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“A Robot Development Project for a World Free from Labor”
Projects that were once led mainly by large corporations and research institutes are now expanding to startups, broadening the foundation of the robotics industry.
As AI technology advances, interest in software has grown and access to development tools has become easier. Open source based control technologies are spreading, creating an environment where more teams can attempt robot development. At the same time, new technologies are emerging to solve industry specific challenges, enabling robotics to expand into a wider range of applications.
However, robot development cannot be completed with ideas and software alone. To become a product that operates reliably in real world environments, a robot must be designed with a well structured mechanical system and a properly engineered drive system. When the goal is to replace human labor, stable motion and a structure capable of enduring repeated operation are essential.
In practice, many companies that begin robot development with strong software capabilities encounter the greatest difficulties at this stage. While their algorithms and control logic may be well prepared, they often lack the hardware infrastructure and drive system design expertise required to implement and validate those technologies in a physical robot.
In this article, we introduce a real customer case to show how Bonsystems’ robot development service transforms ideas into fully functional robotic products.
Who Did We Work With
This robot development project was carried out in collaboration with COCELO, a company that envisions a world where people can be freed from labor. COCELO was founded by researchers from the POSTECH Advanced Control and Automation Laboratory and possesses strong expertise in robot control and software systems.
At the early stage of robot development, COCELO used commercially available general purpose actuators to build their prototype. This approach is common for many teams that want to quickly create a prototype and verify basic motion.
Through various tests with the initial prototype, they encountered limitations. The actuators did not provide sufficient torque for the required tasks, and stability decreased under repeated operation. As a result, it became increasingly difficult to fully validate the performance of their software.
Recognizing that a general purpose solution was not sufficient, COCELO determined that a customized actuator designed to meet their specific drive requirements was necessary. During their search for alternatives, they discovered Bonsystems’ cycloidal drive based actuator, the BCSA V4, and contacted us to evaluate its applicability.
We first reviewed whether our actuators could be integrated into their prototype platforms, including a two wheel two leg robot and a four wheel four leg robot. We also analyzed what level of performance could be expected after integration.
The review showed that simply replacing the actuator would not be enough to achieve the desired performance in a stable manner. The joint structure and external frame would also require redesign, and durability under repeated operation had to be considered as part of the overall system.
Based on this assessment, we proposed a comprehensive approach that included actuator integration and full robot redesign. COCELO agreed with this direction, and the project officially began with the goal of building a robot platform capable of thoroughly testing their software.
Why Is Bonsystems’ Robot Hardware Manufacturing Service Necessary
As mentioned earlier, in robot development the drive system design stage often determines the overall direction of the project. Once drive conditions are defined, joint layout and frame structure must be designed accordingly.
For multi joint robots such as humanoids and quadrupeds, each joint requires different levels of torque and experiences different load paths. Repeated operation, durability, assembly efficiency, and maintenance accessibility must all be considered. Decisions made during the early drive design stage directly influence the success of the entire robot development process.
[Bonsystems Global Youtube Channel | Why do humanoid robot companies develop cycloidal reducer technology in-house?]
Bonsystems has developed and manufactured actuators based on cycloidal reducer technology. Starting from drive system design, we have expanded our capabilities to full robot hardware engineering. We design joint structures and frames in an integrated manner, ensuring mechanical consistency and performance reliability.
Through domestic and international manufacturing infrastructure, we support not only prototyping but also repeated production and small batch manufacturing.
Robot development is an iterative process of design, fabrication, modification, and refinement. A partner that understands hardware design and can carry projects through to production is essential. Bonsystems’ robot hardware development service was built around this integrated and iterative development model.
The Beginning of the COCELO Robot Development Project
Let us take a closer look at how the project progressed.
The target product aimed to move stably across various terrain conditions. It was not limited to indoor environments but intended for industrial field applications, which required both durability and mobility.
[COCELO Two Wheel Two Leg and Four Wheel Four Leg Robot Design]
The first step was to clearly define realistic drive conditions and structural requirements. We carefully analyzed what types of motion the robot needed to perform and how much load each joint would experience during those motions.
This process involved more than calculating torque values. We examined how loads would accumulate during repeated cycles and how the frame would distribute and withstand those forces.
External design was also considered at this stage. Covers and exterior components are not merely aesthetic elements. They affect overall weight distribution and structural loading. Early sharing of design concepts helps minimize structural revisions later in the robot development process.
Next, we selected actuators appropriate for the defined drive environment. Since actuator selection determines a large portion of the robot’s architecture, this is one of the most critical steps.
After selecting the actuator, we proceeded with full structural design centered around it. Frame geometry, joint placement angles, and interference checks were conducted in detail based on actuator size, torque characteristics, and mounting configuration.
[COCELO Robot Design Drawings]
We also considered cable routing for the drive system, the placement of power and control boards, and heat dissipation paths to ensure reliable operation in real industrial environments. Durability against vibration, cumulative load, and external impact was thoroughly evaluated during the design stage.
Once the design was finalized, frame and mechanical components were fabricated according to the confirmed drawings. The prototype was then assembled by integrating the manufactured components and actuators.
During assembly, we evaluated not only mechanical compatibility but also assembly difficulty, working time, and maintenance accessibility.
[COCELO Robot Assembly Components]
After assembly, drive tests were conducted to verify whether the robot operated according to the design intent. We comprehensively assessed abnormal vibration, heat generation, and performance under repeated motion cycles.
Improvements identified during testing were reflected back into the design. Structural modifications and revalidation were repeated to enhance overall system completeness.
Through this cycle of design, fabrication, and validation, the robot was refined into a system capable of stable operation in real world environments.
An Integrated Robot Solution Built on Cycloidal Technology
This project demonstrates how a software focused robotics company can overcome hardware implementation challenges by partnering with a specialized robot hardware development company.
By securing a stable hardware platform, COCELO was able to validate their control technology under real operating conditions. Through repeated drive testing and structural refinement, the overall product maturity improved significantly. This foundation also enabled them to move forward with public demonstrations and technology presentations.
As this case shows, a stable hardware platform in robot development enables software companies to accelerate technical validation and service advancement in a structured and reliable manner. Hardware plays a crucial role not only in prototyping but also in the path toward commercialization.
[Bonsystems Robot Manufacturing Process]
Bonsystems provides an integrated robot development solution that connects actuator design, structural engineering, and prototype manufacturing based on cycloidal reducer technology. We work alongside our partners throughout the entire development process so that ideas can become real machines that move in the physical world.
If you are starting a robot development project but facing challenges in hardware design and manufacturing, we invite you to explore a practical and structured approach with Bonsystems. Please submit your project inquiry through our website, and our team will respond promptly after review.
FAQ
Q. What is a robot hardware service
Bonsystems’ robot hardware service supports the entire process of designing and manufacturing the physical structure required for stable robot operation. This includes actuator selection based on drive conditions, joint and frame design, prototype fabrication, and drive testing.
Q. What materials should be prepared before inquiring about robot development
It is helpful to prepare a target motion scenario, intended operating environment, expected load conditions, and drive concept. If available, existing design drawings, 3D models, or actuator specifications under consideration should also be shared.
If a design concept or exterior styling is already defined, reviewing it at an early stage can reduce repetitive structural modifications later in the robot development process. Even if materials are not fully complete, sharing the current status allows us to define the development direction together.
Q. How long does robot development typically take
The timeline depends on structural complexity, performance requirements, and whether prior designs exist. Technical review and feasibility analysis must be conducted based on target performance and operating conditions.
Since prototype fabrication and repeated validation are generally required, the overall schedule varies by project scope. When specifications and application environments are clearly defined, a more predictable development schedule can be established.
Q. How are actuator specifications determined
Actuator specifications are defined based on target motion, joint load conditions, operating speed, and repeated usage environment.
For applications requiring high torque and strong load handling, the BCSA V4 RO type may be suitable. For relatively lightweight structures requiring faster motion, the BCSA V4 RI type may be recommended. Final specifications are confirmed in alignment with the overall structural design.
[References]
1. Software Policy & Research Institute | Growth of the Open Source Ecosystem and the Expansion of Specialized Companies
2. Samsung Newsroom | Is Software Better When Shared? The Growing Momentum of Open Source
