Unlike industrial robots, cobots or collaborative robots may operate securely with people without safety enclosures. Cobots are perfect for dynamic workplaces since they are adaptable, agile, and easy to reprogram. As manufacturers use cobots for small-batch manufacturing and complicated, multi-step processes, cobot integration is increasing. Global sales surpassed $1 billion in 2023. Cobots' sensor-based safety features allow real-time modifications for human-robot cooperation.
About Legacy Industrial Systems
Legacy industrial systems are older machines and software that use outdated control architectures, including PLCs using Modbus or Profibus, designed long before IoT or real-time data analytics. They are prevalent because industrial equipment can last decades for durability. Moreover, replacing entire systems risks interruption and capital investment.
Yet, they can be challenging for cobot integration. They may lack the necessary APIs, Ethernet-based communication, or standardized interfaces that automation demands. E.g., legacy machines may require custom-developed middleware or hardware retrofit solutions for communication, which increases complexity. Also, without built-in flexibility for reconfiguration or real-time data streaming, cobots' collaboration is hindered due to poor process automation.
The Need for Cobot Integration with Legacy Systems
Cobot integration with legacy industrial systems bridges technological gaps without full-scale replacement. Instead of overhauling entire systems, cobots can extend the life of legacy equipment while taking over high-precision and speed tasks in hazardous environments.
Cobots can handle repetitive welding and material handling in automotive and manufacturing for lower human error. For instance, cobots work alongside older robotic arms in automotive assembly lines and execute part inspection or painting more accurately. In logistics, cobots with legacy conveyors optimize sorting and packaging for throughput. Plus, cobot retrofitting helps increase flexibility and automation without the capital expenditure of a full system overhaul.
Technical Considerations for Cobot Integration
Communication Protocols and Data Sharing
Cobot integration with legacy industrial systems may face the challenges of outdated communication protocols. Legacy systems can rely on proprietary or older standards, including Modbus or PROFIBUS, which may not support cobots using Ethernet/IP or OPC UA. In such cases, middleware solutions like protocol converters are key. They translate data between incompatible networks for data flow. For example, a protocol gateway can enable data exchange between a cobot using EtherNet/IP and a legacy PLC running Modbus RTU. Additionally, cobots with IIoT platforms offer higher interoperability for data sharing, monitoring, and control across systems. Yet, their latency, bandwidth, and security concerns need consideration.
Safety and Compliance
Adapting the cobot's safety mechanisms to legacy environments can be thorny. Legacy factories may lack ISO/TS 15066, which governs human-robot collaboration. In cobot integration, sensors and safety-rated monitored stops are mandatory but tricky when legacy equipment wasn't designed with such capabilities in mind. E.g., integrating a cobot with a machine without safety-rated I/O may require retrofitting light curtains or laser scanners. Plus, machine placement and workflow layouts can be risky if not addressed in compliance assessments. Retrofitting legacy machinery with area scanners or fail-safe PLCs might be necessary but can result in complexity.
Control System Compatibility
Synchronizing the cobot's controllers and existing PLCs or DCS is technically difficult. Cobots can operate using proprietary controllers that may not natively integrate with older control systems. Real-time coordination in legacy systems using ladder logic or specific DCS configurations can be difficult. Cobots in a PLC-controlled system require cycle synchronization if both cobots and machinery operate within tight time constraints. Programmable gateways and customized software logic can help synchronize system commands. Another approach integrates cobots into SCADA systems for central coordination of cobots and legacy equipment.
Retrofitting and Customization
Fitting cobots into existing legacy machinery layouts needs a high level of customization. Unlike new installations, legacy systems could be designed without considering future automation or cobot integration. So, cobots must match existing factory floor layouts, including retrofitting for conveyor belt systems, material handling setups, or cramped workspaces. For example, custom grippers or additional tool attachments might mimic human dexterity when integrating cobots into a packaging line for human operators. Retrofitting may reprogram the cobot's motion paths and install custom end-of-arm tooling to handle materials or product shapes.
Overcoming Cobot Integration Challenges
ü Assessing Legacy Equipment: Evaluate the control interfaces and communication protocols of legacy systems. Check for mechanical wear, obsolete software, or data integrity issues. It can affect the feasibility and cost of cobot integration. Map out dependencies; older systems may have minimal support for automation standards.
ü Choosing the Right Cobot Technology: Select a cobot after assessing its interfacing with the legacy equipment's control architecture. Guarantee that the cobot can adapt to different PLCs or SCADA systems without overhauls. Focus on ease of reprogramming; older systems can limit flexibility in real-time data sharing or synchronization.
ü Training and Skill Development: Skilled operators must learn both cobot programming and the peculiarities of legacy machines. Offer focused retraining on cobot-specific software while bridging gaps in legacy system knowledge. Apart from that, cross-training on diagnostic tools can decrease stoppage during early cobot integration phases.
ü Cybersecurity Concerns: Legacy systems built before cybersecurity standards are risky during cobot integration. Safeguard communications between the cobot and legacy systems with secure gateways or network segmentation. In addition, data integrity should be warranted with encryption protocols when retrofitting older systems.
We recommend cobot integration for legacy system industries as a sensible modernization strategy. Nevertheless, industrial innovation and tradition must be balanced to be competitive in the changing technological ecosphere. Contact us to learn more.
