robots must help each other (hybrid assembly, where some steps are performed by the machine and some by the operator).
When to Choose?
If you need extreme speeds in pick & place (hundreds of cycles per minute), choose a Delta. However, if you value flexibility and safety when working with humans, as well as the ability to easily reconfigure the robot for different tasks, cobots will provide a more versatile and user-friendly implementation.
Cobots vs. Gantry (Portal) Robots
The Concept of Collaboration vs. Large Reach and Payload
Gantry systems are often massive structures with X and Y axes (and sometimes Z), which can handle a very large working area - for example, an entire warehouse or production line. Cobots focus on safety and direct cooperation with the operator, usually in a smaller area. They do not achieve the same reach or payload as Gantry robots.
Applications
Gantry robots are a solution for transporting bulky or heavy loads between several stations or racks. Cobots most often appear in precise operations, light assembly, testing, or packaging - where humans often need automated assistance, but can also step in at any time and work together with the robot.
When to Choose?
Choose a gantry robot if you need to handle large horizontal distances and/or significant payloads (e.g., several hundred kilograms). If the priority is human-robot collaboration and operation in a limited area, but with high task variability, a cobot will fully utilize its nature as a safe and flexible solution.
Collaborative robots (cobots) focus on safety and easy interaction with the operator, making them ideal for processes that require humans to perform part of the operations. They do not achieve such high speeds as Delta robots, such a range as gantry robots, or such simple kinematics as cylindrical robots. However, in situations where we value quick changeovers, flexibility, and readiness for changing assembly tasks, cobots definitely excel.
Frequently Asked Questions
Frequently Asked Questions
Collaborative robots (cobots)
Cobots are designed for complete coexistence with humans. They are equipped with sensors that detect collisions and limit speed/force upon detecting resistance. Additionally, they comply with ISO. ISO 10218, ISO/TS 15066), which means that any impact is less severe and the risk of injury is significantly lower compared to conventional robots.
Not necessarily. According to the risk assessment approach, if the robot operates in collaboration mode (with limited speed and torque), it is usually sufficient to mark the zone or use basic light curtains. Full enclosure is needed when, during certain operations, the robot reaches higher speeds or handles dangerous objects.
Yes, this is one of its biggest advantages. Many models allow you to "teach" the arm by physically guiding it along a given path (so-called hand guiding). Changing applications and adapting to a new line therefore takes much less time than with traditional industrial robots.
Most modern models provide repeatability at around ±0.05-0.1 mm, which is sufficient for many assembly, packaging, or quality control tasks. More precise applications (e.g., micromounting) may require the use of special grippers or sensors.
Although the main segment of the cobot market focuses on payloads in the range of 5-15 kg, there are also models that can handle 20-35 kg or even more. The choice depends on the application's needs, but as the payload increases, so does the weight and size of the arm itself, and working in collaborative mode may require a review of additional safety measures.
Yes. Cobots typically support major communication protocols (EtherCAT, Profinet, OPC UA) and can be equipped with cameras (2D/3D) to recognize the position of parts or verify quality. In addition, many manufacturers offer IoT platforms that enable remote monitoring and data analytics in the cloud.
Usually up to 1 m/s (sometimes faster), but in collaborative mode, speeds are often limited to around 0.25-0.5 m/s, depending on the risk assessment and safety settings. If the application requires very fast cycles, it is better to consider SCARA, Delta or articulated robots in a fenced area.
Thanks to built-in force sensors, the cobot detects a collision and stops (or significantly reduces speed). This eliminates the risk of serious injury. The operator can usually then resume the process after a short procedure confirming safety.
In theory, yes, provided that there is proper maintenance and breaks in accordance with the manufacturer's recommendations. Frequent downtime may be due to the need to change tooling or supply the line with new materials, rather than 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 taking full training from the manufacturer or using an integrator's services to learn how to maximize the potential of robot-human collaboration.
Do you have more questions?
Contact us or visit the FAQ section to get detailed answers to all your questions about collaborative robots.
- Experience in Various Industries From electronics to automotive, food processing, and pharmaceuticals - our portfolio includes numerous implementations where cobots work with people, supporting assembly, packaging, and inspection tasks. Thanks to this, we can adapt the appropriate robot model to 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 the characteristics of the production line can we select the optimal cobot and accessories (e.g., grippers, cameras).
- Comprehensive Integration and Training We provide full implementation support - from selecting and installing the cobot, through configuring communication protocols, to training personnel and conducting production tests. This minimizes the risk of downtime and accelerates the return on investment.
- Latest Industry 4.0 Technologies Our solutions can be easily integrated with IoT systems, Big Data analytics, or remote monitoring. We focus on innovation so that you can continuously improve processes and keep up with the rapidly changing market.
- Various Financing Options We understand that investing in a cobot can be a challenge for smaller companies, which is why we offer flexible financing options - leasing, long-term rental, or even Robot-as-a-Service, so you only pay for the actual use of the device.
If you want to see how NexaRob helps with real projects, check out 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 extensive expertise in robotics and automation with international experience. Our presence in many markets allows us to effectively adapt solutions to various legal, cultural, and business requirements.
- Regional Teams of Experts Thanks to our extensive network of offices and partners, we offer technical and service support in over 100 countries. This means that our engineers and consultants can respond quickly, ensuring the smooth operation of your production.
- Knowledge of Local Standards Each market is characterized by its own health and safety standards, certification guidelines, or customer preferences. We know the specifics of local industries and can design an implementation that meets all requirements.
- Transfer of Innovation We collaborate with clients from various sectors and regions, which enables us to cross-transfer best practices and innovative solutions between different areas of the world. As a result, your project benefits from NexaRob's global experience.
Whether you run a small production facility in Europe or manage a factory in Asia, NexaRob will provide you with the highest standards of collaborative robot implementation, tailored to local realities and the priorities of your company.
NexaRob
Do you want to become our Partner?
At NexaRob, we believe that the development of the robotics and automation industry requires cooperation between various entities - from component manufacturers and software suppliers to integrators and consulting firms. If you have a technology or service that can complement our collaborative robot solutions, we encourage you to establish a partnership!
Why is it worth cooperating with NexaRob?
Creating New Solutions
Together with our partners, we develop dedicated grippers, tools, vision interfaces, or AI systems that enhance the functionality of cobots and open the way for innovative applications.
Training and Technical Support
We offer regular webinars, educational materials, and engineering sessions for our partners. This allows you to develop your skills in collaborative robotics and implement new ideas more quickly.
Joint Business Development
Our global network enables us to promote our partners' solutions among customers from various industries and regions of the world. Together, we participate in trade fairs, conferences, and events, which helps us gain visibility and reach potential customers more effectively.
Who is cooperation with NexaRob for?
- Companies that create accessories for cobots (special grippers, vision systems, AI software)
- Manufacturers of solutions in the field of IoT and production analytics
- Integrators of complex industrial lines who need support in the field of collaborative robotics
- Innovators and start-ups looking for an experienced partner in developing prototypes and launching products on the market
Join the global NexaRob community!
Contact us, and together we will discuss how we can mutually enrich our offerings and create solutions that are not only innovative but also realistically improve comfort and efficiency in production facilities around the world.
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