Industrial Automation Magazine India

The robot is limited only by its ability to carry a certain payload and length of the arm

Published on : Tuesday 02-04-2024

Ayush Chadha, Business Development Manager, KUKA.

What are the current global trends in the use of robots and cobots in manufacturing industries?

The current global trends for robots & cobots differ based on the industry which is looking for it, either manufacturing or R&D.

Manufacturing industries expect easy to use machines which do not require a trained person to operate and the latest developments in the programming softwares of robots are based on UI based programming, which has programming blocks and essentially avoids the need to write any kind of syntax. Hence, robot OEMs have adapted their UI for the same.

R&D facilities require easy integration and toolboxes in the operating software, which makes the connection of robot tools, third party softwares much easier. For most applications which are developed in these facilities the focus is to engineer a unique application which requires software development for the main controller, like AI based machine vision or milling, the robot is a small part which is used to guide the tool and investing a lot of time in integration of different component is not ideal for them.

New manufacturing technologies also see OEMs offering new age products such as mobile robots which have cobot mounted on top of an AMR, which increases the possibilities of automating tasks on the shopfloor.

In what ways do robots and cobots contribute to increased efficiency and productivity in manufacturing?

These machines are designed to work 24x7 with very high MTBFs, this enables the manufacturing companies to run maximum shifts and reduce their processing time for each task. Repetitive tasks such as handling or dangerous tasks such as welding have been automated in a large scale by robots, which have been big help increase efficiency in the factories.

Cobots have also helped in automating smaller task such as inspection or material handling, and tasks which require force feedback to ensure proper execution such as plugging sockets or meshing gears. Now the newest addition for cobots is palletising, where you do not require a fenced area and the advantage of them being safe around humans helps increase the utilisation of space as well. Such increase in applications for cobots is a great thing as it would bring down the costs of these machines and make them more accessible to different manufacturing industries across the country.

How can manufacturers effectively integrate robots and cobots into existing workflows? Do these replace human labour or create additional opportunities?

There are specific companies in India who are in the business of offering integration/engineering & consultation services who have an expertise in the different fields of integration such as mechanical & electrical commissioning, fabrication, PLC programming and robot programming. Not to forget, their teams also have process knowledge which helps them to deliver the solution with the best quality and understanding of the application which their customers have been pioneering in for many years.

Increase in automation as per my understanding is no threat to human jobs. In the past, unskilled labour was seen in factories doing repetitive or dangerous tasks where they were compensated with low incomes. New technology also creates new kinds of job roles as robot operators, programmers, and developers. This encourages people to learn new skills which increases them employability and standard of living.

What skills are required for workers to effectively operate and collaborate with robots or cobots?

Knowledge of a robot cell with basic information about its components is useful while operating a robot. Just like, if you own a car/bike then knowing about its components helps you in troubleshooting if something goes wrong. As for a robot programmer, they should know a programming language such as C++, or any similar, for them to know the functioning of logical operators such as logic gates, loops, or interrupts. With new user interface developments, knowing the syntax is not necessary now since we have block programming structure.

For people who integrate robots, it is required for them to have knowledge of the peripherals with which the robot would communicate such as a PLC, or digital IOs. In terms of the application which the robot is working on, then a basic knowledge of the tool which the robot is using such as a welding gun, arc welding torch, gripper, or machine vision camera is very useful to make an optimised solution. 

How are manufacturers addressing the need for training and upskilling their workforce in the era of robotic automation?

OEMs, Integrators and now Universities/Diploma Institutes also offer robot programming training through certification courses. With the availability of some courses online, people now have access to these courses from anywhere in the world. When manufacturers procure robots, the practical training is included with the project, and later they also have the option to get trained at the OEM’s training centres or on site.

Training and upskilling is very important for the manufacturers’ team so that they become independent of using the machine and resolving any errors. This is also strongly advised by us for almost every project we deliver, to ensure the customer's team understands the working of the robot + cell + application process to be able to maintain the machine properly.

Apart from programmer & operator training, we also provide the customer with servicing and maintenance training so they are able to have a holistic ownership of the product.

How well do robots and cobots contribute to the flexibility and adaptability of manufacturing processes?

Industrial automation with robots has been in India for a significant amount of time now. Basic operations such as lifting and welding are now very easy to automate with robots/cobots since the ecosystem of robot integration in India is quite stable and support is readily available. When the need comes to change the application being run on the robot with something new or to speed up/optimise the application to cater to the increased demand and lowered cycle times that is when the USP of having a robot which offers flexibility in the application design comes into effect. The robot is limited only by its ability to carry a certain payload and length of the arm, but if the base software of the robot offers you the freedom to run any application, then the adaptability of the robot gets increased exponentially.

If the robot selection is done from the top robot OEMs of today, which offer this kind of freedom to the customers, then they benefit the most in the long run where they can re-use the robot again for any application as per their requirement.

With respect to cobots, the flexibility goes one step further, where the need for setting up a protective fence is completely avoided, and the robot can be kept in an environment where there is a lot of dense human movement and still be okay with maintaining the safety.

(The views expressed in interviews are personal, not necessarily of the organisations represented.)

As a Business Development Manager, Ayush Chadha works for building relationships, cultivating partnerships, retaining top accounts and growing profit channels by establishing trust with key decision-makers in the domain of autonomous mobile robot solutions. Ayush has a Bachelor of Technology degree in Mechatronics, Robotics, and Automation Engineering from SRM University, where he developed a strong foundation in research, design, and programming of robotic systems.

Ayush has been working in the automotive and automation industry for over 4 years, and has gained valuable experience in robot installation, maintenance, and process programming for various applications. He has also contributed to the development of a SLAM-based 3D mapping AGV project and a collaborative robot application. Ayush is skilled in using various software tools, such as KUKA KSS, MATLAB, and Java. He is passionate about learning new technologies and solving complex problems in robotics and automation.

https://www.linkedin.com/in/ayushchadha12/