Hubachse ZH90 für Hochvoltspeicher
Hubachse ZH90 für Hochvoltspeicher
Guide · Automation without robots
Not every automation process requires a robot.
Imagine a manufacturing process where a component needs to be inspected, fitted with attachments, and then ground. With a robot, this process takes place in four separate steps: the robot places the component, the operator processes it, the robot picks it up again, and places it down once more. With a collaborative lifting axis, the machine holds the component while the operator works directly on it, inspecting, assembling, grinding, and then placing it down themselves. Two steps instead of four, without the need for placing and picking up components in between.
When people think about automation, they usually think of robots first, as they are the most familiar form. In reality, there are four fundamentally different ways to automate or relieve the burden on a workplace: industrial robots, cobots, exoskeletons, and handling technology. This guide objectively categorizes all four and shows when each solution is actually the more economical.
CHAPTER 1
Why do so few people recognize handling technology as a separate category?
Industrial robots have been part of the public image of factory automation for decades. Cobots and exoskeletons receive additional media attention because they are currently the subject of intensive research, for example, on combinations of wearable assistance and collaborative robots. In contrast, handling technology has been operating quietly in factory halls for decades, without its own research community or media presence. The result: Those who don't work directly in the industry simply don't know the category and therefore don't look for it when faced with an automation decision, even though it would be the more economical choice for many applications.
CHAPTER 2
An overview of the four types of automation
The four types differ along two lines: Who carries the load, the machine or the human, and who controls the movement, the human or a programmed machine? Industrial robots and cobots answer both questions the same way: The machine carries and the machine controls, programmed according to fixed paths. With exoskeletons, the human remains responsible for both; they continue to carry the load themselves, only with assistance, and fully control their own movement. In handling technology, i.e., manipulators and lifting axes, the machine carries the load completely, while the human guides the movement directly with their hand. This very combination—machine carries, human controls—is the gap that is usually missing in the public perception of automation.
Handling technology
Machine carries, human controls. Manipulator, lifting axis.
exoskeleton
Humans carry with support, humans steer.
Industrial robot / Cobot
Machine carries, machine controls, programmed.
Hardly used
Human carries, machine controls. Not an established category.
CHAPTER 3
The four types in detail
Handling technology
Handling technology refers to manipulators and lifting axes that support a load without swinging, while the operator guides the movement directly by hand. There is no stored path and no programming of the movement itself; the human operator handles the fine control at every moment. This allows for true simultaneous collaboration: The operator can inspect, attach, or process a component while the machine holds it, without the putting-down and picking-up steps that a robot would require. A detailed definition with all types is provided in the guide "What is a Manipulator?"
Cobot
A cobot is a collaborative robot equipped with safety sensors that can operate alongside humans without a separating safety fence because it automatically reduces its speed when a person approaches. This doesn't change its fundamental functionality: a cobot is programmed like an industrial robot, follows fixed movement paths, and requires reprogramming whenever a component is changed. Eliminating the safety fence saves space, but not the programming effort.
industrial robot
An industrial robot is a programmable, usually stationary system that moves components along pre-programmed paths. It is the right choice for very high production volumes with consistent components, for example, at the end of a production line, where the programming effort pays for itself over tens of thousands of cycles. It typically requires precise, repeatable component positioning, often additional feeding technology or sensors, and a safety fence. Every change to the component necessitates reprogramming the paths.
exoskeleton
An exoskeleton is a body-worn device, usually a type of backpack with a motor or spring mechanism, that assists the user's own muscle power, for example, when lifting with the arms or holding objects overhead. The load is still borne entirely by the user, but with less effort. An exoskeleton doesn't automate anything in the true sense; it relieves the person of tasks that they still perform completely manually. Its use in industrial practice is currently limited, and many applications are still in the research phase.
CHAPTER 4
The process difference specifically
The difference is most evident in a single work cycle. With a robot, a typical cycle consists of four separate steps: the component is placed down, the operator processes it at a separate station, the robot picks it up again, and the cycle concludes with the final placement. Each of these transitions consumes time and space because the component has to be transferred between the machine and the operator. With a collaborative lifting axis like the ZH90, two of these four steps are completely eliminated: the axis picks up the component and holds it, the operator works directly on it, and then places it down themselves. Two steps instead of four mean less cycle time and less space required at the workstation because no separate placement point is needed for the intermediate step.
CHAPTER 5
What a component modification really costs
With a robot, a component modification falls into two separate tasks: the mechanical modification of the gripper and the subsequent reprogramming of paths and positions. This applies regardless of who supplies the gripper; even if the integrator also supplies the fixture, reprogramming remains necessary because the robot moves according to fixed coordinates. In handling technology, mechanical adjustment of the gripper is generally sufficient; reprogramming is completely unnecessary because the human operator performs the movement anew in each cycle anyway. The guide "Robot Gripper or Custom Fixture?" discusses the comparison between standard grippers and custom fixtures in more detail.
CHAPTER 6
Where a robot is still the better choice
Handling technology is not a one-size-fits-all solution. For very high, consistent production volumes without product variations, the programming costs of a robot are quickly recouped. Two in-depth guides explain in detail how to choose between robots, manipulators, and intermediate options: Manual, Semi-Automated, or Robot? and Manipulator or Cobot?
FAQ / Q&A
Frequently Asked Questions
01 Ist ein Manipulator ein Roboter?
No. A manipulator doesn't have its own control system that follows a path; it is guided directly by the operator in every movement. A robot, on the other hand, moves along programmed positions, even if a person is standing next to it.
02 What is the difference between cobot and handling technology?
Despite its safety sensors, a cobot remains a programmed robot with a fixed path. Handling technology, on the other hand, has no programmed path; every movement is initiated by the operator's hand. A detailed comparison of when each system is worthwhile can be found in the guide "Manipulator or Cobot?"
03 Does handling technology need a safety fence?
No. Since the employee controls the movement himself and no autonomous movement sequence takes place, there is no need for a separating protective device, as is required for most industrial robots.
04 What is an exoskeleton compared to handling technology?
An exoskeleton supports the employee's own muscle power, allowing them to continue carrying the load themselves. In handling technology, a machine, manipulator, or lifting axis carries the load completely; the employee only guides the movement.
05 Can handling technology be combined with a robot?
Yes. In practice, a robot often takes over repetitive sub-steps, while a lifting axis or manipulator covers the areas that require flexibility or human intervention. The two systems are not mutually exclusive.
06 How quickly is handling technology ready for use?
Because no movement path needs to be programmed, handling technology is typically ready for use within a few days to a few weeks, depending on how customized the device needs to be for the specific component. A comparable robot system requires additional time for programming, simulation, and path calibration.
07 What is the biggest limitation of handling technology?
The biggest limitation is the cycle time: Since humans control the movement, handling technology is bound to the speed at which an employee can work safely and ergonomically. At very high cycle rates that exceed human working speed, or in unmanned shift operations, a robot has the advantage.
CHAPTER 8
Related Guides
What is a manipulator ? Function & types: the detailed definition
Manipulator or cobot ?: an in-depth comparison
Manual, semi-automated, or robot ?: finding the right level of automation
Robot gripper or custom device ?: Standard gripper compared to a tailor-made solution
How much does a manipulator cost ?: Price factors and ROI
Product comparison : which ZHHT system suits your needs
Product finder : find the right solution in just a few steps