Status · Opportunities · Prospects

ONTEN

2 Low Cost Robotics

 Foreword 2

About Dr.-Ing. Sebastian Feldmann 4

What is Low Cost Robotics? 8

Low Cost Robotics and Man-Machine Interaction 9

1 The Triumph of Robotics in the Context

of Industry X.0 10

Categorization of Robot Systems 14

2 Before using Low Cost Robotics 16

3 Possible Application Scenarios

for Low Cost Robotics 20

Development of Robot Use 26

4 Opportunities and Risks 30

Comparison of Purchase Costs 32

5 Prospects 34

Frequently Asked Questions 36

Low Cost Robotics 3

 This e-Book about
Low Cost Robotics ...

4 Low Cost Robotics

 provides a comprehensive overview of
how the field of robotics has developed and
triumphed in the age of Industry 4.0. Specifi-
cally the digital revolution of Industry 4.0 will
be examined, considering today’s conventio-
nal robot models can increasingly be enhan-
ced or completely replaced by smaller, more
cost-effective models. In addition, it will be
examined how automation applications that
have previously been considered useless
are now becoming more and more practi-
cal. Young, innovative companies have also
shown that the use of low cost robotics can
be quite cost-effective.
Within this e-book, an initial insight into the
complex world of industrial robots, as well
as the meaning and purpose behind the use
of such technology will be provided. The ov-
erarching purpose of “Low Cost Robotics”
is to provide support for the formulation of
decision-making criteria and the selection of
industrial robot technology, especially within
the industrial environment.
The relatively new field of low cost robotics,
where cost-effective robot models with inno-
vative functional concepts are used, offers
the potential to completely revolutionize the
future market environment. An extremely
active community of low cost robotics fol-
lowers is developing, which is tackling re-
search, new innovative product creation and
system solution development. Technological
entry barriers are also becoming increasin-
gly reduced for non-technical users, allowing
even the most complex application scenari-
os to be implemented much faster and more
cost-effectively than in previous years.
New, motivated and flexible research teams
are doing a great deal of the work contribu-
ting to the rapid development in this young
market segment. However, the possibilities
arising raise new questions for considerati-
on. How would someone adequately assess
the risks involved? How do you make the
right decision for your own specific applica-
tion based on a multitude of possibilities?
In addition, the persons responsible for the
system must ask themselves the question;
what must be given priority in the purchase
and implementation of a low cost robotics
system?
Low Cost Robotics 5
 These topics and specific aspects are exa- gic possibilities of applications used in cor-
mined in detail in this e-book. A preliminary porate environments. The following topics
understanding into the topic of low cost ro- are discussed:
botics is essential in order assess the strate-

· What is low cost robotics?

· How did low cost robotics evolve from a historical perspective?
· Categorization of robot systems
· Low cost robotics-what must be considered before use?
· Possible application scenarios of low cost robotics
· Development of robot use
· Opportunities and risks when using low cost robotics
· Purchase costs in comparison
· Prospects

6 Low Cost Robotics

Dr.-Ing. Sebastian Feldmann earned
his doctorate in Mechatronics Engineering
at the University of Duisburg-Essen. In the
course of his various research projects, he
developed several driving simulator proto-
types (presented at the ‚Designstudio NRW‘,
www.nrw-car-2030.de) and a series of robot
prototypes, including the medical assistance
robot FAROMIR (www.faromir.de) and the
humanoid robot HUMECH (www.humech.
de).
Furthermore, Feldmann is an honorary mem-
In 2015, Feldmann won the Adesso Solutions ber on the board of the Kaliber Kulturverein
Award for his concept of barrier-free interac- in Kamp-Lintfort, and a lecturer at the De-
tions of robots, machines and plants via a partment of Communication Systems at the
cloud-based infrastructure. Hochschule Rhein-Waal. He is also currently
heading the development of a high-tech door
Later, he established the company NectOne protection system for motor vehicles at Kie-
using proceeds from the EXIST Founders kert AG in Heiligenhaus.
Scholarship award he received. The founda-
tion of the company is based on mechatronic Dr. -Ing. Sebastian Feldmann has published
product development (sensors, actuators, a large number of relevant pieces about ro-
control technology), the cross-divisional in- botics. He is a well-known expert in the de-
teraction of machines and plants within the velopment of robotics and industrial auto-
framework of Industry 4.0, and the develop- mation solutions, as well as in mechatronic
ment of state-of-the-art applications in the processes, the integration of cloud technolo-
automotive industry. gies, image processing, and sensor and actu-
ator systems for machines and plants.

Low Cost Robotics 7

 WHAT IS
LOW COST ROBOTICS

Since low cost robotics is a relatively new
subject, there is no universal definition for
the term. The common misunderstanding
regarding the topic is how low cost robotics
is different from traditional industrial robo-
tics. So, what are the differences between
low cost robotics and conventional industri-
al robots in terms of performance, quality or
functionality? Low cost robotics is not only
utilized in “pick and place” scenarios, but
also in complex applications and collaborati-
ve forms of man-machine interaction.
can be achieved in the implementation pro-
cess. The industrial robot BAXTER from Re-
think Robotics can be used as an example.
Using sophisticated sensor technology, BAX-
TER is capable of working in close proximity
to humans. BAXTER costs more than 26,000
US dollars for the end customer and can be
programmed without prior programming
knowledge. In addition, modular expansion
components are available, which help this
robot to be used in a variety of scenarios as
soon as it is needed.

One of the most important reasons to choose

a low cost robot system is how cost-effective
they are. They often amount to only one tenth
of the price of a conventional robot. Howe-
ver, there are many more differences that are
more technical in nature. For instance, low
cost robots are often freely configurable with
respect to the drive units and control, while
conventional systems are not. This results Systems such as BAXTER can usually be
in an increased flexibility on one hand, and a easily controlled or programmed. In addition,
potentially increased implementation on the the simple and modular design of the com-
other hand, which should be considered in ponents makes sending extensive specifica-
the calculation of total costs. A major advan- tion lists to the manufacturers unnecessary,
tage of low cost robots is that they are built thus obstacles of such systems are elimina-
with lightweight components. The systems ted as a result.
are therefore considerably more compact in
their dimensions, they do not require separa-
te devices of peripherals for assembly and
they can be used in office-like environments.
By increasing efficiency, further advantages

8 Low Cost Robotics

 LOW COST ROBOTICS AND
MAN-MACHINE INTERACTION
The focus on integrating robots into the
production process has been increasingly
fixated on the aspect of man-machine inter-
action. Traditional industrial robots are gra-
dually being replaced by mobile double-arm
robots that interact with humans. This is
apparent in the example of the robot system
BAXTER. Such systems are capable of being
programmed quickly, and are priced lower
than industrial robotic products from estab-
lished manufacturers.
The goal is for humans and robots to colla-
borate in the workplace so that humans don’t
have to perform monotonous and repetitive
tasks, thus improving efficiency. Humans
have motor skills that allow them to carry out
far more demanding tasks than a machine
can, and therefore they can devote themsel-
ves to more important responsibilities. Fur-
thermore, within the interactions between
man and machine, it is particularly important
that the robots being used are capable of
perceiving their surroundings. That way, the
robot can know when the human has com-
pleted his/her tasks, as well as if there are
humans standing within hazardous areas of
the robot. Additionally, the robot should be
able to provide feedback on work progress
and follow-up procedures.
In the industrial robotics field, there are requi-
rements for movement dynamics, program-
ming capabilities, strength of the machines
and injury prevention. Many new prototy-
pes, even in the low cost robotics segment,
have new capabilities when interacting with
humans. For example, an integrated sensor
system can determine its surroundings, and
thus understand the gestures and move-
ments of a human. This significantly redu-
ces the risk of injury when humans interact
with the system. Very light components used
in systems such as the articulated arms of
the igus® robolink series can be used in the
immediate vicinity of a human, because in-
jury prevention can be reduced in advance
through programming.
Smart surfaces that recognize contact
do their best to identify future interaction
scenarios. Essentially, the concept of the ro-
bot is changing from a rigid and expensive
machine to a flexible, cooperative and affor-
dable partner to humans that helps increase
productivity and efficiency.
Low Cost Robotics 9
 1

// The Triumph of Robotics

in the Context of Industry X.0

THE STAGES OF DEVELOPMENT

The concept of an autonomously ope-
rating apparatus that can take on complex,
monotonous and dangerous tasks has been
inspiring scientists and engineers to explo-
re new limits of physics for ages. Since the
days of machine “walking tests,” numerous
devices have been developed, which should
be considered in the processes of today’s
modern enterprise. Therefore, outlining im-
portant milestones in industrial history, spe-
cifically the outstanding key technologies of
industrialization, is essential.
One of the main reasons for this was that
there was a constantly growing competitive
pressure in the globalized market, thus in-
dustrial companies had to respond to more
individual customer requirements. It was
then that robotic technology gradually deve-
loped into a key building block in the process
chains of modern companies.

Within Industry X.0, there are four develop-

mental stages that have led to the current in-
dustrial age. Autonomous, intelligent robots
and machines have been playing an increa-
singly important role since the 20th century.

10 Low Cost Robotics

 1

around 1800
Railways
Coal mining

INDUSTRY 1.0 Heavy industry

Steam navigation
Weaving looms

Assembly line, electricity

around 1900
Motors
Telephone, telegram
INDUSTRY 2.0 Globalization
Light bulbs
Passenger airlines

around 1970
Electronics
Computing machines

INDUSTRY 3.0 Personal computers

First industrial robot
PCB assembly
since 2000

The internet
Digitalization
INDUSTRY 4.0 Cyber-physical systems
Lean manufacturing techniques

Low Cost Robotics 11

 Robotics for Flexible and Complex Appli-
cations
Observing the developmental stages of in-
dustrialization shows the impact of intro-
ducing new technologies and how complex
requirements on products and production
processes come into play. The potential for
automated machines and systems is de-
monstrated in the earliest stage, like the need
to manufacture uniform quality goods and
laborers having to spend time on monoto-
nous and dangerous tasks.
The patent for a mechanized loom was sub-
mitted during the First Industrial Revolution
in 1785. In the first version, looms had to be
operated by two employees to generate po-
wer, but they were enhanced soon after. In
1787, Edmond Catwright opened a steam-
powered loom factory, which led to a subs-
tantial improvement in the efficiency of fab-
ric production.
12 Low Cost Robotics
During the introduction of motors, the tele-
phone, the combustion of engines and elec-
tricity came the globalization process of the
Second Industrial Revolution. The inventions
made during this time contributed signifi-
cantly to the success of the automobile in-
dustry, which gradually developed into one of
the most important technology influencers
of the modern age. Global transportation of
goods and services was now also much ea-
sier to handle. As a result, the potential sales
market of a product was globally accessible.
On one hand, there were great opportunities
for the owners of these technologies, but on
the other hand, many of the traditional sales
markets completely changed. Local sup-
pliers could often no longer stand up to the
pressure of new costs. Markets were flooded
with a variety of low-priced, high-quality and
mass-produced products, which made the
economy unprofitable for many local busi-
nesses and led a massive collapse of enter-
prises.
With the introduction of microprocessors
and the mass production of assembled
PCBs, the Third Industrial Revolution began.
Products were increasingly found equipped
with mechatronic functionalities. The de-
mands of the functionality and complexity of
many products rose progressively. The key
technologies required for this were, however,
 1

steps were implemented in the shortest pos-

sible time. The core technologies of robotics
became increasingly widespread and gradu-
ally interesting for small and medium-sized
enterprises, as well as for private operators.

With the turn of the century, a completely

becoming available in other countries. The new chapter of industrial history developed,
question concerning this was how to coun- which is referred to as the Fourth Industrial
ter competitors who, for example, had better Revolution. Products and procedures started
access to resources or more effective pro- rapidly developing within the framework of
duction costs. Industry 4.0. The entire product lifecycle is
now monitored from the handling of raw ma-
It has been proven that those companies terials to the execution of products. The field
were able to significantly stand their ground of industrial robotics is no longer confined
in a globalized market, respond compliant- to clunky and expensive industrial robots—
ly to customer requirements and regularly mobile robots are being used to transport
develop new and improved products. It was products from one workstation to the next,
therefore no longer sufficient enough to pro- and smaller, more cost-effective systems are
duce a single product line in bulk. Rather, pro- being used where conventional industrial
ducts had to be made more attractive to the robots have been unviable for economic re-
customer in certain iteration steps in order asons.
to be a step ahead of the competition—be
it new design, advanced functionality or in-
novative features, it could be anything that
gave customers new buying incentives. As
soon as it had to be retrofitted into a new
product line, a conventional production line
became regularly too expensive and unviab-
le. The triumph of industrial robotics began
at this point. Production lines equipped with
industrial robots were able to react much ea-
sier to production steps, and new production

Low Cost Robotics 13

 CATEGORIZATION OF ROBOT SYSTEMS

Different prototypes are being tested in al-
most all fields of robotics. There is now
a whole range of robotic systems criteria
that help to appropriately classify desired
systems. There are many categories used
to distinguish the robotic systems. Subdi-
visions of the criteria include, for example,
whether the robots are operated in a statio-
nary manner, how many degrees of freedom
they have, and the driving method on which
they are based. Whether the required system
has a stationary or non-stationary operation
should also be the first factor that is verified.
The latter categories usually include mobile
robots that drive, swim or fly.
also differentiated into parallel and serial
systems. Parallel-driven robots are often
used where high precision and fast travel dis-
tances are required. Serial systems are used
in places where, for example, a large working
chamber (space that the robot can reach by
its arm/manipulator) has to be covered.
The possibility to program the systems as re-
quired and equip them with appropriate grip-
pers, sensors or accessories makes low cost
robotics a true triumph. Although not all sys-
tems will meet all flexibility, performance and
cost requirements, an accurate analysis of
the framework conditions can help find and
implement the optimal system.

MANIPULATOR & ACTUATOR

Stationary robots are generally used in indus-

trial production processes, adding efficiency
to the workflow. Stationary robot systems
usually consist of the moving part of the ro-
bot (manipulator) and various motors (actu-
ators) that drive the manipulator. This makes
direct interaction with the environment of
the robot possible. Tasks such as gripping,
sorting, packaging, assembly of PCBs, laser
welding or the fine machining of a product
can be implemented. Stationary robots are

14 Low Cost Robotics

Stationary robots (including robot arms with global motion axes)

• Cartesian robots/line- • Single-wheel robot

ar robots (ball)
• Cylindrical robots • Two-wheel robot
• Spherical robots • Three-wheel and
• SCARA robots (Selec- multi-wheel robots
Mobile robots (drive wheels)
tive compliance as-
sembly robot arm)
• Articulated robots
(robot arms)
• Parallel robots

• Bipedal robot (Huma- • Floating robots

More robot models (stationary/non-stationary)

noid robot) • Flying robots

• Tripedal robot • Mobile spherical ro-
• Quadrupedal robot bots (Robotic balls)
• Hexapods • Swarm robots
Mobile robots (driving legs)

• Others

Low Cost Robotics 15

 2
// Before using
Low Cost Robotics
WHAT SHOULD BE CAREFULLY CONSIDERED BEFORE USE?
Young companies in particular are currently
stimulating the market with new and uncon-
ventional technologies. These companies
handle obstacles well, such as high acquisi-
tion costs or burdensome programming con-
cepts. Through testing innovative applica-
tion scenarios and keeping costs down, the
development of low cost robotic concepts by
these companies is often worthwhile. Howe-
ver, caution is necessary to avoid falling into
a cost trap: if products aren’t well-received,
savings can quickly turn into debt. Products
that have not been tested to stand up to high
16 Low Cost Robotics
loads or long life cycles are generally not
meant for use in lengthier or larger operations.
Companies will typically make a large in-
vestment when implementing robotic sys-
tems, which must be paid, ideally, in part via
increased operations. If after a few years, no
adequate support is guaranteed by the ma-
nufacturer, companies could pay the price.
Established manufacturers, such as igus®
or KUKA, can counteract this risk with well-
established product lines, with KUKA serving
the low cost segment only conditionally.

Some of the greatest dangers of low cost ro-
botics in professional application scenarios
are the basic technical and economic con-
ditions. As the saying goes, “you get what
you pay for,” the use of innovative and cost-
effective concepts utilized by mostly young
companies entails a number of risks. There
is often no guarantee of long-term mainte-
nance of the apparatus or the repair of com-
ponents and wear parts. One reason for this
lies in the fact that the market environment
is very fast-growing in the field of robotics.
Moreover, a reliable supply of spare parts for
several years can rarely be guaranteed by
these companies. Users also have questions
about the reusability and recyclability of the
robot arms in changing application scenari-
os. Can your robot arm, for example, undergo
a modular extension or can the length of the
arm be varied?
In conclusion, a suitable robot must be ap-
plied to an application with great thoughtful-
ness. A solution can be, for example, the use
of a low cost articulated arm from the igus®
robolink series. If this is the case, an estab-
lished manufacturer is always available, who
also ensures long-term and reliable product
support. This ensures planning reliability, as
well as access to tested components verified
by stress tests that can also withstand con-
tinuous operation. If you plan to use a low
cost robot for any application scenario, the
existing basic conditions should be conside-
red first. Subsequently, the technical require-
ments that are necessary to allow a robot to
perform a work step are considered. These
2
basic questions can be broken down into a
few core themes. Regardless of the purchase
price of the robot, the specified, basic techni-
cal conditions determine to what extent a pl-
anned production scenario can be implemen-
ted. In order to make an accurate decision,
the following general conditions are usually
considered:
Number of available degrees of freedom of
the robot (degree of freedom = DOF)
Stationary or non-stationary system (mobi-
lity of the robot)
Required precision or accuracy at the end
effector (requirements on the component
that interacts with the environment)
Load capacity of the robot at the end effec-
tor
Required working chamber
Travel speeds and number of movement
cycles
Modular, flexible configurability of the
entire system (including later rebuilding
possibilities)
Required sensors for environmental detec-
tion
Programming and compatibility with exis-
ting control systems
Processing quality and protection against
environmental influences
Investment and maintenance costs
Low Cost Robotics 17
 A number of well-known prototypes were
compared from a series of existing product
brands. It is easy to see that there are big dif-
ferences in the design, sales price and load
capacity, depending on the manufacturer.
The comparison of these important factors
can help make a rough estimation on the
suitability of the appropriate model before
purchasing it. The example of the Youbot
from Kuka clearly shows that good optics
does not automatically suggest compre-
hensive integrated technical features of a
robot. For example, significantly more cost-
effective models are also suitable to enable
modular configurability, or to achieve a high
load-bearing capacity of the end effector.
Therefore, a high selling price and a great
look does not correlate to the product’s ca-

Phanton X Reactor DesiArm Widow X Mark II igus robolink DC (BV)

Estimated
Sales Price [$] 550 850 1.500 4.240

Degrees of freedom 6 4 6 5

Absolute weight [kg] 1,36 0,75 1,33 18,5

Load capacitiy [kg] 0,6 1,4 0,8 2,5

ROS compatibility Yes Yes Yes Yes

Material ABS PLA/ABS ABS Alu/Plastic

Modular design No Yes No Yes

Injury-proof Yes Yes Yes Yes

18 Low Cost Robotics

 2

pabilities in harsh environmental conditions, sal Robots UR3, it is evident that similar per-
or to its overall quality. Most importantly, it formance data can potentially save a large
always depends on the individual application amount of investment costs.
conditions in which the robot arm is used.
Some robotic models from the low cost seg-
ment are now capable of achieving the ba-
lance between quality, technical features and
an affordable selling price. In comparing the
igus® robolink D articulated arm with Univer-

Dr. Robot Jaguar Cyton Gamma 1500 Universal Robot UR3 KUKA Youbot

Estimated
8.750 12.000 23.000 24.200 Sales Price [$]

4 7 6 5 Degrees of freedom

10 2 11 7,4 Absolute weight [kg]

4 1,5 3 0,5 Load capacitiy [kg]

Yes Yes Yes Yes ROS compatibility

Aluminium ABS Alu/Plastic Aluminium Material

No Yes Yes No Modular design

No Yes No Yes Injury-proof

Low Cost Robotics 19

 3

// POSSIBLE APPLICATION
SCENARIOS FOR
LOW COST ROBOTICS

Living in the Fourth Industrial Revolution,
we are seeing many new business segments
develop, especially outside the conventional
sales markets of traditional industrial com-
panies. New technologies such as 3D prin-
ting or the large-scale integration of cloud
technologies into products and production
machines lead to an intensive, cross-divisi-
onal interdependence of private companies
and households.
Numerous small and medium-sized busines-
ses are now able to fill market gaps that have
not previously been relevant for large com-
panies from an economic point of view. New
ideas can be materialized at very low costs
through modern production processes, and
can be directly tested. Many technologies
are now so cost-effective that they have be-
come affordable even for small businesses.
For example, the 3D printing technology ena-
bles a previously constructed printing com-
ponent to be produced autonomously in a
very short time with a huge range of availab-
le materials. The component can then be in-
tegrated directly into the application without
any time delay. Thus, the product develop-
ment cycle is dramatically shortened, which
gives companies even more flexibility when
working with customers.
3
USE OF LOW COST ROBOTICS SMALL SE-
RIES PRODUCTION USING THE EXAMPLE OF
3D PRINTING
In order to achieve flexibility, especially with
respect to small and very small series, the
use of conventionally and expensively pro-
duced robots is often no longer valuable for
reasons of cost and space. For example, if a
small to medium-sized business whose ap-
plication scenario uses 3D models that are
taken automatically by a robot gripper, the
3D print process should be particularly con-
cerned with the correct timing of the cooling
process. If components are removed too ear-
ly from the printer, cracking or unwanted ra-
pid shrinkage may occur. This can adversely
affect the quality of the components, or even
damage them. Removing the component too
late increases standstill times and causes
the 3D printer to not reach its full investment
potential. Thus, accurate timing is essential
for this method for several reasons and can
be improved by using a suitable robot sys-
tem.
Low Cost Robotics 21

OPTIMIZING OCCUPANCY TIMES
Due to cost pressure, expensive automation
solutions cannot be used here. With such
a process, high investment costs would
quickly make production unprofitable. A low
cost robot can therefore be a useful alterna-
tive. In this application example, it does not
matter if the component is taken out of the
printer precisely or quickly. On the contrary,
when handling a robot arm, the component
needs to be removed from the machine in
the correct phase of the cooling process, and
then the next component can immediately
go to print. This ensures a consistent quality
of the products, while at the same time op-
timally utilizing the occupancy times of the
3D printer. This is therefore an ideal scenario
where the use of Low Cost Robotics should
be considered.
Since there are various robotic models al-
ready offered on the market by numerous
manufacturers for professional and semi-
professional applications, the question now
arises as to what the criteria are for selec-
ting an appropriate product. Looking closer
at the environmental conditions of this con-
crete application scenario, it is quick to un-
22 Low Cost Robotics
derstand that very high or low temperatures
are to be expected here. There is also no high
ambient humidity here. What does have to
be considered is whether the manufactured
components are difficult to grip or not (grip-
ping points, fragility, etc.).
In this case, an appropriate gripper must be
mounted on the robot arm, which also ma-
kes it possible to pick up complex structu-
res without destroying them. For example,
a pneumatic system or a system with soft,
flexible grippers could be used to remove the
component from the printer. Using a powder-
coated process in 3D printing can lead to the
accumulation of dust and deposits on the
employed robot. Therefore, for example, a
model that withstands these dirt accumula-
tions must be selected.
• Home and household robots
• Military robots
• Entertainment robots
• Mechanical robots
• Industrial robots
• Service robots
• Outer space robots
• Hobby and competition robots
 3

Service
robots

Industrial
robots

Home and
household robots

Mechanical
robots

Military
robots
Entertainment
robots

Outer space
Hobby and robots
competition
robots

Low Cost Robotics 23

 In addition, the aspect of maintenance plays
a greater role here than in other application
scenarios. Companies that produce 3D print
models for customers usually do not employ
specialists in robotics and industrial auto-
mation. Therefore, a durable, tested system
should be selected in advance, which can be
used in the long term with little maintenance
necessary. Many smaller providers fail if they
can’t provide appropriate support, experi-
ence and extensive product tests.
Large, established companies such as igus®
offer cost-effective systems in the field of
low cost robotics. igus® produces individu-
ally configurable articulated arms in various
lengths, designs and sizes, using lightweight,
modular, dirt-resistant and self-lubricating
components. As a result, the articulated arm
is not only flexible and cost-effective, but it
is also low maintenance with a long service
life. Manufacturers also offer comprehen-
sive consultation or online configurators to
match companies’ available resources.
24 Low Cost Robotics
IGUS ROBOLINK ARTICULATED ARM
Such consultation can provide, in advance,
important aspects that help to configure the
suitable system. The igus® robolink articu-
lated arms can also be used, for example,
in damp environments or in liquids such as
oil to protect against corrosion. In addition,
the robot arms from the robolink series are
very light. People are therefore not at risk, as
mostly light materials like plastic and alumi-
num are used, and the moving masses are lo-
wer than in industrial robots or other low cost
models. Humans’ risks of injury in the imme-
diate vicinity of the robot drops considerably,
even around robots that lack elaborate sen-
sors or barriers. During man-machine inter-
action, this is a considerable advantage and
a further building block in which costs of the
overall system can be reduced. A robolink
articulated arm weighs only 1.3 kg in total
with 5 degrees of freedom, which also has
considerable advantages in terms of energy
efficiency. The decoupled motors only need
to move the actual robot arm without drive
units. As a result of the light structure, drive
energy is saved while providing the same
motion dynamics of a conventional robot.
 3

Such a robot can therefore also be operated models. For example, light flexible manipula-
with a conventional 230 V socket without a tors (robotic arms) can help those who are
complex power supply or power electronics. disabled with the use of a gripper arm moun-
ted on wheelchairs, among other things.

APPLICATIONS IN MEDICINE

Often, low cost robotics uses innovative

drive concepts or new types or sensors or
drives. With that, a large number of possibili-
ties to identify new application fields and to
participate directly in market development
are emerging. What is especially difficult is
identifying suitable providers who have ad-
vanced the technology to a practical and
market-ready product. When looking at the
target groups that are to be addressed by
these technologies, very different applica-
tion scenarios arise, which initiates extreme-
ly varying demands on the used technology.

In medical technology, a strong emphasis is

inherently placed on reliability and quality of
used robots, such as surgical robots. Never-
theless, there are also some areas of medi-
cine that can very well utilize cost-effective

Low Cost Robotics 25

 DEVELOPMENT OF ROBOT USE
It is not surprising that an overhaul of the
planning of production processes since the
emergence of the first industrial robots has
taken place. Due to the possibility of flexible
adaptation of automated work steps and pro-
cesses to the respective product, the variety
of products that can be processed by such
methods has abruptly increased. This means
that processes need to be interlinked more
effectively so that the addition of optimal va-
lue can be drawn from the process chain.
Looking at current market data, the market
growth for industrial robots has steadily in-
creased for a number of reasons. One reason
is due to increased economic growth, while
another is due to the migration of advanced
technology in Asia, specifically countries in-
cluding India, China and their other neighbo-
ring countries. In many cases, the production
of sub-assemblies has been shifted to a low
26 Low Cost Robotics
cost service provider, which is now catching
up technologically with the long-established
industrialized countries.
CLEAR GROWTH PREDICTED
With a total market volume of 290,000 indus-
trial robot units, the market growth reached
its current peak in 2016. The International
Federation of Robotics is forecasting ano-
ther significant increase. If we look at the
sales markets of industrial robots in more
detail and split the sales figures among the
individual sectors, the Automotive Division
is undisputedly at the forefront of customers
worldwide. Close behind is electronics and
metal processing.
 Estimated annual sales of industrial robots worldwide from 2005 to 2019

2017 to 2019: + 13% average growth

per year

450
414
400
363
350

290
300
254 254
250
221
200 178
166 159
150
120 120 113 121
111
100
60
50

0
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016* 2017* 2018* 2019*

Units in a thousand pieces Source: IFR -International Federation of Robotics, September 2016
* forecast

Looking at the sales figures in detail from
2013 to 2015, a change of trend is apparent.
In the automotive sector, an overall progres-
sion seems to be emerging. The growth rate
from 2014 to 2015 virtually stagnates at a
high level, and in the process there seems to
be a real boom happening in the electronics
and semiconductor industries. In compari-
son to the sales figures for 2014, the sales
of industrial robot units are disproportionally
above average. It remains to be seen whether
this trend will continue. The automotive mar-
ket is regarded as almost full, while many ex-
citing products are currently conquering the
market in the semiconductor and electronics
industry—be it the robot and drones techno-
logy or the entertainment industry.

Low Cost Robotics 27

 Determined worldwide annual sales of industrial robots of the years 2013 - 2015 divided according
to industry

Automotive

Elektronics

Metal

Chemicals,
Plastic, Rubber

2015 2014 2013

Food

Others

Unspecified

0 20 40 60 80 100 120

Units in a thousand pieces Source: World Robotics 2016

Looking at the growth rates worldwide, es-
pecially in Asia, there are many opportuni-
ties for robotic use. The projected sales of
industrial robots in the Asia/Australia region
amounts to 285,000 units per year, while sa-
les in Europe and America are growing mo-
derately but steadily. Therefore, it can be
understood that robot technology is in the
forefront of its time. There is an urgent buil-
dup that needs to be cleared up from Europe
in order to not lose out in the long term. The
large-scale distribution of cost-effective ro-
botic prototypes can especially help to find
new methods, ways to use the methods and
establish them as a product on the market. In
addition, a number of conventional products
are not equipped with connected, intelligent
features riding on the digitization wave of In-
dustry 4.0. The large-scale distribution of 3D
print technology is another growth engine.
Essentially, it is worth keeping an eye on this
field. Comparing the growth rates of individu-
al continents confirms this assumption. In
the course of the shift of production from the
industrialized countries to the emerging mar-
kets, there is a special dynamic in the field
of automated production. Although there are
obvious advantages in terms of labor costs,
Asian countries are increasingly focusing on
low cost automation.
Particularly in the electronics and semi-
conductor industry, as well as in the food,
chemicals and plastics industries, turning
away from established industrial robots and
instead considering low cost robotic sys-
tems is worthwhile in order to explore further
possibilities for automation. Since the ap-
plication complexity is manageable and the

28 Low Cost Robotics

 3

Annual sales of industrial robots of 2014 - 2015 and the forecast for 2016 - 2019

300

250

200

150

100

50

2014 2015 2016* 2017* 2018* 2019*

Units in a thousand pieces Asia/Australia Europe America Source: World Robotics 2016
* forecast

workpieces to be processed are lightweight suitable method for controlling the robot and
with small dimensions, more cost-effective calibrating it to the required accuracy must
robot systems with lower capacity can be be clarified. “Out of the box systems” are cur-
reliably and frequently used. The necessary rently being offered by both established and
precision in a very small installation space very young companies. This causes a consi-
could be a problem in these application derably easier introduction into this techno-
scenarios. This can currently only be achie- logy. Some of the systems can be program-
ved by very few low cost systems. In order to med and configured simply by smart phones
be able to offer the system cost-effectively or tablets. Examples of this include Maker-
on the market, components of poor quality arm, Dobot Magician, the Franka Emika, or
are often used. The bearings, gears and dri- Techman Robot.
ves in particular should, however, satisfy the
quality requirements, as these components
may otherwise lead to an increased joint
clearance of the robot or motor. Often, only
the actual manipulators without actuators
or drives are offered in the field of low cost
robotics. It is up to the user to decide what
drives he will implement and how they would
ultimately be actuated. Choosing the most

Low Cost Robotics 29

 4

// Opportunities
and Risks

Due to the boom in newly available and
affordable robot prototypes, products can be
manufactured more efficiently, and in higher
quality. New concepts of the movement, and
the processing and handling of products ge-
nerates new opportunities, which can secure
an economic advantage in the long term. The
scanning and identification of a produced
component with a 3D scanner is an examp-
le of another possibility for implementing
innovative production technologies. In this
instance, a robotic manipulator is equipped
with a sensor, which is capable of detecting
an object in a multidimensional manner. This
method can help to reveal hardly visible de-
fects on the surface or in the structural form
at an early stage. Such applications can be
implemented through the platforms of sever-
al innovative providers.
There are risks concerning the possible lack
of expertise in the maintenance of such sys-
tems. In order to avoid this, a corresponding
maintenance strategy should be developed
in coordination with the manufacturer, which
on one hand ensures process reliability, and
on the other hand makes the costs predic-
table. Due to sometimes high technological
hurdles, like in control and programming,
4
many companies have missed out on oppor-
tunities for investing in the field of modern
manufacturing technologies for many years.
One main reason for this is due to a wides-
pread unfamiliarity about robotic potential,
and another is that companies needed to
wait until the technology was mature enough
to ensure adequate operational safety.
Many companies also fear that they do not
have enough resources to use complex
industrial robot systems. To solve this, a
structure needs to be created that sets up,
programs and operates these systems. In in-
stances like this, the potential for low cost
robotics becomes obvious. Significantly lo-
wer investment costs and the manufacturer-
independent community often offer ample
support. There is thus an enormous potential
for low cost robotic use, particularly for com-
panies that have not yet considered the field
of process automation.
Low Cost Robotics 31
 COMPARISON OF PURCHASE COSTS
In analyzing the initial prices of a conventi-
onal robot system in the automotive sector,
it becomes clear that a trend towards more
favorable overall investment costs is emer-
ging. According to Statista, the average price
of a spot welding robot plus its accessories
in the US automotive industry was 45,000
US dollars in 2014. However, the purchase of
just the robot itself is not enough. In addition
to the purchase costs of the hardware, con-
siderable costs are also incurred in the fields
of system engineering, project management
and the implementation of additional acces-
sories such as sensors or safety barriers.
All in all, in 2014 the average total invest-
ment cost for a conventional industrial robot
amounted to 133,000 US dollars. The costs
for systems engineering are very important
here. In the case of a professional design of
such a robot system, corresponding system
requirements must be planned and specified.
Afterwards, the robot also has to be installed
on site and given appropriate connections to
energy and information networks. In additi-
on, the immediate working area of the robot
must be protected by appropriate sensors
and safety barriers.
Low cost robotics, however, can score well in
all of these cost blocks. Typically, purchase
32 Low Cost Robotics
costs amount to 25 - 40% of conventional
systems. Further significant cost advantages
arise in systems engineering, since low cost
systems can often be controlled with apps or
trained by manual placement. The low cost
system is also impressive due to cost ad-
vantages of safety measures, since they are
already designed so that people won’t get in-
jured during interaction with the low cost ro-
bots by means of internal safety algorithms,
integrated sensors or their structural const-
ruction (lightweight construction).
Overall, the investment costs for the
purchase and implementation of a low cost
robotics project can be reduced to approxi-
mately one third of the costs of a conventi-
onal system—of course, always on the pre-
mise that the requirements for load capacity
and dynamic specifications can be covered
by the low cost system.
 4

Forecast of the price development of an industrial robot in the US by item through 2025 until
[in 1,000 USD]

150

9 9 9

46 46 46
100

45 45 45
50

33 33 33

0
2014 2020 2025

Project management Systems engineering, Peripherals, Robots

i.e.: programming, instal- i.e.: safety barriers; sensors including software
lation

Forecast of the price development of an industrial robot in the US by item till 2020
[in 1,000 USD]

60

40
15

20 15

10

0
2020

Project management Systems engineering, Peripherals, Robots

i.e.: programming, instal- i.e.: safety barriers; sensors including software
lation

Source: Statista.com

Low Cost Robotics 33

 PROSPECTS

34 Low Cost Robotics

 5

As time goes on, robots will be increasingly used in various

fields. For example, in the case of delivery services, they can be
used in the care sector or as helpers in households and offices. The
technology is increasingly improving due to the innovative power of
young, well-trained engineers. Globally, robotics will benefit greatly
in the future from globalization and the associated opportunities
that come with it. If companies start focusing on low cost robotics
now, they can draw considerable advantages from this crucial trend
of process automation. They can also benefit from the strong com-
munity, as well as established structures with only a few market-
dominating providers. All in all, in the future, a whole series of tasks
can be carried out by low cost systems. Due to the steady downfall
of technological and financial barriers of low cost robots, there is
great potential in this technology, which should also be utilized at
an early stage.

Low Cost Robotics 35

 // FAQ
How can low cost robots can be optimally
used in today’s business environment?
The use of low cost robots is particularly
useful in automation, where expensive and
complex industrial robot systems have previ-
ously been very unsuccessful. Even in indus-
tries where automation has not yet been pos-
sible, manual and monotonous work steps
involved in these industries can be eradica-
ted if low cost robotics is implemented. Here,
there is the opportunity to further utilize sy-
nergies of process automation through cost-
effective systems. Low cost robots can now
easily be implemented and programmed for
the respective work tasks. This opens up
entirely new possibilities for implementing
further work tasks (i.e.: sorting, pick & place,
scanning, loading) using cost effective sys-
tems. Low cost robotics also helps small and
36 Low Cost Robotics
medium-sized enterprises to use automation
technology at an early stage in the process.
A multitude of new options have opened up,
especially in the areas where the use of in-
vestment and resources were not profitable
for the company.
What are the advantages and disadvantages
in low cost robotic technology?
Low cost robotics give small and medium
sized companies the opportunity to enter the
process automation field at a low cost. This
can increase the quality and quantity of the
production process. However, there are risks
regarding the durability of the robot and spare
part availability, which can lead to unplanned
costs. To prevent these problems, systems
from established manufacturers should be
used to ensure long-term and professio-
nal product support. Additionally, accurate
planning of the application scenario should
be carried out in advance. In this instance,
for example, questions are raised concerning
the durability, load capacity or programming

capability of the used system. If the appro-
priate steps are implemented early on, low
cost robotics will achieve the desired results.
How does low cost robotics differ from low
cost automation?
Regarding low cost automation, the condi-
tions at assembly workplaces are primarily
designed in a more efficient and/or cost-ef-
fective manner. For example, manual hand-
ling operations are habitually reviewed and
improved based on examinations of the
workflow. This can be seen in the transfer
of workpieces to subsequent workstations,
which is done with roller conveyors. Low
cost robots are used cost-effectively in or-
der to utilize future interactions in terms of
value creation, such as using innovative sen-
sors and actuators. Furthermore, completely
new application possibilities are opening up
in low cost robotics, since cost-effective sys-
tems such as quality monitoring can be used
between the process steps.
How will low cost robotics develop in the fu-
ture?
Particularly in the electro-technical and me-
tal processing industries, there is increased
growth potential in the field of industrial ro-
botics. In places with difficult environmen-
tal conditions where products are handled,
processed, checked or packaged, there will
5
be a need in the future to use additional
process automation technology. Very small
and medium-sized enterprises are creating
a multitude of new possibilities that can be
used to achieve a competitive advantage
with little investment. The use of low cost ro-
botics offers an ideal foundation, which is al-
ready being used by a number of companies
around the world.
What are the criteria used to find a suitable
system for your own application?
The application scenarios of robot systems
are now very diverse. Due to the large number
of available systems, the possibilities are al-
most unlimited. With moving systems, there
are now robots that perform both swimming
and flying tasks. Even with industrial appli-
cations, there are a lot of options. Industrial
robots can be driven in a parallel kinematic
or serial manner, conventionally via rigid
connecting elements, rope-based or via fle-
xible components. In order to find a suitable
system, it is very important to consider the
requirements for system dynamics (speed,
precision, load capacity, etc.). Experienced
providers offer comprehensive and compe-
tent advice, as well as even some online con-
figurators.
Low Cost Robotics 37
 Is low cost robotics a trend that should not
be ignored?
Low cost robotics is a trend that should defi-
nitely not be overlooked. By using new, easy-
to-configure low cost systems, low cost ro-
botics is currently moving into both industrial
and household areas, which were previously
inconceivable due to high purchase costs,
difficult configurability and installation of ro-
bots. Overall, low cost robotics is currently
developing into a helpful human interaction
technology, and can be a worthwhile invest-
ment in certain professional and private situ-
ations. Continuously developing technology
and more intuitive programming interfaces
will significantly increase the spread of the-
se robot systems. Small and medium-sized
enterprises in particular can benefit enor-
mously from the opportunities created in
this way. Where industrial automation was
not previously worthwhile, new market seg-
ment can be gained through innovative appli-
cations with low cost robotics.

Why is low cost robotics considered an im-

portant part of future production processes?
The industrial production process is current-
ly undergoing a major change. The concept
of the robot is transitioning more and more
towards a partner and helper of humans,
and shifting further away from an autono-
mously industrial apparatus. Robots can
be programmed through apps or by manual
placement, and are able to respond to human
gestures and touches via smart interfaces or
internal sensors.

38 Low Cost Robotics

 5

Low Cost Robotics 39

 Published by:

igus® GmbH
Spicher Str. 1a
D-51147 Cologne

Dr.-Ing. Sebastian Feldmann

40 Low Cost Robotics