Why Robotics is the Key to the Next Wave of Industrial Automation

Robotics is rapidly transforming many industries, bringing new levels of efficiency, precision, and adaptability. As technology advances, the integration of AI, Machine Learning, IoT, connectivity, and other cutting-edge technologies allow robots to tackle increasingly new and difficult tasks with minimal or no human intervention. This shift not only boosts productivity, but also positions robotics as a key driver of global competitiveness and sustainability. In this blog, we’ll explore more about the critical role of robotics.

An Overview of Modern Industrial Automation

What is industrial automation? Industrial automation involves using control systems, such as robotics and computers, to manage various processes and machinery, replacing human involvement. This ranges from simple tasks, like pick-and-place robots, to complex systems that can autonomously navigate large facilities. 

This transformation began during the Industrial Revolution, where machines first started to change the manufacturing processes. Over the next several decades, innovations like the assembly line, programmable logic controllers (PLCs), and computer-aided manufacturing (CAM) have changed the way industrial environments operate.

Key Technologies in Industrial Automation

A few key technologies that form the backbone of modern automation: 

1. Programmable Logic Controllers (PLCs): These are industrial computers that use custom programming to monitor and control manufacturing processes, such as assembly lines, robotic devices, or any activity that requires programming. 
2. Supervisory Control and Data Acquisition (SCADA): SCADA systems are a system of software and hardware that allow companies to control, monitor, and analyze industrial devices and processes. They are commonly used in electric power generation, water and sewage management, building systems, and manufacturing. 
3. Distributed Control Systems (DCS): These computerized systems manage processes or plants by distributing control elements throughout the system, rather than being centralized. DCS is often found in applications like electrical power grids or wastewater treatment plants.

Role of Robotics in Enhancing Automation

These technologies are important as they help integrate robotics within automation systems. For example, PLCs can control robotic arms on assembly lines, while SCADA systems monitor the overall performance of both robots and machinery, making sure operations are running smoothly and quick responses to any irregularities. 

Robots are increasingly used to perform tasks that are repetitive, hazardous, or need high precision, such as welding and painting. Their integration has led to the development of smart factories where robots not only perform tasks but also interact with other machines, collect and analyze data, and adapt to changing conditions in real-time.

Use Case Example

In a fully automated assembly line, robots equipped with sensors and connected to a SCADA system can identify issues like misaligned parts, component quality, and unexpected delays in the workflow. These robots, such as a robotic arm, can make real-time adjustments by notifying the operator to recalibrate movements or reroute tasks to different lines, preventing bottlenecks. 

The incorporation of IoT and connectivity further enhances robots’ capabilities by allowing real-time data exchange and remote monitoring. This improves decision-making, predictive maintenance, and overall efficiency, paving the way for smarter, more connected factories.

The Role of Robotics in Industrial Automation

Types of Robots Used in Industrial Automation

There are over 2-3 million robots in use worldwide, each designed for specific applications. Here are a few key types:

• Articulated Robots: These robots feature rotary joints ranging from two to more than ten interactive points, mirroring human arm movements. Commonly found in manufacturing facilities, 6-axis articulated robots are often used in assembly lines for tasks such as welding, painting and assembly, where flexibility is critical.  
• Automated Guided Vehicles (AGVs):  travel through a pre-fixed path using sensor guidance along magnetic tape or barcodes.
• Autonomous Mobile Robots (AMRs): utilize sensors and cameras to navigate through dynamic environments creating their own path. These robots can perform tasks like material transport, loading and unloading items, and tugging and towing of carts. Next-generation AMRs are also being used for more complex applications such as cleaning, security, and inventory tracking. 
• Cartesian Robots: Cartesian robots move in three orthogonal axes-X, Y, and Z direction. They are commonly used in applications that require linear movements, such as CNC machining, 3D printing, and material handling. Known for their high precision, Cartesian robots are ideal for straightforward, repetitive tasks.  

Benefits of Using Robotics 

The integration of robotics offers many benefits. Robotics can improve time to market by freeing up skilled labor, easily scales to meet production needs, and consistently delivers high-quality results. Here are some key benefits: 

1. Increased Efficiency and Productivity: Robotics significantly boosts production efficiency by performing tasks faster and more accurately than humans. In industries like electronics, robots can assemble parts with greater speed and precision, leading to higher throughput. This efficiency is also crucial in fulfillment centers. According to McKinsey & Company, e-commerce has increased 30% above pre-pandemic levels and over 90% of consumers view 2-3 day delivery as a baseline expectation. AGVs and AMRs help streamline these operations to increase capacity. Read more about this use case in our case study: Mobile Robots Improve Productivity for Fulfillment Centers. 
2. Enhanced Precision and Consistency: Robots excel in jobs that require high accuracy and consistency. New technological advancements like vision systems and AI have further improved their precision, allowing robots to “see” and understand their surroundings. For example, robotic arms in electronics manufacturing can place tiny components onto circuit boards with micron-level accuracy, keeping consistent quality across large volumes of products. 
3. Reduction in Human Error and Workplace Injuries: Beyond efficiency and precision, robots are important in taking over repetitive and hazardous tasks. In heavy manufacturing and chemical processing, robots handle dangerous materials, reducing the risk of human error and workplace injuries. For example, robots can safely manage, transport, and mix chemicals, minimizing the chance of spills and incorrect mixing. 
4. Scalability and Flexibility: Robotics allow manufacturers to quickly scale operations and adapt to changing production demands. Robots can be reprogrammed and reconfigured for new tasks as product lines change. This flexibility is especially valuable in industries with fluctuations in volume, like fulfillment centers during peak season. Additionally, using Ezurio’s System-on-Modules ensures these robots can be future-proofed by upgrading to the latest processing and connectivity options, to keep peak productivity levels.

Key Applications of Robotics in Industrial Automation

Robotics can be applied in various settings, with each type of robot offering unique benefits. Common use cases include material handling, pick-and-place, palletization, welding, assembly, and transporting. Here are a few examples in more detail:

• Assembly Line: Robots are essential in assembly line automation, handling repetitive tasks like assembling components, screwing, welding, and applying adhesives. With the integration of the Internet of Things (IoT) and enhanced connectivity, assembly line robots are now smarter and more interconnected. They communicate in real-time with other machines and systems, using Wi-Fi or Bluetooth mesh to adjust operations based on production flow. For example, if one robot detects an issue with a component, it can automatically sync with the other robots to adjust its pace, minimizing downtime and keeping a smooth and accurate assembly line. 
• Material handling: AGVs and AMRs can move, sort, and manage materials within manufacturing facilities, warehouses, and distribution centers. They perform tasks like unloading, palletizing, and transporting materials, reducing the manual labor burden on employees. These robots can also be programed to carry out inventory tasks, such as selecting items from a conveyor belt based on real-time data from the inventory system. This connectivity ensures that robots accurately scan and load the correct items, whether for storage or shipping. 

                To learn more , read our case study on Advancing Warehouse Operations with Wireless Devices. 

• Quality Control: Quality control is critical in manufacturing, and advanced robotics equipped with vision systems, sensors, and AI are increasingly used to inspect products and detect defects with exceptional precision. Thes robots can instantly share inspection data with the facility’s system that monitors quality across the production line. If a defect is detected, the robot alerts the system, which can then adjust necessary parameters in real-time to prevent further defects. This real-time feedback loop helps address quality issues, reducing errors and increasing production standards. 

                Learn more with our case study: Leveraging System-on-Modules in Vision Inspection Systems. 

Integration of Robotics with Other Technologies

AI and Machine Learning (ML) are transforming robotics by improving their capabilities. By incorporating AI through components like processors, neural processing unit, and specialized software, robots can learn from previous actions and make real-time decisions. For example, machine learning allows robots to learn specific tasks by observing and mimicking human actions, while AI provides computer vision, allowing robots to navigate, detect, and react to their surroundings. This helps robots go beyond simply performing repetitive tasks to more advanced, complex ones.

IoT (Internet of Things) plays a huge role in creating smart factories and smart warehouses, where robots and machinery are interconnected and communicate in real-time. IoT-enabled robots are equipped with sensors and wireless modules, such as the Sona™ IF513and IF573, to collect and analyze data. This connectivity allows robots to operate more intelligently, such as rerouting their path to avoid congested areas. It can also perform predictive maintenance by monitoring the health of machines, helping to reduce downtime.

With the rise of IoT and connectivity, the volume of data generated in factories and warehouses has surged. Through Big Data Analytics, this data can be analyzed to identify patterns, optimize workflows, and support data-driven decision-making. How do robots “learn” from Big Data? Robots can utilize Machine Learning and AI, to improve their performance over time, learning and adapting without the need for manual reprogramming for new tasks or situations.

Collaborative Robots (Cobots) represent a major advancement. Traditionally, robots are isolated from human workers due to safety concerns, however, cobots work directly alongside humans in a shared space as they are equipped with sensors and safety features that allow them to interact safely with humans. To learn more about cobots, ready our whitepaper: AGVs, AMRs, Cobots and Connectivity: Accelerating Wireless Design for Next-Gen Industrial Robotics.

Challenges Implementing Robotics in Industrial Automation

While robotics offer many benefits in industrial automation, several challenges can complicate widespread adoption. Successful implementation requires careful planning, investment in training, and strategic integration to overcome these obstacles. Key challenges include:

• High Initial Investment: The upfront costs of purchasing robotic systems, including hardware, software, and the necessary infrastructure, can be significant. Beyond these initial costs, additional investments are often needed to upgrade existing system, train employees, and cover ongoing maintenance costs.
• Complexity of Integration: Integrating robotics into existing facilities is often complex as many legacy systems were not designed with robotics in mind. This process may require custom solutions, extensive training, and potential reconfiguration of the facility, which can be both time-consuming and costly.
• Workforce Displacement Concerns: The introduction of robotics raises concerns about job displacement. According to Oxford Economics, robots could displace 20 million manufacturing jobs worldwide by 2030. This potential for job loss can lead to lower morale and job dissatisfaction from employees. To address these concerns, businesses need to communicate the benefits of robotics, such as reducing the need for dangerous or tedious tasks and offer retraining programs to help displaced workers transition into new roles.
• Maintenance and Technical Expertise: Maintaining and programming robotics requires a high level of technical expertise. Finding skilled technicians and engineers with robotics experience can be difficult, and keeping up with the rapid technological advancements requires ongoing education and training.

The Future of Robotics in Industrial Automation

Emerging technologies are shaping the future of robotics, with AI, Machine Learning, and smart sensors allow a robot to learn, adapt, and make autonomous decisions. Sustainability is also becoming a critical focus, with robots being designed to reduce energy consumption and align with global environmental goals, driving the adoption of greener technologies across many sectors. 

Looking ahead, robotics will become more autonomous, adaptable, and key for smart facilities. By 2030, it is projected that around 90% of large-scale businesses will use some kind of robotics. To stay competitive, companies will NEED to implement robotics as these systems become smart, more sustainable, and pivotal to industrial innovation. 

Learn more about robotic challenges, connectivity options, and solutions with Ezurio’s Robotics Market Page.