Task Complexity and the Skills Dilemma in the Programming and Control of Collaborative Robots for Manufacturing

While traditional industrial robots participate in repetitive manufacturing processes from behind caged safety enclosures, collaborative robots (cobots) offer a highly flexible and human-interactive solution to manufacturing automation. Rather than operating from within cages, safety features such as force and proximity sensors and programmed protection zones allow cobots to work safely, close to human workers. Cobots can be configured to either stop or slow their motion if they come in contact with a human or obstacle or enter a protection zone, which may be a high pedestrian traffic area. In this way, a task can be divided into sub-processes allocated to the cobot or the human based on suitability, capability or human preference. The flexible nature of the cobot makes it ideal for low-volume, ‘just-in-time’ manufacturing; however, this requires frequent reprogramming of the cobot to adapt to the dynamic processes. This paper reviews relevant cobot programming and control methods currently used in the manufacturing industry and alternative solutions proposed in the literature published from 2018 to 2023. The paper aims to (1) study the features and characteristics of existing cobot programming and control methods and those proposed in the literature, (2) compare the complexity of the task that the cobot is to perform with the skills needed to program it, (3) determine who is the ideal person to perform the programming role, and (4) assess whether the cobot programming and control methods are suited to that person’s skillset or if another solution is needed. The study is presented as a guide for potential adopters of cobots for manufacturing and a reference for further research.