Collaborative robots: what they are and what they are used for

The role of cobots in improving the efficiency and safety of production processes

Collaborative robots (or cobots) are profoundly transforming the manufacturing industry, offering new possibilities for flexible, safe automation integrated with human work. Unlike traditional industrial robots, cobots are designed to share workspaces with operators, interacting directly with them without the need for physical barriers. This characteristic also makes them particularly suitable for small and medium-sized companies and sectors with high production variability.

In industrial carpentry, in particular, collaborative robots are increasingly used to optimize welding, assembly, material handling and light mechanical processing processes, supporting operators in welding metal structures, improving the precision and repeatability of operations, reducing at the same time physical stress and the risk of injury. From a technological point of view, collaborative robots make use of force sensors, artificial vision, artificial intelligence and simplified programming interfaces, which allow rapid configuration even by non-specialized operators.

Let’s see in more detail what collaborative robots are, what technical characteristics distinguish them, and their main applications and advantages offered in the field of industrial metal carpentry.

What are collaborative robots or cobots

As we have seen, collaborative robots or cobots are industrial robots specially designed to work in complete safety alongside human operators, without requiring physical protective barriers. Unlike traditional industrial robots, they have advanced sensors, advanced artificial vision systems and intelligent software capable of perceiving the presence of operators and automatically modifying their behavior to prevent collisions and guarantee absolute safety.

These collaborative robots are widely used in multiple industrial fields: from precision assembly of delicate components to automated screwing to ensure uniformity and reliability, to material handling in dynamic environments and packaging to improve logistics and reduce waste. Thanks to their simplicity of programming and considerable operational flexibility, cobots represent a valid support by automating repetitive or ergonomically difficult tasks, reducing human errors and increasing productivity and quality.

They are also easily integrated into pre-existing production systems, take up little space and can be quickly reconfigured, easily adapting to changes and allowing for agile and versatile production.

The different welding techniques of cobots and their applications

Collaborative robots for welding are among the most advanced and interesting solutions in the field of human-robot collaboration, combining precision, safety and versatility. They are capable of operating with different welding techniques, each with specific areas of application, starting from MIG/MAG (Metal Inert Gas / Metal Active Gas) welding, particularly suitable for medium-heavy carpentry and the processing of carbon steels, stainless steels and light alloys. This technique, ideal for repetitive and high-volume operations, allows cobots to guarantee uniform welds, minimizing splashes and defects common in manual processing. Cobots are also often used for TIG (Tungsten Inert Gas) welding thanks to their precision and ability to control welding parameters. As a slower but high-quality technique, TIG is particularly used in the stainless steel furniture, food and pharmaceutical industries, and in the processing of delicate pipes and components.

In addition to the most common techniques, cobots are now also used in pulsed arc welding, useful for thin materials or to reduce thermal deformation, and in laser welding, in very high precision contexts such as electronics or micro-mechanics. Collaborative systems can also be integrated with spot welding devices, used in the automotive sector and in the production of frames and light structures. Some advanced cobots, equipped with tracking sensors, can adapt to variable joints or follow complex profiles detected via artificial vision or laser scanner, and are therefore also ideal for welding unique pieces or in very small batches, as happens in carpentry workshops or in contract production.

From an application point of view, cobots are used in the construction of frames, railings, metal supports, bases, high precision metal components and metal structures, street furniture and industrial mechanics. In highly variable environments, where mass production alternates with customized batches, the speed with which a cobot can be reconfigured is a huge advantage. Furthermore, in small and medium-sized companies, cobots represent a cost-effective solution for automating repetitive welding, improving product quality and reducing dependence on skilled labor.

All the advantages of using cobots in welding

Using collaborative robots for welding operations offers a number of strategic, operational and economic benefits that are driving an increasing number of manufacturing and industrial carpentry companies to adopt this technology. Among the main advantages of using cobots in welding are:

• improvement of the quality and repeatability of the process: cobots ensure uniform, constant and precise welding, regardless of the number of pieces to be processed or the complexity of the production cycle. This allows many of the variables related to fatigue or human error to be eliminated, reducing defects such as porosity, lack of fusion or irregular joints. The ability to program millimeter trajectories and customized parameters allows you to maintain high quality standards even on small batches;
• increased productivity: a cobot can work without breaks, ensuring a continuous flow even on long shifts or at night and, consequently, a significant increase in productivity without compromising the quality of work. What’s more, the reduced set-up time and ease of reusing cobots on new orders make them perfect for flexible, short-cycle production;
• reduction of operating costs: although the initial investment may seem challenging, the deployment of cobots allows for a rapid economic return due to the reduction of waste, the lower need for rework and the possibility of deploying staff in higher value-added activities;
• increased safety in the workplace: welding poses risks related to burns, fumes, exposure to UV radiation and incorrect postures. Cobots, operating collaboratively, can be employed to carry out the most dangerous or strenuous operations, helping to reduce the incidence of occupational injuries and illnesses. The integrated sensors also ensure immediate shutdown in the event of contact with the operator;
• greater flexibility in production: unlike traditional industrial robots, cobots can be quickly repositioned or reconfigured for new processing without the need to modify the entire line. This makes them ideal for companies working on order, for rapid prototyping and for low serial batches.

Ferrero Industrial represents a point of reference in metal carpentry, standing out for the use of advanced production technologies such as robotic welding systems that allow the creation of high precision components and structures intended for key sectors such as aerial work platforms, drilling machines and industrial vehicles.

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