Industrial Robot Arms and Cobots

Cobot and Robot Arms

Understanding Robot Arms and Collaborative Robots (Cobots)

In the rapidly evolving industrial landscape, robot arms have emerged as transformative tools that drive productivity and precision. Since first being deployed on job sites in 1961, industrial robotic arms have evolved from sophisticated systems accessible only to large-scale automotive assembly lines to versatile robotics and automation solutions for businesses of all sizes. Today’s industrial robots, including collaborative robots and advanced 6-axis robot arms, offer the ability to optimize precision while improving operational efficiency and safety at a range of robotic arm cost structures.

What is an Industrial Robot Arm?

An industrial robotic arm, like this FANUC M-710iC/45M Industrial Robot Arm, is a programmable machine designed to mimic the functions of a human arm, but at faster rates and higher payloads. These robotics and automation systems consist of segments connected by joints that allow for precise movement and positioning in three-dimensional space – in manufacturing environments in order to perform tasks traditionally handled by workers. Rather than replacing humans, successfully implementing robot arms and cobot robots leads to strategic workforce utilization as companies redeploy human talent to higher-value tasks while enhancing overall productivity and competitiveness.

How Does a Robot Arm Work?

Industrial robot arms vary in design, from simple two-axis models to complex robot arm 6-axis, 7-axis, and even 8-axis robot arm configurations, offering flexibility for diverse applications.

Mechanical Structure of Common Industrial Robot Arms

The mechanics of a robot arm consists of a series of rigid segments (links) connected by joints that provide degrees of freedom (DOF), or the number of independent movements the robot can make. Each DOF represents either translational or rotational motion, linear movement along or angular movement around the X, Y, or Z axes, respectively. The more degrees of freedom a robot has, the greater its range of motion and flexibility.

The most common industrial robot arm configurations include:

Articulated 6-axis robot arms

With rotary joints analogous to a human shoulder, elbow, and wrist, articulated robot arm 6-axis designs offer exceptional dexterity and reach for a wide range of payload sizes. Each axis provides a degree of freedom, creating a spherical or irregular-shaped workspace that allows the robot to approach workpieces from virtually any angle and orientation. This extraordinary flexibility makes articulated robot arms some of the most commonly deployed robotic and automation systems. Rotational kinematics with joint-based servo motors create moderate to high speeds that vary across arm positions, although the arm’s precision decreases slightly at greater extensions.

Articulated 7-Axis Robot Arms (Robot 7th Axis)

Building upon the flexibility of 6-axis articulated arms, 7-axis robot arms incorporate an additional degree of freedom through a vertical lift column or linear actuator. This enhancement allows the robot base to move along a vertical axis, significantly expanding its operational workspace and enabling tasks at varying heights. The vertical 7th axis is particularly advantageous in applications such as palletizing, where stacking at different elevations is required, or in automated pick and place operations, where different heights of bins or shelves must be reached. By adjusting the robot’s vertical position, manufacturers can optimize the robot’s reach and maintain ideal working angles, improving efficiency and reducing cycle times.

Articulated 8-Axis Robot Arms (Robot 8th Axis)

Expanding upon the capabilities of 7-axis robotic systems, 8-axis robot arms integrate an additional degree of freedom through an overhead linear rail system. This configuration allows the robot to traverse horizontally along a track, significantly extending its operational reach and enabling it to service multiple workstations or machines within a production line.
The overhead linear rail system is particularly beneficial in applications such as machine tending, where the robot needs to access equipment arranged in a linear fashion, or in assembly lines requiring high flexibility and efficiency. By moving along the overhead rail, the robot can maintain optimal positioning and orientation, reducing cycle times and increasing throughput.

Cobot Robot Arms

Cobot robot arms are designed to work safely alongside human workers, blending robotic efficiency with human flexibility. Like articulated robot arms, they typically feature 6 DOF and an irregular workspace; however, they usually have a lower payload capacity. Collaborative robots are equipped with torque-sensing joints that detect and respond to external forces and safety sensors. Force-limited operation and collision detection features limit speed but allow cobot robots to work alongside humans without safety barriers.

End-of-arm tooling (EOAT), also known as the robot arm’s end effector, attaches to the robot’s wrist flange and enables it to interact with the workpiece. From grippers to process tools such as welding guns, sanders, or spray nozzles, the choice of end effector transforms the robot arm from a simple positioning device into a functional manufacturing tool.

Cartesian or Gantry Robots (XYZ Robots)

Gantry robots create a rectangular work area with linear movement systems operating along perpendicular axes (X, Y, and Z, plus optional rotation) for 3-4 DOF. Direct drive motion control with linear actuators on each axis creates moderate but consistent speeds and very high repeatability. With the ability to support heavy loads, they utilize robot transfer units and linear gantry systems to extend operational range and cover large areas with consistent precision needs. Here are some examples of XYZ Gantry Robot and Overhead Gantry Robot designs.

SCARA Robot

Selective Compliance Assembly Robot Arm designs feature a distinctive structure with two parallel rotary joints that provide compliance in the horizontal plane while maintaining vertical rigidity. With a base, two horizontal arms, and a vertical Z-axis with an end effector, SCARA robots typically handle small and/or light payloads. Their cylindrical work envelope and 4 DOF offer exceptional precision and speed for assembly and insertion tasks in horizontal plane. Some of the most popular and reliable SCARA robots are FANUC SCARA robots and Epson SCARA robots.

Delta Robots

Delta robots feature a parallel linkage system with three arms connected to a common base, typically providing 3-4 DOF within a dome-shaped work area. Because all the motors are mounted on the stationary base, the moving mass is reduced, enabling exceptional acceleration for high-speed pick-and-place applications, albeit with a relatively limited payload capacity.

Robot Programming

Most modern robot arms use programming methods that focus on ease of use by integrating robotic teach pendants. These handheld control devices allow operators to physically guide the robot through desired movements, recording positions and creating motion paths without requiring advanced programming skills.

Other programming methods, such as offline programming (creating and simulating movements in virtual environments) and text-based programming (writing code directly in robot-specific languages), are available for more complex applications but are less commonly used in day-to-day operations. Additionally, digital twins—highly accurate virtual replicas of physical robots and their operating environments—allow for real-time monitoring, analysis, and optimization of real-world robot task completion. By leveraging digital twins, engineers can anticipate and mitigate potential issues, enhance robot performance, and streamline the integration of complex automation tasks.

Robot Operation and Integration

The robot arm’s control system executes the programmed instructions, ensuring accuracy despite variables like payload weight or position. It calculates the precise movements required for each joint to move the end effector along the desired path (a process called inverse kinematics). Servo motors position the arm based on feedback from sensors monitoring position, force, and environment.
Modern industrial robotic arms rarely operate in isolation. They function as part of larger automated systems, communicating with machine vision systems, safety systems, execution systems (MES), programmable logic controllers (PLCs) and other controllers like MachineMotion AI controller. This integration capability allows robot arms to become intelligent components in smart factories that are capable of responding to dynamic production needs.

What are Robot Arms Used For?

Industrial and collaborative robot arms are remarkably versatile, with specific designs optimized for different applications across various manufacturing and packaging/material handling landscapes. Understanding the common types of robot arms and their ideal use cases helps you select the right robotic solution for your specific operational tasks or challenges.

How Industrial Robot Arms are Used

Cobot Robot Arms

Cobots offer unique flexibility that excels at tasks requiring complex movement paths and the ability to navigate around obstacles. Key applications include complex assembly operations requiring multiple approach angles, palletizing, machine loading and unloading, welding, and painting. Cobot robot arms transform automation integration as collaborative robots designed to work safely alongside human operators without traditional safety barriers.

ABB

ABB Robot Arms are renowned for cutting-edge SafeMove Technology. With a focus on modular and scalable solutions for smart factories, Vention offers powerful and fast 6-axis collaborative robot arms designed for industrial automation tasks requiring both speed and precision.

FANUC

FANUC Robot Arms are known for their hallmark ease of use, industrial-grade quality, and unmatched reliability stemming from the complete in-house production of robotic components. From compact models to some of the highest payload capacities, learn about Vention’s lineup of FANUC cobot robot arms designed for manufacturers with little to no robotic experience.

Universal Robots

Universal Robots, one of the most well-known cobot arm manufacturers, was the first company to launch a collaborative robot to safely operate alongside humans without the need for cages or fencing. UR cobots are space-efficient and quick to deploy, making them ideal for first-time and experienced users. Learn more about the complete line of UR series cobots offered by Vention.

SCARA robots

SCARA robots’ rigid vertical axis and horizontal flexibility make them ideal for precise assembly operations. They are implemented for circuit board placement in the electronics industry and tasks in laboratory automation like the high-speed transfer of lightweight items, sample handling, and test processing.

Cartesian or Gantry Robots

Cartesian robots (also called XYZ Gantry Robots) excel at applications requiring coverage of large rectangular work areas, including material handling of heavy components. Often implemented via robot transfer units or linear gantry systems, these configurations extend the range of traditional robot arms to enable automation across larger work areas than conventional articulated robots can cover.

The inherent safety features of cobots make them ideal for environments where robots need to share workspaces with human operators, including in operations where complete automation is impractical or undesirable. Cobots are used where applications require the consistent evaluation of product characteristics, such as quality inspection, or for supporting human operators with repetitive loading tasks like end-of-line preparation of finished goods in packaging and palletizing applications. Vention’s industrial automation marketplace carries cobot arms from a range of manufacturers to make sure you find the right fit for your application.

Benefits of Robot Arms

The benefits of robot arms include improved efficiency, consistency, and safety while making manufacturing more predictable to help optimize operations and bring down costs.

Advantages of Robot and Cobot Arms

Consistency and Quality

Robot arms are designed to perform repeated movements extremely accurately – often measured in hundredths or even thousandths of a millimeter – delivering consistent quality regardless of shift, operator fatigue, or environmental factors. This translates into lower defect rates and the costs associated with rework, and higher customer satisfaction.

Enhanced Competitive Positioning

By leveraging robotic and automation technology, manufacturers can quickly respond to changing market demands and operate economically despite inconsistent and expensive labor. Robots offer consistent 24/7 production capacity and eliminate shift-to-shift variance, resulting in increased throughput and more predictable output rates for better production planning.

Workplace Safety

Automating dangerous, repetitive, or ergonomically challenging tasks with cobot and robot arms helps employers improve workplace safety. Robot arm deployment contributes to reduced workplace injuries, minimized exposure to hazardous environments or materials, and decreased long-term health issues related to repetitive motion.

Labor Cost Stabilization

Robot arms provide predictable operational costs unaffected by labor market fluctuations. This makes manufacturers less dependent on scarce skilled workers for repetitive tasks and helps lower long-term training costs for routine operations.

Process Improvement

Modern robot systems collect operational data that allows production metrics to be monitored in real-time. The information gathered by robot arms can help identify process improvement opportunities and offer enhanced traceability for quality control or regulatory compliance.

Unlike fixed automation equipment that can only perform a single function, robot arms can be programmed to take on a wide variety of tasks ranging from simple pick-and-place operations to intricate assembly or automated inspection processes. This versatility makes them valuable assets central to the robotics and automation strategies of manufacturers of all sizes.

Robotic Arm Cost: How Much Do Robot Arms Cost?

The cost of cobot and robot arms varies based on several key performance features and your application’s requirements. Higher payload capacities require more powerful motors and reinforced joints, and a longer reach extends the workspace but necessitates a more robust design. Robots with more axes can perform more complex tasks but are more expensive because of the increased mechanical and control complexity. Collaborative robots are often the most accessible entry point into robotic automation, with simple programming, lower speeds, and payload capacities designed for safe human interaction.

While small SCARA robots can cost below $10,000, industrial 6-axis robot arms typically range in price from $30,000 to $100,000 depending on payload capacity, reach, and precision requirements. Cobot robot arm costs generally fall between $30,000-$60,000. A heavy-duty vertical two-axis or small three-axis gantry robot price starts at $40,000 with a variety of design and expansion options.

When evaluating robotic arm costs, determine what robot you need based on your task’s reach and payload. Then, head to the Vention parts library where over 1,000 modular components, including robot arms, all compatible and field-tested over tens of thousands of deployments, are available for plug-and-play ordering or as part of custom configurations.

Robot Arm Real-world Success Stories

Automated Precision Manufacturing with Robot Arm Technology

Gasbarre, a global supplier of custom capital equipment, partnered with Vention to develop an automated system for delicately unloading components from a hydraulic press onto trays. The challenge required precise part placement to maximize spatial efficiency on the trays without overlapping parts, demanding a robust and stable structure with minimal lateral movement. Streamlining operations with minimal human involvement allowed Gasbarre to reallocate a full-time worker to more meaningful tasks and increase throughout up to 100% with lights-out production. Read the full story about implementing a Universal Robots UR10e robot arm through Vention.

Cobot Robot Arm for Palletizing Increases Production 30%

Polykar, a sustainable packaging manufacturer, faced growing demand that outpaced its labor-intensive packaging process. Manual palletizing was error-prone, repetitive, and limited production capacity. Cobot robot arms automated the entire end-of-line process – picking bags, filling boxes, and stacking pallets – tasks previously causing worker strain and process bottlenecks. This strategic deployment of robotic automation technology resolved its core challenges by increasing production by 30%, eliminating physical strain on workers who were reassigned to more valuable roles, and creating a predictable production flow without human error or fatigue limitations. Read the full story about how Polykar partnered with Vention to implement FANUC CRX-25iA cobot robot arms in a two-week timeline.

How to Choose the Right Robot or Cobot Arm

Before investing in an industrial robot arm, evaluating the right factors to ensure your robot or cobot arm aligns with your operational goals, budget, and growth trajectory is essential.

Factors to Selecting the Right Robotic Arm

Application Assessment

Begin by thoroughly analyzing your operations for task repeatability, ergonomic concerns, or quality issues. Develop specifications for the appropriate robotic system based on requirements like payload and accuracy, as well as volume and variability needs. Know your workspace layout and any size restrictions to ensure robot arm compatibility.

An integral part of this assessment is planning for a Site Acceptance Test (SAT) checklist. The SAT is a critical step in deploying machines or industrial equipment, involving the on-site testing and verification of equipment and systems after installation. It ensures that the robotic arm and its associated systems function correctly within your actual operating environment, meeting all specified requirements. This process helps identify and rectify any issues related to installation, integration, or performance before full-scale operation begins. Utilizing a comprehensive SAT checklist, such as the one provided by Vention, can guide you through this validation process, covering aspects like system functionality, safety checks, and operator training.

Incorporating the SAT into your application assessment not only verifies that the robotic arm meets your operational needs but also facilitates smoother integration and reduces the risk of unexpected downtime.

Payload, Reach, and Functionality

Whether pick-and-place, palletizing, or welding, choosing a robot with sufficient reach and payload for your specific application is critical. Understand the maximum weight the robot will carry, including any tooling or parts, and the distance the arm can extend from its base to perform tasks effectively. Investigate the speed in order to calculate cycle times and look at repeatability to understand how closely the robot can return to a specific point – essential for high-precision applications.

Robotic Arm Cost and ROI Considerations

While the initial investment price of a robot arm may sometimes seem to be high than manual alternatives in the short term, the total cost of a robotic arm over the operational lifetime typically triumphs when accounting for labor savings, quality improvements, and increased throughput. Cost transparency helps in understanding the impact of robot and cobot arms on expenses, calculating expected ROI, and staying within budget​​. Use an ROI calculator to calculate payback on a manufacturing project easily.

Robot Safety Equipment and Features

Safety comes first, and modern robot arms come with various safety mechanisms, especially cobot robot arm models. Look for arms that are compliant with safety standards like ISO 10218 and opt for features like force-torque sensors, collision detection technology, and compatibility with external safety devices like area scanners and light curtains​​.

Robot Programming and Ease of Use

Is the robot arm intuitive or overly technical? Visual programming and drag-and-drop interfaces can help reduce the learning curve of adopting new technology, and many cobot and robot arms allow “teaching by demonstration,” minimizing programming requirements. Integration with PLC systems and MachineMotionAI controllers with popular programming languages matters for complex environments.

Flexibility and Scalability

Evaluate whether the robot can switch tasks, adapt to new lines, or integrate with modular systems such as robot range extenders or linear gantry units. The Manufacturing Automation Platform (MAP) by Vention is the only all-in-one platform for designing, programming, and operating industrial automation and robotic systems. This gives way to greater flexibility and scalability, allowing easy reconfiguration or expansion of your system as manufacturing needs evolve​​.

Robot End-of-Arm Tooling (EOAT)

EOATs allow the robot arm to interact with the product to perform various tasks - they are the grippers, welders, or suction cups that handle the payload. Vention offers a range of modular EOATs, such as dispensers, vacuum systems, and clamps, for various products​​.

Robot Support and Maintenance

You’re not just buying a robot arm – you’re buying into a support ecosystem. Vention provides comprehensive support for installing, training, and maintaining your robot arm, ensuring a successful transition to automated manufacturing​​.

How to Implement Cobot Robot Arms for Manufacturing

Implementing cobot robot arms with the Manufacturing Automation Platform drastically streamlines and simplifies industrial automation. Vention’s Manufacturing Automation Platform offers a user-friendly experience, for drag-and-drop robot cell, conveyor, or servo-powered automated machines, along with offline Digital Twin programming capabilities that reduce the risks and complexities typically associated with robotics and automation. The cloud-first, self-serve platform ensures that businesses aiming to stay ahead can easily embrace industrial and collaborative robot arm technology through the combination of our modular design platform, simple integration, and robust customer support before, during, and after deployment.

Best Practices for Robot Arm Implementation

It’s crucial to maximize the value of your robot arm investment and avoid common pitfalls with best practices across the design, deployment, and maintenance lifecycle. Let’s get into the best practices for deploying or implementing robotic automation in your plant or facility.

Process-First Approach

Analyze your workflow, load characteristics, and system requirements thoroughly,​ including the payload’s dimensions and your factory footprint​​. Standardize components and presentation methods where possible and eliminate unnecessary complexity that could compromise robotic efficiency.

For manufacturers newly embarking on their automation journey, starting with clearly defined objectives and selecting appropriate applications provides the foundation for success. By focusing on processes with clear ROI potential and gradually building internal expertise, companies can establish a sustainable approach to automation that delivers lasting value.

Strategic Robot Selection

Choose a solution based on application requirements, not just price of the robot arm. Match payload capacity and reach to your application with appropriate safety margins and consider future flexibility needs.

Robot End-of-Arm Tooling Excellence

Invest adequately in high-quality end effectors because they directly impact system capability. Opt for modular and adaptable tooling that caters to various product types and sizes. Consider weight optimization of your tooling to maximize robot performance.

Workspace Optimization

Design cell layouts that minimize robot motion requirements and optimize robot placement to maximize the effective work area coverage. Consider robot range extenders or linear gantry systems where expanded work envelopes are needed. Implement safety-rated sensors, protective barriers, and well-defined work zones to ensure safe operation of robot arms alongside humans and provide adequate access for maintenance and material flow.

Regular Robot Maintenance and Monitoring

Regular maintenance is crucial for optimal performance. Develop a maintenance schedule and utilize key performance monitoring technologies​​ to identify potential issues early. Understand the specific payload and reach limits of your robot or cobot to avoid overburdening that can lead to damage​​.

Robotics and Automation System Integration and Data Utilization

Leverage robot-generated data for process improvement and integrate robot performance data with manufacturing execution systems. Create a culture of continuous improvement by establishing a formal process for collecting operator input and identifying enhancement opportunities.

Transforming Productivity with Robot Arms and Cobots

Industrial robot arms represent one of the most versatile and valuable technologies available to manufacturers seeking a competitive advantage in an increasingly challenging global marketplace. From collaborative robots working alongside humans to sophisticated multi-axis robot arms performing complex tasks with exceptional precision, these remarkable machines offer manufacturers a scalable robotics platform for sustainable growth.

The organizations that achieve the greatest success treat robotic automation not as a one-time project but as a strategic capability that evolves alongside their business.

As your trusted robotics and automation partner, Vention brings extensive experience across diverse manufacturing environments and industrial robot technologies. With our MachineBuilder tool and comprehensive selection of robot arms, cobot robots, and 6-axis robot arm solutions in our online store of plug-and-play components, we provide the expertise and support to help you select the perfect industrial robot for your specific requirements and robotic arm cost considerations. Our commitment to manufacturer success means that your adoption of robot arm technology will be seamless and efficient, delivering measurable ROI and competitive advantage.