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Analysis of 7 Cognitive Mistakes in Industrial Robot Application
With the rapid advancement of industrial robot technology, more and more enterprises are integrating robots into their production lines. While these machines offer significant benefits in terms of efficiency and precision, improper use can lead to costly errors. To help robot engineers work safely and effectively, we’ve outlined some common misconceptions that should be avoided.
One of the most frequent mistakes is underestimating the robot’s payload capacity. Many users forget to account for the weight of the end-effector or tool attached to the robot arm, which can lead to overloading. This is especially critical in SCARA robots, where overloading the rotating axis can cause mechanical stress and reduce the robot’s lifespan.
It’s also important to note that a robot’s rated load is only valid at its specified speed. If you want to use the maximum load, you must reduce the robot’s speed accordingly. Operating beyond the recommended limits can affect both performance and accuracy.
Another common issue is trying to make robots handle too many tasks at once. Before deployment, it’s essential to conduct simulations to determine the robot’s stroke, load capacity, and cycle time. If additional functions are added later, the system must be re-evaluated to avoid unexpected failures or downtime, which can result in significant financial losses.
Cable management is another often-overlooked aspect. Cables can easily become damaged due to overload or improper routing. Long-term overloading leads to overheating and aging, while poor cable routing can cause wear from repeated movement between the arm and the end effector.
Understanding the difference between accuracy and repeatability is crucial. A robot with high accuracy can perform precise movements, but a robot with good repeatability simply follows the same path repeatedly. Repeatability doesn’t guarantee accuracy, so it's important to choose the right robot based on your specific application needs.
Some may believe that choosing a robot system depends solely on the control system. However, the mechanical performance of the robot—such as its speed, durability, and precision—is equally, if not more, important. Even the best control system can't compensate for mechanical limitations, which can quickly negate any time-saving advantages.
Many people also lack proper knowledge about how to operate industrial robots safely. These machines are complex and require specialized training. Operators must be properly trained in safety protocols before they can work with the equipment, as improper handling can lead to serious accidents.
Finally, ignoring related equipment during project planning can lead to inefficiencies. It’s essential to consider all necessary components—such as sensors, software, and peripheral devices—when designing a robotic system. Focusing only on the robot itself without considering the full ecosystem can lead to integration issues and reduced overall performance.