Representing one of the major developments of
industrial robotics in recent years, collaborative robots
are designed to work alongside human beings. Human-robot
collaboration on the manufacturing floor is paving the way
for unprecedented efficiency and productivity. The present
article will discuss the ongoing efforts aimed at enhancing
the capabilities, widening the applications, and overcoming
the physical security implications of collaborative robots.
It will also present the federal R&D tax credit
opportunity available for companies engaged in constructing
a new paradigm, where humans and robots become coworkers.
The Research &
Development Tax Credit
Enacted in 1981, the Federal Research and
Development (R&D) Tax Credit allows a credit of up to 13
percent of eligible spending for new and improved products and
processes. Qualified research must meet the following four
criteria:
• New or improved products,
processes, or software
• Technological in nature
• Elimination of uncertainty
• Process of experimentation
Eligible costs include employee wages, cost
of supplies, cost of testing, contract research expenses, and
costs associated with developing a patent. On January 2, 2013,
President Obama signed the bill extending the R&D Tax
Credit for 2012 and 2013 tax years.
Collaborative Robotics
Collaborative robots are here to stay.
Increasingly, they are being integrated into real-world
manufacturing settings, where they work together with humans.
They are responsible for a shift in the business model of
robots, from machines to labor. These paradigm-shifting
robots, which often present humanlike characteristics, are
designed to operate in human-occupied spaces without many of
the safety constraints required in the past. In other words,
they are “cage-free”. The combination of physical proximity
and anthropomorphism has shed a new light on the potential
collaboration of humans and robots, establishing a novel,
somewhat natural connection between them.
Generally speaking, collaborative robots are flexible and
capable of performing multiple tasks. They are designed for
non-expert users and therefore present unprecedented ease of
use. Most of the time, interacting with them does not require
high-level programming experience or technical skills. The
need for sophisticated programming tends to disappear as this
new breed of “teachable” robots emerges. In addition to a
simplified interface, collaborative robotics are marked by the
application of various innovative technologies:
I.
Kinematic Redundancy: the development of a 7
degree-of-freedom manipulator, or the 7-axis arm, has been
crucial to perfecting the movements of collaborative:
robots. A significant evolution from traditional robots,
which usually feature 6 axes, this innovative
configuration mimics the human arm and enables a wider
variety of forms and shapes of the robotic arm when
performing a given task. Particularly useful for robots
working in crowded spaces, the 7 joints allow them to
swivel their elbows around to get out of the way of people
or objects while maintaining their grasp in one location.
Figure 1: Example of a 7-axis arm.
II. Force-Torque Sensing:
for safety reasons, collaborative robots often incorporate
power and force limiting features. Force-torque sensors give
robots a sense of feeling and are used to adapt the effort
engaged in performing different tasks. They also make sure
the robot stops and adapts when reaching a certain threshold
or unforeseen resistance.
For instance, a robot knows
the exact amount of force required to insert a shaft into a
hole. When sensors detect an increase in resistance, due to
misalignment, for example, it automatically adjusts its
movements and position to properly accomplish its task. In
addition to preventing harm, such as a broken shaft,
force-torque feedback is crucial to applications that
require precise force to achieve quality results.
Expected to be one of the
next big advances in the robotics industry, force-torque
sensors are an essential aspect of major ongoing R&D
efforts. Incorporating this technology into a wider range of
applications would enhance accuracy and precision of robots
and pave the way for progress in areas such as haptic
technology and teleoperation.
III. Collision Detection:most collaborative robots are capable of detecting
unexpected contact with objects or humans. Collision sensors
are designed to prevent costly damage caused by crashes as
well as dangerous accidents involving human workers. In some
cases, robots are programed to suspend their full-speed mode
and enter a compliant mode when contact is detected, meaning
that they can be easily pushed away. Others are designed to
simply back off at the slightest human contact, enhancing
security at the workplace.
By incorporating technologies such as
force-torque sensors and collision detection mechanisms,
collaborative robotics has rendered many of the safety
measures that have traditionally segregated robots from humans
obsolete. Such measures considerably limited the tasks that
robots could perform, preventing both robots and humans from
realizing their full productive potential.
Not only do collaborative robots allow for a surge in
productivity, but they do so in humans’ terms. The so-called
“human-scale automation” makes sure that no major changes in
the workplace are necessary to welcome collaborative robots.
Machine layouts and factory floor plans stay the same, people
rule.
The Collaborative
Robots Family
Though presenting common traits, robots
capable of collaborative operations come in many forms. In
fact, a growing number of robotics companies are investing in
new and improved collaborative solutions. The following
paragraphs will present the latest developments by some of the
most preeminent companies in this field.
Meet Baxter
Manufactured by Rethink Robotics, Baxter
has redefined the way robots can be used in manufacturing
environments. The dual-arm humanoid was introduced in
September 2012 and has since been incorporated by a wide
variety of companies, including many that had never considered
a robotic automation solution before. Among Baxter’s potential
applications are kitting, packaging, loading and unloading,
machine tending, and material handling.
Manufactured by Rethink Robotics, Baxter
has redefined the way robots can be used in manufacturing
environments. The dual-arm humanoid was introduced in
September 2012 and has since been incorporated by a wide
variety of companies, including many that had never considered
a robotic automation solution before. Among Baxter’s potential
applications are kitting, packaging, loading and unloading,
machine tending, and material handling.
Weighing 165 lbs., Baxter has two 7-axis arms connected to a
torso, each of them capable of lifting up to 5 lbs. It
features an LCD display for an animated “face” that reacts to
human interaction. Additionally, Baxter has a built-in 360
sonar and front camera sensors to detect humans presence,
integrated vision for movement and object detection, and
interchangeable end-effectors for easily switching tasks.
Baxter requires no complex programming or costly integration.
It presents behavior-based “common sense”, or intuitiveness.
In other words, it is capable of sensing and adapting to a
task or environment.
Baxter’s $25,000 base price has made it an affordable solution
for a growing number of businesses. Regular software releases
promise to improve the robots’ capabilities. Such is the case
for the 2014 Intera 3, which enables Baxter to perform with
over twice the speed, precision, and motion quality of its
flagship version.
As more and more leading U.S. manufacturers purchase Baxter,
improvements in functionality, manufacturing processes, and
software development should follow. The MIT Technology Review
has listed developments related to the Baxter Robot as one of
the top ten R&D opportunities of the future.
Figure 2: Rethink
Robotics’ Baxter Robot
Yaskawa Motoman’s SDA
Robots
Headquartered in West Carrollton, OH,
Yaskawa Motoman is an American subsidiary of the Japanese
company Yaskawa Electric Corporation. With nearly 300,000
Motoman robots, 10 million servos, and 18 million inverter
drives installed globally, Yaskawa provides automation
products and solutions for virtually every industry and
robotic application. The company has over 175 distinct robot
models in its product line, which includes the innovative
Motoman SDA, a series of 15-axis robots. Available with 11,
22, and 44 lbs. handling capacities, SDA robots offer ultimate
flexibility due to two 7-axis arms plus waist rotation.
This groundbreaking solution combines a compact footprint with
“human-like” dexterity, which makes it ideally suited for
assembly, part transfer, machine tending, packaging, and other
handling that formerly could only be done by people. SDAs’
arms can work together or perform simultaneous independent
operations. This line of robots uses a FS100 Controller, whose
unmatched open architecture enables software customization in
widely accepted environments such as C, C++, C# and .NET.
Yaskawa is an advocate of collaboration through control. For
this reason their controllers offer a “Functional Safety
Unity” (FSU) that respects the most recent AINSI standards.
The system features safety-rated monitored stops, along with
speed and separation monitoring. Safety-rated lasers and
sensors are also part of the system and are used to detect the
presence of humans in collaborative environments. All sensors
used in FSU have built-in fail-safes, meaning that two
different pieces of software and hardware perform
cross-checking for each and every signal received. If either
of the two drops, the system goes into a safe condition. In
the following video, Erik Nieves, Technology Director for
Yaskawa Motoman in Miamisburg, Ohio, presents the functional
safety features of Motoman robots.
Danish company Universal Robots works to
make robot technology available to all. It has developed a
highly specialized, flexible, and low-cost robot arm that can
be used in almost any industry, particularly where traditional
robots are too large, expensive, noisy, or inflexible. The UR
series comes in two models, with 11.3 and 22.6 lbs. payload
6-axis arms. Perfect for repetitive, mundane tasks, such as
loading and unloading, Universal Robots are collaborative, or
capable of operating without safety fencing after a risk
assessment is conducted.
Designed to work as production assistants, URs are pioneers of
automation in industries and applications where manual
operations have traditionally prevailed. Very easy to use and
set up – installation can be done in less than one hour - the
UR is more taught than programmed. This “teachability” has
driven workers closer to robots and empowered them to actively
take part in the automation process. Universal Robots
lightweight, portable arms have been widely adopted by small
to midsized companies who seek fast, easy, and affordable
automation. In order to keep up with a growing demand, the
company has recently opened a new 129,000-square-feet
production facility.
Figure 4: UR5 and UR10
KUKA’s LBR
iiwa
German manufacturer of industrial robots
and solutions for factory automation, KUKA is the creator of
the LBR iiwa, a highly sensitive robot for industrial
applications. The 7-axis arm has a “light touch” particularly
suited for sophisticated assembly tasks. LBR stands for
“Leichtbauroboter”, which means lightweight in German, and
“iiwa” is an acronym for “intelligent industrial work
assistant”. This revolutionary line of extremely sensitive
robots, has enabled automation in areas where it was
previously impossible or not economically viable.
Made entirely of aluminum, the LBR iiwa is very portable and
provides outstanding payload-to-weight ratios. It comes in two
models, capable of handling payloads of 15.4 lbs. and 30.8
lbs., and weighing 52.6 lbs. and 65.9 lbs., respectively.
The LBR iiwa stands out for its extremely high sensitivity,
which is seen as a prerequisite for the safety of humans and
materials. It uses power and force limiting features, which
enable direct contact with a person. This is possible due to
torque sensors built into each one of its seven joints.
Additionally, it features a highly responsive collision
detection system.
Designed for direct interaction with
humans, the LBR iiwa features iconic design and style that
reduce risks of injury in human-robot collaborative
applications. Its organic shapes, soft edges, and smooth
flexibility won the Red Dot Award: Product Design 2014. Also,
the LBR iiwa has a teaching by demonstration feature, which
empowers human operators, leaving the need for programming
skills behind. The following video shows this feature in
action.
As a result of years of research and
development, Swiss industrial robots supplier ABB
unveiled, on September 9th, the YuMi, an innovative,
human-friendly, dual-arm robot. With breakthrough
functionality, YuMi is designed for a new era of
automation, where people and robots work hand-in-hand. The
name “YuMi” is short for “you and me” working together.
The new small parts assembly robot solution includes
flexible hands, parts feeding systems, camera-based part
location, and state-of-the-art robot control. It also
features innovative force-sensing technology built into
its soft padded arms, which ensures a safe incorporation
to the work environment.
Offering great flexibility, agility,
and precision, the novel collaborative robot was
primarily developed to meet the needs of the consumer
electronics industry. Modern electronics manufacturing
plants must keep up with constantly changing product
requirements, which call for modular and adaptable
automation. According to ABB, YuMi can handle
everything, “from the delicate and precise parts of a
mechanical wristwatch to the components used in mobile
phones, tablets, and desktop PCs”. YuMi will be
commercially available in April 2015. It is expected to
unlock vast additional automation potential in the
consumer electronics industry and to be gradually rolled
out to cover other market sectors.
Figure 6: The
YuMi
Robotiq’s Adaptive Hands
Founded in 2008, Canadian company
Robotiq designs and manufactures adaptive grippers for
collaborative robots. Their approach consists of embedding
mechanical intelligence into devices in order to simplify
integration and increase system performance, enabling a
next generation of industrial and service robotic
applications. Robotiq’s 2 and 3-finger adaptive grippers
offer outstanding flexibility and are easily integrated
with the collaborative robots available in the market. The
idea is to provide companies with a flexible, multiuse,
programmable tool, capable of grasping a wide range of
parts with control of the stroke, force, and grip type.
The company offers
installation kits for the UR, KUKA’s LBR iiwa, and the
Baxter Research Robot. The gripper runs on the same
controller as the robot and appears on the teach pendant
interface. By reducing tooling costs and eliminating
changeovers, Robotiq’s hands can maximize returns on
investments for collaborative robotics products.
The following video shows a UR robot with a Robotiq
2-finger gripper performing a machine tending
demonstration.
Though collaborative robots have
been more widely engaged in industrial applications,
innovative solutions aim to consolidate their presence
in the services industry.
Headquartered in
Pleasanton, California, Adept Technology Inc.
manufactures autonomous mobile solutions for
dynamically moving materials. The Adept Lynx is a
self-navigating Autonomous Indoor Vehicle (AIV)
capable of intelligently moving around people and
unplanned obstacles, even in challenging environments
that may include confined passageways. Lynx does not
require facility modifications and is particularly
suited for pharmaceutical, medical, and laboratorial
operations.
Yet another solution for
delivering materials, the SaviOne was designed to
serve the hotel industry. This innovative,
services-oriented robot is the creation of Savioke,
a robotics startup from Sunnyvale, CA who recently
raised $2 million in investments from Jerry Yang’s
AME Cloud Ventures, Google Ventures, Morado Venture
Partners, among others.
Currently being piloted at the
Aloft Hotel in Cupertino, CA, the SaviOne should be
rolled out into more hotels over the next year. The 3
feet tall robot weighs less than 100 lbs., has a
carrying capacity of 2 cubic feet, and can travel
independently between floors via the hotel elevator.
By delivering goods securely and efficiently to hotel
guests, the SaviOne enables the staff to save time and
focus on guests’ needs.
Figure 8: SaviOne, the robotic butler
Safety in Human-Robot
Interaction
As fast-paced collaborative
technologies evolve, safety regulations tend to
struggle to catch up. For this reason, safety is still
one of the main issues surrounding collaborative
robotics. The latest international ISO 10218:2011 and
U.S.-adopted ANSI/RIA R15.06-2012 safety standards
establish that collaborative operations must meet at
least one of the following criteria: 1) Safety-rated
monitored stop; 2) Hand guiding; 3) Speed and
separation monitoring; or 4) Power and force limiting.
The vagueness of
current standards can be explained by a difficulty in
addressing each and every one of the myriads of
potential applications of collaborative robots. In
that sense, companies must devote their efforts to
assessing and mitigating the risks surrounding their
products. Investing in new and improved safety
solutions is a major area for collaborative robotics
R&D and one that can entail significant federal
R&D tax credits. New, more specific
international regulations should be released soon. The
industry expects them to provide more guidance on how
to effectively conduct a risk assessment of
collaborative robots.
The Future of Collaborative
Robotics
By combining the dexterity,
flexibility, and problem-solving capabilities of human
beings with the strength, endurance, and precision of
robots, collaborative robotics promises to
revolutionize almost everything, from manufacturing
facilities to offices, schools, and even homes.
Though advances
made so far are beyond remarkable, there is still a
lot of room for improvements. R&D efforts are
underway to create new software that make programming
collaborative robots even easier, possibly using
speech. The deeper integration of artificial
intelligence and the development of a “common sense”
in robots is yet another promising area for
innovation.
Experts also
consider the need of improving robots’ “social
intelligence”, which consists of small traits and
features that will favor a seamless and friendlier
interaction with humans. Advances in this area are key
to a new breed of “home assistance” or “companion”
robots, which can one day change the face of in-home
care.
The future of
collaborative robots may even bring innovative payback
scenarios. Based in Holland, Michigan, Steel Collar
Associates distributes Motoman dual-arm robots as
contract employees. Understanding that some users may
want to expense a part of their automation as opposed
to capitalizing it, the startup is the first temp
agency for robots.
Collaborative
robotics R&D is expected to become increasingly
human-centric. Innovative efforts tend to place the
human at the center of the entire design, creating
robots that are capable of adapting to humans (and do
not require human adaptation). The ultimate objective
is to enhance multi-modal communication in such a way
that robots will be able to recognize human gestures
and motion intentions, without the need for voice
commands.
Working Together in Perfect
Harmony
By teaming up with people,
collaborative robots have the potential to trigger a
real robotics revolution. They are here not to replace
people, but to empower them. Scalable, flexible, and
easily implemented, collaborative robots serve as
workforce multipliers, enabling new levels of
productivity and efficiency. The future of human-robot
collaboration is exciting to say the least. Federal
and State R&D tax credits are available to help us
get there.
Figure 1: Example of a 7-axis arm.
Manufactured by Rethink Robotics, Baxter
has redefined the way robots can be used in manufacturing
environments. The dual-arm humanoid was introduced in
September 2012 and has since been incorporated by a wide
variety of companies, including many that had never considered
a robotic automation solution before. Among Baxter’s potential
applications are kitting, packaging, loading and unloading,
machine tending, and material handling.
Danish company Universal Robots works to
make robot technology available to all. It has developed a
highly specialized, flexible, and low-cost robot arm that can
be used in almost any industry, particularly where traditional
robots are too large, expensive, noisy, or inflexible. The UR
series comes in two models, with 11.3 and 22.6 lbs. payload
6-axis arms. Perfect for repetitive, mundane tasks, such as
loading and unloading, Universal Robots are collaborative, or
capable of operating without safety fencing after a risk
assessment is conducted. 
Founded in 2008, Canadian company
Robotiq designs and manufactures adaptive grippers for
collaborative robots. Their approach consists of embedding
mechanical intelligence into devices in order to simplify
integration and increase system performance, enabling a
next generation of industrial and service robotic
applications. Robotiq’s 2 and 3-finger adaptive grippers
offer outstanding flexibility and are easily integrated
with the collaborative robots available in the market. The
idea is to provide companies with a flexible, multiuse,
programmable tool, capable of grasping a wide range of
parts with control of the stroke, force, and grip type.
Though collaborative robots have
been more widely engaged in industrial applications,
innovative solutions aim to consolidate their presence
in the services industry. 
