Material handling robots are robotic systems designed to move, manage, and transport materials, products, or components within various environments such as warehouses, manufacturing plants, and distribution centers. These robots enhance operational efficiency, reduce labor costs, and improve safety by automating repetitive and potentially hazardous tasks. Here are the main types of material handling robots:

MOBILE ROBOTS

Let's explore the types of mobile robots and some of the most common applications of mobile robots for smart factories. 

1. AUTOMATED GUIDED VEHICLES (AVGs) 

Automated Guided Vehicles, or AGVs, are mobile robots that follow predefined paths or routes to transport materials and products within a facility. They navigate using markers, wires, magnets, lasers, or vision systems, allowing them to move autonomously without human intervention. AGVs are designed to improve efficiency and safety in environments such as warehouses, manufacturing plants, and distribution centers by automating the movement of goods.

Industrial Applications of Automated Guided Vehicles

Material Transport

AGVs are widely used for transporting materials within warehouses and manufacturing facilities. They can move raw materials to production lines, transport finished goods to storage areas, and deliver components to different assembly stations. For example, in an automotive plant, AGVs can transport car parts from the warehouse to the assembly line, ensuring a steady supply of materials without the need for manual labor.

Order Picking

In distribution centers, AGVs are used for order picking, where they autonomously navigate the facility to collect items for customer orders. This reduces the need for human workers to walk long distances, increasing efficiency and reducing pick times. For instance, in an e-commerce fulfillment center, AGVs can retrieve products from shelves and bring them to packing stations, speeding up the order fulfillment process.

Assembly Line Support

AGVs support assembly lines by transporting parts and components to different stages of the assembly process. They ensure that each workstation has the necessary materials, reducing downtime and keeping production running smoothly. In electronics manufacturing, AGVs can deliver circuit boards, components, and tools to various assembly points, facilitating a seamless workflow.

Pallet Handling

AGVs can handle pallets, moving them around warehouses or production floors. They can pick up, transport, and place pallets in designated areas, such as loading docks or storage racks. This automation improves accuracy and reduces the risk of damage to goods. In a beverage distribution center, AGVs can transport pallets of bottled drinks from production lines to storage or shipping areas efficiently.

Real Examples of Automated Guided Vehicles

One real-world example of an AGV is the Kiva System, now known as Amazon Robotics. These AGVs are used in Amazon’s fulfillment centers to transport shelves of products directly to human workers, who then pick items for orders. This system has significantly increased Amazon’s order processing speed and efficiency.

2. AUTONOMOUS MOBILE ROBOTS ( AMR )

A mobile robot is a robot that can move autonomously around its environment. Unlike stationary robots that are fixed in one location, mobile robots can navigate through different spaces to perform tasks. They use various navigation systems, such as wheels, tracks, or legs, and rely on sensors and software to avoid obstacles and find their way. Mobile robots are designed to perform tasks that involve movement, making them versatile tools in many industries.

Industrial Applications of Mobile Robots

Inventory Management

In warehouses and distribution centers, mobile robots are used for inventory management. They can autonomously navigate through storage areas, scanning shelves to update inventory records and locate specific items. This automation helps maintain accurate inventory levels and reduces the time spent by human workers on inventory tasks. 

Order Picking

Mobile robots are also employed in order picking operations. They can travel through warehouses to collect items for customer orders, bringing them to packing stations for shipment. This reduces the physical strain on human workers and speeds up the order fulfillment process. 

Transporting Materials

In manufacturing and logistics, mobile robots are used to transport materials between different locations within a facility. They can move raw materials to production lines, carry finished products to storage, and deliver components to assembly stations. This automation streamlines the production process and reduces the need for manual handling. For instance, MiR (Mobile Industrial Robots) produces robots that transport goods across factories and warehouses, optimizing workflow and reducing labor costs.

Real Examples of Mobile Robots

One real-world example is the Kiva robots used by Amazon in their fulfillment centers. These robots autonomously navigate through the warehouse, lifting and transporting entire shelves of products to human workers who then pick the items for orders. This system has dramatically increased Amazon's efficiency and reduced the time required to process and ship orders.

COLLABORATIVE ROBOTS

Collaborative robots, often called cobots, are robots designed to work safely alongside human workers. Unlike traditional robots, which are typically separated from humans by safety cages, cobots have built-in sensors, speed limits, and force controls that allow them to operate in close proximity to people. These features ensure that cobots can interact directly with human operators without posing a risk, making them ideal for environments where human-robot collaboration is essential. 

As manufacturers face skilled labor shortages, cobots are becoming an effective solution to bridge the workforce gap by supporting human workers in tasks that require precision and consistency. For more on how cobots are addressing labour shortage challenges, you can explore our article.

Industrial Applications of Collaborative Robots

Assembly

Cobots are widely used in assembly tasks where precision and repeatability are required. In industries such as electronics and automotive manufacturing, cobots can assist workers by performing repetitive assembly tasks, such as screwing, inserting components, and fitting parts together. For example, in an automotive factory, a cobot might help assemble small parts of the engine, working alongside human workers to improve efficiency and reduce fatigue.

Quality Inspection

In quality control, cobots can be equipped with cameras and sensors to inspect products for defects. They can scan items to check for correct dimensions, surface flaws, and other quality criteria. For instance, a cobot might be used in a production line to inspect electronic components, ensuring that each piece meets the required standards before moving on to the next stage of production.

Material Handling

Cobots are also used for material handling tasks, such as moving products from one part of a facility to another, sorting items, and loading/unloading machines. In a warehouse, a cobot might help organize inventory by picking up items and placing them on shelves or conveyor belts, reducing the physical strain on human workers and increasing overall efficiency.

Packaging and Palletizing

In the packaging industry, cobots can perform tasks such as packing products into boxes, sealing containers, and stacking items on pallets. Their precision and ability to handle repetitive tasks make them ideal for ensuring that products are packaged consistently and efficiently. For example, a cobot might be used in a food processing plant to pack snacks into boxes, ensuring each box contains the correct number of items.

Real Examples of Collaborative Robots

One real-world example of a collaborative robot is the Universal Robots UR3, UR5, and UR10 series. These cobots are used in various industries for tasks like assembly, packaging, and material handling. They are known for their ease of use, flexibility, and safety features, making them suitable for small and medium-sized enterprises.

INDUSTRIAL ROBOTS

 1. ARTICULATED ROBOTS

Articulated robots are robotic arms with rotary joints that provide a wide range of motion. Think of them as mechanical arms that can bend, twist, and rotate in several directions, much like a human arm with a shoulder, elbow, and wrist. These robots have a series of joints (or axes), typically ranging from two to ten or more, allowing for highly flexible and precise movements. This flexibility makes them suitable for complex tasks that require a high degree of precision and versatility.

Industrial Applications of Articulated Robots

Welding

Articulated robots are extensively used for both arc and spot welding in the automotive and manufacturing industries. Their ability to perform precise, consistent welds at high speeds makes them invaluable for tasks requiring repetitive accuracy. These robots ensure high-quality welds, which are crucial in automotive manufacturing where safety and durability are paramount. By automating welding processes, articulated robots also reduce the risk of workplace injuries and improve overall production efficiency. For example, the ABB IRB 6700 is a popular choice for welding due to its precision and reliability.

Painting

In the painting industry, articulated robots are used to apply paint uniformly on complex surfaces, ensuring a high-quality finish with minimal waste. These robots can maintain a consistent speed and distance from the surface, resulting in an even coat of paint. This is particularly important in the automotive and consumer goods industries, where the aesthetic quality of the product is crucial. By automating the painting process, companies can reduce the amount of paint used and minimize the release of volatile organic compounds (VOCs) into the environment. The FANUC P-350iA is an example of a robot widely used in painting applications for its efficiency and precision.

Assembly

Articulated robots play a critical role in the assembly of components in electronics and automotive industries. Their high precision and speed reduce the risk of human error, ensuring that parts are assembled correctly and efficiently. These robots can handle tiny components in electronics manufacturing or heavy parts in automotive assembly with equal ease. 

Material Handling

In material handling, articulated robots are used to pick up, move, and place objects within a manufacturing setup, optimizing the production flow. These robots can handle a wide range of materials, from delicate electronic components to heavy automotive parts, with precision and care. They help streamline operations by efficiently managing the flow of materials between different stages of production. The KUKA KR QUANTEC series, known for its versatility and strength, is often employed for material handling tasks, enhancing overall productivity and reducing the need for manual labor. To learn more about the types and applications of material handling, explore this article on i4 Verse.

Packaging

Articulated robots are also used in the packaging industry to quickly and accurately package products. They can perform tasks such as loading products into boxes, sealing packages, and stacking items on pallets. This automation ensures that the packaging process is fast, efficient, and consistent, which is crucial for meeting high production demands. In addition, robotic packaging systems can easily be reprogrammed to handle different products, making them highly adaptable to changing production requirements. 

Real Examples of Articulated Robots

One prominent example of an articulated robot is the ABB IRB 6700. This robot is used in heavy-duty applications such as welding and material handling. It is known for its strength, precision, and reliability. Another example is the FANUC M-20iA, which is used in industries like automotive and electronics for tasks such as assembly and machine tending. These robots demonstrate how articulated robots can be tailored to specific industrial needs, providing high performance in demanding environments.

2. SCARA ROBOTS (Selective Compliance Articulated Robot Arm)

SCARA robots, or Selective Compliance Articulated Robot Arms, are a type of industrial robot that are designed for tasks that require precise horizontal movements. The SCARA robot has a unique design with two parallel rotary joints that provide compliance in a plane. This means they are very flexible in the horizontal direction but rigid in the vertical direction, making them ideal for tasks that involve picking, placing, and assembling parts on a horizontal plane. SCARA robots are known for their speed, precision, and repeatability, which make them highly efficient for many industrial applications.

Industrial Applications of SCARA Robots

Pick and Place Operations

SCARA robots are frequently used in pick and place operations, where items need to be quickly picked up from one location and placed in another. These tasks are common in electronics manufacturing, where components need to be placed on circuit boards with high precision. For instance, in a factory assembling smartphones, a SCARA robot can rapidly and accurately place tiny electronic components onto a PCB, ensuring each part is correctly positioned. This speeds up the production process and reduces the likelihood of errors.

Assembly

In the automotive and electronics industries, SCARA robots are utilized for assembly tasks. They can precisely align and fit together components, such as inserting screws, fitting parts, or attaching small components. For example, in a car manufacturing plant, a SCARA robot might be used to install dashboards or electronic modules, performing each task quickly and accurately. This reduces assembly time and ensures consistent quality across all units produced.

Packaging

SCARA robots are also employed in the packaging industry to handle tasks like packing products into boxes, sealing packages, and preparing items for shipment. In a food processing plant, for example, a SCARA robot can be used to pick baked goods from a conveyor belt and place them into packaging trays at high speeds, ensuring that each item is properly packaged without damage.

Inspection

These robots can also be equipped with cameras and sensors for inspection tasks. They can check for defects, measure dimensions, and ensure that products meet quality standards. In electronics manufacturing, SCARA robots can be used to inspect circuit boards for defects, verifying that all components are correctly placed and soldered.

Material Handling

SCARA robots are used to move materials within a production line. They can transfer parts between different stages of manufacturing, handle delicate items, and organize components for further processing. For example, in a pharmaceutical plant, a SCARA robot might be used to handle vials of medication, ensuring they are correctly oriented and transported between filling and packaging stations.

Real Examples of SCARA Robots

One real-world example of a SCARA robot is the Epson G-Series SCARA Robot. These robots are used in various industries, including electronics and automotive manufacturing, for tasks such as pick and place, assembly, and packaging. 

3. CARTESIAN ROBOTS (GANTRY ROBOTS)

Cartesian robots, also known as gantry or linear robots, are robotic systems that move in straight lines along three orthogonal axes: X, Y, and Z. Think of them as moving along the coordinates of a 3D graph, hence the name Cartesian, derived from the Cartesian coordinate system. These robots are designed for tasks that require precise linear movements and can be configured in various ways to fit different applications. Their structure is usually a simple rectangular frame, making them easy to program and use for straightforward, repetitive tasks.

Industrial Applications of Cartesian Robots

CNC Machine Tool Loading

In the manufacturing industry, Cartesian robots are widely used to load and unload CNC (Computer Numerical Control) machines. They can pick up raw materials and place them into the machine, then remove the finished parts once the machining process is complete. This automation improves efficiency, reduces human labor, and ensures precision in handling materials, thus maintaining consistent quality.

3D Printing

Cartesian robots are integral to the operation of many 3D printers. Their precise linear movements along the X, Y, and Z axes allow for accurate layer-by-layer deposition of materials, which is crucial for creating detailed and complex parts. By using Cartesian robots, 3D printers can produce high-quality prints with intricate designs, making them valuable in industries like aerospace, healthcare, and automotive.

Pick and Place Operations

In electronics manufacturing, Cartesian robots are used for pick and place operations, where they place electronic components onto circuit boards. Their ability to move accurately along the three axes ensures that components are placed exactly where needed, reducing errors and increasing production speed. This precise placement is essential for producing reliable electronic devices.

Material Handling

Cartesian robots are employed in material handling tasks within warehouses and manufacturing plants. They can move goods along predefined paths, stack items, and organize materials efficiently. By automating these tasks, Cartesian robots help streamline operations, reduce manual labor, and enhance productivity in material handling processes.

Real Examples of Cartesian Robots

These robots are used in various applications, such as 3D printing, machine tool loading, and pick and place operations. Their design allows for easy integration into different systems, providing high precision and reliability.

4. PALLETIZING ROBOTS

A palletizing robot is a type of industrial robot designed to automatically load and unload goods onto pallets. These robots can arrange products in a specific pattern on a pallet, ensuring optimal use of space and stability of the stacked goods. Palletizing robots are equipped with sensors, grippers, and advanced software to handle various types of products, from boxes and bags to bottles and drums. They improve efficiency, reduce labor costs, and enhance workplace safety by automating the repetitive and physically demanding task of palletizing.

Industrial Applications of Palletizing Robots

Food and Beverage Industry

In the food and beverage industry, palletizing robots are used to stack products like cases of soda, boxes of snacks, and bags of flour onto pallets. These robots can handle high volumes and ensure that products are stacked securely for transport. For example, a palletizing robot might be used in a bottling plant to stack crates of bottled drinks onto pallets, ready for shipment to retailers. This automation speeds up the packaging process and ensures that products are handled hygienically.

Pharmaceutical Industry

Palletizing robots are also employed in the pharmaceutical industry to handle boxes of medicines and other medical supplies. They ensure that products are stacked correctly and labeled properly, reducing the risk of errors. In a pharmaceutical manufacturing plant, a palletizing robot can stack boxes of packaged medicines onto pallets, ensuring that each box is oriented correctly for easy identification and transport. This helps maintain the integrity of the products and streamlines the logistics process.

Consumer Goods Industry

In the consumer goods industry, palletizing robots are used to stack a wide range of products, including electronics, clothing, and household items. They can quickly and efficiently stack items of varying shapes and sizes, improving overall productivity. For example, a palletizing robot might be used in a warehouse to stack boxes of electronics onto pallets, ensuring that they are organized and ready for distribution. This reduces the need for manual labor and increases the speed of order fulfillment.

Real Examples of Palletizing Robots

One real-world example is the KUKA KR QUANTEC PA. This robot is used in various industries for palletizing tasks due to its high speed, precision, and ability to handle heavy loads. It can stack products quickly and accurately, making it ideal for high-volume operations. 

SUMMARY

Material handling robots are more than just tools; they are transformative agents that redefine traditional industrial practices. As businesses continue to seek efficiency and safety, these robots will play a crucial role in shaping the future of manufacturing and beyond. The ongoing development of robot technology promises not only to enhance operational capacities but also to open up new possibilities for innovation and growth in various industries. Checkout our Mobile Robots Solutions Category to explore and find suitable material handling and industrial robot that can help you achieve your goals.