Robotics Software Makes Protective Fences Unnecessary

Machine Safety Robotics Software Makes Protective Fences Unnecessary

2025-06-23 From Fraunhofer IWU | Translated by AI 2 min Reading Time

The start-up Botfellows has developed an intelligent safety solution that can be directly integrated into the robot control system, where dynamic safety zones replace physically separated workspaces between humans and (industrial) robots.

Botfellows Dynamic Safety creates the conditions for an efficient and safe collaboration between humans and robots through its dynamic speed and distance monitoring.(Image: Botfellows) — Botfellows Dynamic Safety creates the conditions for an efficient and safe collaboration between humans and robots through its dynamic speed and distance monitoring.
(Image: Botfellows)

Botfellows is a spin-off from the Fraunhofer Institute for Machine Tools and Forming Technology IWU, founded in 2024. The team, consisting of Dr.-Ing. Mohamad Bdiwi (CEO), Sebastian Krusche, Paul Eichler, and Jayanto Halim, focuses on high-tech solutions where flexible—dynamically changing, meaning situationally optimal—safety zones replace rigidly defined workspaces.

Botfellows' software dynamically adjusts the movement of lightweight or industrial robots by only reducing their speed—up to a complete stop if necessary—when people actually approach the work area. If the combination of sensors and cameras detects that there is no risk of collision, the robot or robots operate within the intended motion paths and at regular speed.

Seamless Integration Into the Robot Control System

The research results from Botfellows on safe teamwork between humans and robots have passed numerous practical tests; their software solution is now integrated into a manufacturer's robot control for the first time. The Chemnitz-based robotics specialists are cooperating with the Chinese manufacturer Estun for this purpose. Botfellows Dynamic Safety is integrated directly, without additional interfaces. Simple implementation and operation were key development goals: "This is the key to being able to automate highly flexibly and ensure maximum safety—because our software integrates perfectly into the robot control rather than increasing its complexity," emphasizes Bdiwi.

In a shared workspace without separating protective fences, various scenarios can be realized thanks to the Botfellows solution:

Coexistence: Humans and robots work in parallel within a shared workspace without the need for a protective fence. The robot performs automated palletizing tasks, such as stacking and sorting boxes, while the human conducts quality controls or restocks materials nearby.
Cooperation: Humans and robots share the same workspace and take turns in palletizing tasks. The robot stacks heavy boxes on the pallet, while the human adds smaller, delicate products and ensures the stability of the pallet. This allows for flexible adaptation to different types of products.
Collaboration: Humans and robots work simultaneously in the same workspace and directly complement each other. The robot lifts and hands over heavy or awkward boxes, while the human precisely positions them on the pallet, fills gaps, and checks the final alignment. This form of collaboration increases the efficiency and ergonomics of the palletizing process.

Overall, the Botfellows Dynamic Safety software offers several advantages: the elimination of physical safety fences significantly reduces investment and maintenance costs, as well as space requirements. At the same time, production layouts can be quickly and easily adjusted without having to move safety barriers. Finally, the dynamic adjustment of safety zones enables fast and safe operation of robots in close proximity to humans.

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Date: 08.12.2025

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