Collaborative Robotics:
A History of Industrial Robots
Read the full Collaborative Robotics eBook:
By Alex Misiti for Mouser Electronics
In recent decades, as automation has emerged as the central competitive factor in manufacturing operations across
the globe, the use of industrial robots has grown substantially. To provide perspective on this growth, consider the
fact that in 1970 the total number of industrial robots in use in the US was 200. By 1980, that number had risen to
4,000, and by 2015, it was 1.6 million. This growth is expected to accelerate even further in the coming years, as
another 1.4 million industrial robots are expected to enter service by 2019, according to a report from the
International Federation of Robotics.
Industrial Robotic Beginnings
Industrial robots are often discussed in the context of 21st century innovations. However, their roots date back
much further to the 1950s, when George Devol developed the first industrial robot—a two-ton device that
autonomously transferred objects from one place to another with hydraulic actuators. Since that time, as sensors,
electronics, and computer software have advanced, the capabilities of industrial robots have greatly expanded to
include complex tasks such as welding, painting, assembly, packaging, palletizing, inspecting, and testing—all
accomplished with speed, precision, and repeatability.
Robots were first used commercially on assembly lines in the early 1960s. Most featured hydraulic or pneumatic arms
and were primarily used for heavy lifting. Although the devices were primitive, sensorless, and featured limited
programmability, they proved to be an invaluable tool for increasing production in manufacturing facilities and set
the stage for what would be a prolonged period of robotics development.
Throughout the late 1960s and early 1970s, as the need for automation of manpower-intensive tasks in manufacturing
increased, the focus of industrial robotics shifted away from heavy lifting to materials handling and precision
work. This gave birth to the development of smaller electric robots with advanced controls, microprocessors,
miniaturized motors, gyros, and servos, which made them ideal for lighter assembly tasks, such as bolt and nut
tightening.
By the late 1970s, the capabilities of robots expanded even further to include tasks such as material transferring,
painting, and arc welding. They also began taking over dangerous tasks in manufacturing facilities. In steel mills,
for instance, robots were used to move parts and materials in high temperature environments that were inhospitable
for humans. This significantly improved facility safety and drove increased workforce productivity by freeing up
skilled laborers to direct their focus to more important manufacturing operations.
Robotic Technology in the 1980s: Foundation for the Future
The mid 1980s started to see increased interest and excitement in robotics. In seeing robots as the “machines
of the future,” engineers began pushing the frontier forward to support industrial development and achieve
greater manufacturing competitiveness. It was during this period that the foundation of the present-day industrial
robot was laid, as they began incorporating advanced sensors and rudimentary machine vision systems (Figure 1).
Figure 1: Advances in sensors and computer vision revolutionized the way
industrial robots interacted with their environment.
The emergence of these technologies, coupled with a substantial reduction in costs of computer hardware, like
microprocessors, resulted in a step change of advancement in industrial robotic capabilities. Using precision force
sensors and lasers, industrial robots were given the ability to detect and follow manufacturing components along
assembly lines. These lasers and sensors provided the robots with a human-like sense of sight and touch and
revolutionized their interactions with the industrial environment. As a result, robots were transformed from simple
mechanical devices that were programmed to perform repetitive tasks to more elaborate machines that possessed what
many categorized as “limited intelligence.”
Industrial Robots of Today and Tomorrow
Since the early 2000s, developments in industrial robotics have largely been driven by advancements in software.
Emerging fields, such as machine learning (ML) and artificial intelligence (AI), are now pushing forward the
frontier of what robots can do—giving them the ability to learn, improve, and make decisions without direction
or guidance from humans.
Most industrial robots in use today are equipped with a multitude of advanced sensors that gather immense amounts
of data. When integrated with advanced analytics and ML software, the robots can interpret this data and use it to
adapt, alter mechanical motions, and better complete the task at hand. This quest to provide robots with “real
intelligence” is now the primary focus of robotics engineers.
In the coming years, as industrial robots become smarter, they will be able to take on more complex tasks and
execute them with an efficiency that far exceeds human capabilities. They will also be able to safely work alongside
humans in the manufacturing environment. This is something that is already occurring today with the emergence of
collaborative robots, or cobots.
Cobots are a relatively new type of robot designed to safely operate in close proximity or even in direct contact
with humans (Figure 2). They utilize advanced technology, including force-limited joints and computer vision to
detect the presence of humans in their environment. Cobots are often much smaller and lighter than traditional
industrial robots, easily moveable, and trainable to perform specific tasks.
Together, humans and cobots offer a unique level of skill that neither can offer on their own, which results in
manufacturing products far better and faster than would be if either were working without the other. Cobots
generally serve one specific purpose when employed to perform a job. For example, a cobot may provide the force
required to move an object, while a human provides guidance on where to place it. In recent years, the use of
collaborative robots in industries like manufacturing, construction, and healthcare has grown rapidly. By 2020, the
cobot market is expected to reach $1 billion—with an estimated 40,000 machines in operation across the globe,
according to ABIresearch®.
Conclusion
Industrial robots have come a long way from the hydraulic arms and bolt turners of the 1950s and 1960s. Today,
these smart mechanical devices can work safely alongside humans to perform a wide array of complex tasks, such as
painting, welding, complex product assembly, and even surgery. In the coming years, as automation continues to drive
competition among manufacturers across the globe, the robotics market will continue to expand, and the role robots
play to help drive efficiency and throughput within industrial environments will grow in importance.
Alex Misiti is a freelance technical writer
and copywriter with a background in engineering. His areas of expertise include oil and gas, renewable energy,
industrial manufacturing, automation, process control, IoT, civil engineering, and construction.
Bulgaria
