Table of Contents
A smart factory integrates production equipment, robots, sensors, and control systems to improve the efficiency and coordination of manufacturing processes. Robots used in smart factories take many forms. Industrial and collaborative robots perform tasks such as assembly, machining, loading, and material handling, while mobile robots transport parts and materials between production stages.
For multiple pieces of equipment to work together effectively, production data and equipment status need to be managed within an integrated system. At the same time, the reducers and actuators that generate robot movement must be selected according to the robot’s structure, application, and operating conditions.
No matter how sophisticated the information system is, the robot’s drive system is ultimately responsible for generating physical movement. This is why the selection of reducers and actuators is an important consideration when designing and implementing smart factory automation.
The Role of Robots in a Smart Factory
Key Summary In a smart factory, robots not only perform production tasks but also connect different processes as part of the overall automation system.
Manufacturing processes generally consist of multiple stages, including machining, assembly, inspection, packaging, and material transport. Within these processes, robots can perform repetitive tasks that were previously carried out by workers and connect different stages of production.
Industrial robots can move, assemble, or process parts within fixed work areas and are also widely used for tasks such as welding, painting, and machine tending.
Collaborative robots can perform tasks such as parts feeding, machine loading, and light assembly while operating in workspaces shared with human workers.
Mobile robots move between production stages and transport parts, materials, and other items so that work can continue without unnecessary interruptions.
When robots are introduced across multiple manufacturing processes, the arrangement of production equipment and the sequence of operations may also change. For this reason, smart factory planning should consider not only the performance of individual robots but also how they integrate with other equipment and contribute to the overall production process.
Integrating Robot and Production Equipment Data
Key Summary Smart factory systems integrate robot and equipment data so that production status can be monitored and reflected in operating plans.
In a smart factory, sensors and control devices installed throughout the production environment collect information about equipment status and operation.
The system can manage not only production volume and process progress but also whether individual pieces of equipment are operating normally.
A robot is not simply a standalone piece of equipment. It operates as part of a broader production system and performs tasks according to commands from control and production management systems.
For example, when one production stage is completed, a robot may transfer parts to the next process. If the production plan changes, the robot’s work sequence or movement path may also be adjusted accordingly.
IoT technologies can provide the communication infrastructure needed to exchange information between equipment and management systems. Digital twins can also be used to represent an actual factory or production system in a virtual environment, allowing manufacturers to review equipment layouts, process flows, and robot movement paths before or during operation.
However, stable system operation depends not only on the accurate exchange of information but also on the physical performance of the robot.
Even if control commands are transmitted correctly, the planned operation may not be performed consistently if the robot’s joints and motion axes cannot reliably generate and transmit the required torque.
Why the Robot Drive System Matters
Key Summary A smart factory robot’s drive system must provide the required output within limited installation space while maintaining reliable performance during repeated operation.
Robot motion is generated through the coordinated operation of components such as motors, reducers, sensors, and control systems.
The motor generates rotational motion, while the reducer lowers the motor’s rotational speed and increases the torque available for the robot’s operation.
Industrial and collaborative robots typically consist of multiple interconnected joints. Within each joint, drive units, sensors, wiring, and other components must be arranged together.
Mobile robots also need to integrate drive components within the limited space available around wheels, steering mechanisms, and internal frames.
If the drive unit becomes excessively large or thick, the robot joint or frame may also need to become larger. On the other hand, if the drive unit is made too small without maintaining sufficient torque, the robot may face limitations when handling loads or performing repeated tasks.
For this reason, drive-system design should consider torque, actuator dimensions, installation space, wiring arrangement, and repeated operating conditions together.
Integrating the motor and reducer into a single actuator can also simplify component arrangement and make it easier to design the drive unit around the structure of the robot joint or automation equipment.
Bonsystems Drive Solutions for Smart Factory Robots
Key Summary Based on cycloidal reducer and actuator technology, Bonsystems develops drive solutions that can be considered for robot joints and automation equipment used in smart factories.
Robots used in smart factories often perform repetitive motions or handle parts continuously, which can subject their drive systems to repeated loads over extended periods.
Because workpiece weight, operating speed, installation space, and motion requirements vary depending on the equipment, reducers and actuators should be selected according to actual application conditions.
A cycloidal reduction mechanism transmits torque through the engagement of curved profiles across multiple contact areas.
Because the load can be distributed across multiple contact regions, this type of reduction structure can be considered for drive systems used in robot joints and automation equipment that experience repeated loads.
The Bonsystems BSR is a reducer product family based on cycloidal reduction technology.
It lowers motor speed while transmitting the torque required by robot joints and automation equipment. As a component-level reducer, the BSR can be considered for applications in which the drive unit needs to be configured according to the equipment structure, motor arrangement, and mounting conditions.
The BCSA is an integrated actuator that combines a frameless motor and a cycloidal reducer in a slim, compact structure based on Bonsystems’ cycloidal technology.
Its compact structure is designed to provide the required torque while minimizing the space occupied by the drive unit, making it suitable for consideration in robot joints and automation equipment with limited installation space.
The BCSA V4 series incorporates a Pinless structure that reduces some of the coupling elements used in conventional pin-based configurations.
By simplifying the internal component arrangement, this design can help reduce the space required by the drive unit and may also simplify assembly and maintenance by reducing structural complexity.
Depending on the equipment design, developers can consider the BSR when a component-level reducer is required or the BCSA when an integrated motor-and-reducer solution is more appropriate.
Key Takeaways
In a smart factory, robots do more than replace repetitive human motion. They physically connect production, material handling, and automation processes by carrying out the movements commanded by the factory’s control and management systems.
Even if production information and work sequences are managed accurately, the planned process cannot be carried out consistently if the robot’s joints and motion axes cannot reliably generate the required movement and torque.
Drive-unit selection therefore cannot be based on torque alone.
Actuator dimensions, installation space, wiring arrangement, operating duration, repeated-load conditions, and overall equipment structure should all be considered during the design process.
Integrating the motor and reducer into a single actuator can simplify component arrangement and support more compact joint designs.
The Bonsystems BSR reducer and BCSA actuator provide different drive-system options depending on whether an application requires a component-level reducer or an integrated motor-and-reducer solution.
Frequently Asked Questions (FAQ)
Q1. What role does a robot play in a smart factory?
A. Robots perform production tasks such as machining, assembly, inspection, loading, and material transport. They can also connect different stages of the manufacturing process by moving parts or materials according to commands from the factory’s control and production management systems.
Q2. How is a smart factory robot different from general automation equipment?
A. Rather than operating only as standalone automation equipment, smart factory robots can exchange information with production management and control systems. Their work sequence, operating status, or movement path may be adjusted according to production conditions and process requirements.
Q3. What should be considered when selecting a drive unit for a smart factory robot?
A. Developers should consider factors such as workpiece weight, required torque, operating speed, repeated-operation time, installation space, and equipment structure. It is important to evaluate whether the drive unit is suitable for the actual application rather than relying only on rated output specifications.
Q4. How do the drive-system requirements of industrial and collaborative robots differ?
A. Industrial robots often handle relatively high loads in fixed work areas, so torque, rigidity, and repeatability are important considerations. Collaborative robots operate closer to human workers, so joint size and weight, installation space, and the system’s response to external forces may require additional consideration.
Q5. Why are cycloidal reducers used in smart factory robots?
A. Cycloidal reducers transmit torque through multiple contact areas within the reduction mechanism. This load-distribution characteristic can be beneficial in robot joints and automation equipment that are exposed to repeated operating loads.
References
• [1] Bonsystems Official Website — https://www.bonsystems.com
• [2] International Federation of Robotics (IFR) — https://ifr.org
• [3] Korea Institute for Robot Industry Advancement (KIRIA) — https://www.kiria.org
• [4] Ministry of Trade, Industry and Energy – Robot Industry Policy — https://www.motie.go.kr
Bonsystems
A specialist in Pinless cycloidal reducers and actuators
