In today's industrial landscape, sustainability is increasingly becoming a crucial focus for companies aiming to reduce their environmental footprint. Cognibotics, a Swedish robotics company, exemplifies this commitment through its energy-efficient technologies and innovative approaches to minimizing material use. By focusing on both the mechanical and software aspects of its robots, Cognibotics has established itself as a company whose technology inherently supports green objectives. Developments over the past years have been done in silence; we do not do green-washing but it is time to state some facts.
One of the environmental challenges in industrial automation is energy consumption. Robotics, particularly in large-scale manufacturing, can be energy-intensive. Cognibotics addresses this issue through the design of robots that are lighter and more energy-efficient than conventional alternatives.
For instance, Cognibotics’ robot, SigmaTau, exemplifies this energy-conscious approach. Building on the parallel kinematic machine (PKM) principle, SigmaTau is engineered to weigh significantly less than traditional robots for comparable tasks. In applications requiring large work areas, such as 4x3x6 meters, the moving parts of SigmaTau weigh approximately one-third of a typical gantry system. This reduction in weight not only decreases material use but also directly contributes to lower energy consumption during operation.
The core principle that enables the uniquely engineered Cognibotics arms is based on identifying the inherently required end-effector constraints, placing all of motors and moving masses as far as possible away from the end-effector, and then mathematically in terms of elasto-kinematics determine the best possible tradeoff between energy and cost, in particular for large-workspace robots since those waste much energy in themself rather than on work:
In subtractive applications such as milling, drilling, grinding, deflashing, deburring, etc., the end-effector is rational symmetric with that rotational degree of freedom (dof) built into the tool. By assuming the 6th dof (as needed for general manipulability in x, y and z plus orientations around those 3) being that rotational tool dof, a stiff wrist can be steadily locked within the robot wrist, and a deep analysis then shows that a super-stiff tool orientation and precise tool position can be accomplished by actuating via carbon-fiber links connected to motors located close to the static frame. The most energy efficient solution to this problem is the 8-linked SigmaTau PKM robot arm.
In handling applications such as pick-and-place within intra-logistics the end-effectors needs to rotate by means of the highest dof of the arm, which is a motor-controlled Axis 4 since the grasping/gripping tool is to be kept vertical by mechanical means all over the workspace. This is the opposite to the SigmaTau requirement where the final dof did not need a robot axis, but instead needing tilting motions away from the vertical, which required the 7th and the 8th link of the PKM. For the HKM it means that the kinematic equations apply to the elbow of the robot, if there would be a solution that is different from Scara, Delta or Gantry type of robots. It turns out those equations only have two solutions, both patented by Cognibotics. The one solution with lowest energy over the largest workspace is the one embodied in the HKM1800.
A key advantage of Cognibotics' robots is their ability to perform tasks at high speed while consuming less energy. For example, the SigmaTau robot has demonstrated that it can achieve the same production output in High-Speed Cutting (HSC) applications as traditional machines but with up to 90% lower energy consumption. Additionally, its slim construction and kinematic structure eliminates the need for special foundations or workshop adaptations, dramatically reducing the associated indirect CO2 footprint.
This reduction in energy usage is achieved without compromising the robot’s operational capacity. The design of the robot allows for efficient movement, which contributes to a marked decrease in overall energy consumption. Additionally, SigmaTau's process does not require the use of cutting fluids or oil mist, resulting in cleaner operations. The waste generated, primarily in the form of metal chips, can be recycled without additional treatment, further contributing to the company’s sustainable approach.
Cognibotics places considerable emphasis on the sustainability of the materials used in its robots. A prime example of this is the HKM1800 material-handling robot, which is constructed using carbon fiber. The robot’s moving components weigh just 25 kg, with a total weight of 125 kg, making it one of the lightest robots in its class. Competitors’ robots with similar performance metrics can weigh up to twice as much.
The lightweight design of the HKM1800 is integral to its energy efficiency, as less energy is required to move and operate the robot. Additionally, Cognibotics collaborates with suppliers who produce carbon fiber components in an environmentally responsible and recyclable manner, ensuring that sustainability is embedded throughout the supply chain.
Cognibotics' green approach is not limited to hardware. The company has also developed advanced software solutions that optimize the robots' performance, contributing to more efficient use of energy and reduced wear on mechanical components. The intelligent control systems developed by Cognibotics allow the robots to move precisely and at high speeds, while minimizing unnecessary stress on their joint transmissions.
By managing movement parameters, such as acceleration and deceleration, the software ensures that the robots avoid abrupt and inefficient changes in motion. This results in smoother, more controlled operations, which not only improves the lifespan of the robots but also reduces energy consumption.
While Cognibotics’ current robots already offer substantial energy savings, the company is continuously exploring future improvements in efficiency. Currently, the energy consumption of its robots is so low that recovering energy from braking during motion is not yet economically feasible. However, as technology evolves, Cognibotics anticipates that advancements will make such energy recuperation possible.
Additionally, Cognibotics is actively engaged in research collaborations with academic institutions, including Lund University (LTH), to further optimize and measure the energy efficiency of its robots. Preliminary studies indicate that robots like the HKM1800 consume less than half the energy of typical material-handling systems for similar applications.
Cognibotics demonstrates how robotics technology can contribute to environmental sustainability through a combination of material innovation, energy-efficient designs, and intelligent software systems. By focusing on reducing both the material inputs and the operational energy consumption of its robots, Cognibotics aligns its products with the growing demand for greener industrial solutions.
The company’s focus on long-term sustainability, from responsible sourcing of materials to continual refinement of its energy-efficient technologies, positions it as a responsible player in the evolving field of robotics. As industries seek to reduce their environmental impact, Cognibotics’ approach offers a pathway to integrating advanced automation with sustainable practices.
