Sensors are at the heart of modern robotics and uncrewed systems. They make for precise control, reliable automation and safe navigation in a wide variety of environments. The market increasingly calls for solutions that guarantee a flexible and efficient connection between robots and machines. Here IO-Link plays a pivotal role. At XPONENTIAL Europe, which will bring together experts for uncrewed systems and robotic technologies in Düsseldorf from 18 - 20 February 2025, the latest sensors will be presented to name but one exhibit.
In robotics and uncrewed systems a wide variety of sensors for status control are deployed – ranging from inductive and photoelectric sensors to capacitive, pressure and temperature sensors. They deliver essential data for placing and gripping objects and capture various parameters such as vibration, temperature and other physical parameters in real time. “This allows potential problems to be detected and preventive measures to be taken early on,” explains Sebastian Weik, Marketing Manager at Balluff, one of the world’s biggest producers of sensor technology. “This real-time monitoring contributes significantly to maximising the reliability and lifecycle of machinery and systems. In addition, smart sensors are particularly important in both stationary and mobile robots to ensure safe and efficient navigation.”
Reliability under extreme conditions
Another highly relevant issue is the reliability of sensors under extreme conditions. To reduce downtimes and ensure a constantly high product quality the sensors have to withstand both high heat and also flying sparks – as emitted during welding jobs – but also survive extreme cleaning processes to comply with the cleanliness standards in clean-room environments.
Safety as a priority
Alongside technical performance, safety plays a decisive role. Sensors and systems deployed in safety-critical applications, must comply with highest safety standards. Internationally recognised organisations such as the International Electrotechnical Commission (IEC) and the International Organization for Standardization (ISO) subject sensors and systems to strict testing before issuing a certification.
Connecting robots and machines
The communication protocol IO-Link is the current answer to the increased demand for flexible and efficient solutions for connecting robots and machines. “IO-Link permits the simple integration of sensors and actuators in automation systems,” explains Weik. This technology offers crucial advantages such as easy installation, comprehensive diagnosis options and the dynamic adaptation of equipment parameters during operation. It is particularly relevant to robot cells, tool and gripper change as well as complex assembly and handling processes.”
In future, new technologies such as IO-Link Wireless and inductive couplers will play an increasingly important role. These innovations make for quick and flexible tool and gripper change while ensuring high data transmission rates as well as energy efficiency at the same time. The continuous further development of sensor technologies and their integration in the Internet of Things (IoT) will revolutionise robotics even further.
Importance of cobots is rising
Over the years collaborative robots (cobots) have gained more and more importance. However, many cobots have so far been used like traditional industrial robots – i.e. without direct man-robot interaction. “As smart sensors and Artificial Intelligence (AI) are developed further, however, these robots will increasingly be able to act as supporting tools in production by assisting and relieving workers in repetitive, hazardous or physically demanding tasks,” says a convinced Weik.
The successful operation of uncrewed machines decisively depends on a perfect interplay between hardware, software, sensors and AI. Only if all of these components interact seamlessly can machines perform their tasks efficiently and reliably. To this end, the close cooperation between sensor producers, robotics providers and research institutes is indispensable. Such collaborations promote innovations and contribute to the development of new production concepts. An example of one such partnership is the research platform ARENA2036, which looks into the future of production and primarily works on new concepts. “Only such cooperations can drive innovation processes and identify and test technology and market trends early on,” says Weik.
Author: Sonja Buske
