Constructive measures for the safe use of Cobots

Machine safety Constructive measures for the safe use of Cobots

2024-06-25 From Item | Translated by AI 5 min Reading Time

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Cobots play a key role in automation. Many medium-sized companies often shy away from embracing new technology because they feel overwhelmed by the complex safety aspects of collaborative robots. However, with flexible designs, Cobots can be easily and above all safely integrated into existing production.

Cobots cannot simply be parked on the production line. They need a periphery tailored to them. And above all, all safety requirements to protect employees must be met.(Image: Item) — Cobots cannot simply be parked on the production line. They need a periphery tailored to them. And above all, all safety requirements to protect employees must be met.
(Image: Item)

Cobots are currently the hype in automation. According to the International Federation of Robotics (IFR), 55,000 models were sold worldwide in 2023, which corresponds to growth of 31 percent. Cobots now make up 10 percent of all robots sold globally. And they also show where robotics is headed. Cobots have partly already incorporated all future technologies, including artificial intelligence (AI), thus simplifying implementation. They prove that a balance between high-tech and easy operation is possible, that an employee without special knowledge can benefit from AI: artificial intelligence without headaches.

Versatile in use

Hannes Fröhlich, product manager for robotics at Item Industrietechnik GmbH in Solingen, Germany, sees the cobot as an ideal entry point into automation: "Manufacturers are focusing on plug-and-play and easy handling. The user doesn't have to be a robotics expert to use the technology." Moreover, the models can be flexibly used at various points in the production line: "If, for example, increased quantities need to be produced, the user can bring in one or more cobots, instead of expanding the assembly line with another station and an industrial robot," says Fröhlich.

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When an enclosure makes sense is determined by the process. "If the cobot is always moving collaboratively, I don't necessarily need an enclosure," says Hannes Fröhlich, product manager for robotics at item.(Image: Item)

Behind the large, impact-resistant windows of the partially enclosed cobot cabin, the cobot can move quickly continuously. The worker is well protected from the robot and still has a good view of the process.(Image: Item)

Decisive for a secure stand are not only the installation surface and the center of gravity characteristics of the overall solution, the weight of the robot, the load capacity, the traversing speed and the range. When considering tipping safety, Item looks at the extreme case and checks whether the construction can withstand the forces occurring.(Image: Item)

As an efficient protective measure, a surface sensor that is mounted on the construction near the ground is suitable. When an employee approaches the cobot, the sensor sends a signal to the control in time and the cobot switches to collaborative mode.(Image: Image:)

Gallery with 7 images

Despite all their intelligence, cobots cannot simply be left on the production line. They need a periphery tailored to them. And above all, all safety requirements must be met. Item recognised this years ago and expanded their modular system to accommodate cobots. The kit consists of around 4,500 components. The aluminium profiles can be screwed together with a flexible connection technology to create individual constructions.

On their website, Item currently shows 120 sample solutions, which are continuously supplemented by more. These are to show potential customers what is possible with the modular system. Nineteen suggestions on robotics alone are listed there. These include, for example, mobile robot islands for cobots with central cable routing, compact robot columns with levellable floor mounting or partially enclosed cabins for cobot use. Most solutions can be ordered directly or serve as a source of inspiration. Many sample solutions can be individually redesigned and adapted to the requirements in production with the help of Item's comfortable engineering tool.

Safe cable management in every solution

With all solutions from the modular system, the issue of safety is top of the agenda. This starts with the individual building blocks. A preload in the flanks of the profiles ensures stability and a strong hold, even under high loads that can occur in robotic applications. The mobile constructions are equipped with steering or lifting rollers and can thus be easily moved from one location to another. Since the transport is not strenuous work, the employer is also on the safe side with regard to occupational safety regulations. Item also has a safe cable management in mind.

"Most of the solutions are designed in such a way that there is always a way to optimally guide the cables," says Hannes Fröhlich. The profiles are equipped with intelligent cable management that simultaneously protects the lines. The cable channel is accessible from the outside, so the cable management can be changed or adapted at any time.

The developers at Item have made sure that all cables can be routed from the supply level to the cobot without being kinked or pinched. The cables run through dense brush strips, preventing dust and dirt from penetrating. The cobot is connected to the construction via mounting plates. The user can choose between the plates for the different models of the manufacturers. "We also support the plug-and-play principle here," emphasizes Hannes Fröhlich. "The user does not have to worry about a milled plate with threaded holes, but simply orders it." There are also universal mounting plates with exclusive hole patterns for individual processing.

Load testing ensures tipping safety.

The construction with a cobot literally stands or falls with tipping security. In addition to the setup area and the center of gravity properties of the overall solution, the weight of the robot, the load capacity, the travel speed, and the range are crucial for a secure stand. Item has dealt intensively with this complex topic. A calculation aid, which can be downloaded as a PDF on the website, allows the customer to check their system with the given figures. "For the calculation, the customer does not need a completed mechanical engineering degree; basic knowledge of classical mechanics is sufficient," emphasizes Hannes Fröhlich. "However, if the customer chooses to use a sample solution, they can also delegate the test to us."

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Date: 08.12.2025

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In terms of tipping safety, Item plays it safe and always considers the worst-case scenario. In this extreme case, the robot moves at maximum speed and maximum load with an extended arm, while the employee presses the emergency stop button at the critical point. If the construction withstands the forces occurring in this test, then nothing can happen even in industrial use under the most severe loads.

Enclosure allows for higher travel speed

If the cobot stands freely on a construction and no further protective measures such as safety sensors are used, for safety reasons it may only move at the so-called collaborative speed, which is 0.25 m/s. However, this is only a guideline. Depending on the travel height and the workpiece hanging on the gripper, further safety measures may have to be taken. In order to ensure an efficient process, the solution can, for example, be supplemented with an area sensor that is attached to the construction near the ground. If an employee approaches the cobot, the sensor sends a signal to the control in time and the cobot switches to the collaborative mode.

Those who do not want to do without speed in principle are well served with a partial or complete housing of the cobot. This variant is implemented in some sample solutions, but can also be installed on request at a later date. The cobot can run fast permanently behind the large, impact-resistant windows of the housing. The employee is well protected from the robot and still has a good insight into the process.

Additional controls are simply clicked into the integrated cable channel. If necessary, all cables run safely and protected within the profile frames. Special connection sets serve as cable passage between the vertical and horizontal profiles and ensure a kink-free transition of the lines.

Whether an enclosure makes sense depends on the process. "If the cobot operates collaboratively all the time, I don't necessarily need an enclosure," says Hannes Fröhlich. "The same applies if the employee works with the machine and, for example, has to regularly replenish materials and therefore constantly open and close the door."

Safe solutions

When planning a solution, many aspects need to be considered. Therefore, Item provides a guide on their website that the customer can use as a guide. This enables potential dangers to be identified in advance and suitable protective measures to be taken. "We want the customer to not only have a safe solution that suits him," emphasizes the product manager. "He should also be sure that he is on the right track to advance automation in his company."