May. 26, 2025
An automation system integrates sensors, control elements, and actuators to execute tasks with minimal or no human intervention. This cutting-edge technology is a part of the Mechatronics field, an interdisciplinary branch of engineering integrating mechanical, electrical, and electronic systems.
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Generally, automation systems are derived from traditional manual operations such as drilling, cutting, and welding. These systems frequently employ robotic arms to manipulate the tools necessary for executing these tasks. In applications focused on process control, automation systems observe and modify process parameters by operating equipment like heaters, motors, pumps, and compressors, or by managing process routes with valves. Automation systems are available in a variety of configurations tailored for distinct tasks. Some prevalent applications include:
The primary goal of an automation system is to minimize human intervention in industrial, manufacturing, and production processes. Human operators are naturally susceptible to errors, fatigue, and inconsistent performance, which can cause productivity bottlenecks, costly mistakes, and workplace accidents. By integrating automation solutions such as robotic automation systems, industrial robots, programmable logic controllers (PLCs), and advanced machine vision systems, manufacturers can achieve higher efficiency, precision, and safety. Automation technologies also pave the way for Industry 4.0 advancements such as smart factories, IoT connectivity, and real-time data analytics. Below, we explore the advantages and disadvantages of utilizing automation systems across various industries:
More Consistent Production: Robotic systems, including automated assembly lines and industrial automation equipment, are engineered for optimal efficiency. High-speed robots can perform complex tasks such as welding, material handling, packaging, and machine tending with exceptional consistency. By eliminating manual variability and downtime, these automated solutions deliver a substantial increase in production rates, larger production volumes, and higher overall profitability. Both hardware and software integrations—such as motion controllers and servo drives—ensure smoother workflow, maximizing throughput and reducing idle time. Additionally, powerful computer processing enables round-the-clock operation, far surpassing what a human workforce can achieve in speed and endurance.
Increased Repeatability: In a manufacturing environment, process repeatability is vital for maintaining uniform standards. Automated systems excel in repetitive tasks such as pick and place operations, vision-guided robotics, and automated inspection. Production lines retain efficiency as every movement—programmable through industrial software like SCADA (Supervisory Control and Data Acquisition) and HMI (Human Machine Interface)—remains consistent with minimal deviation. This high degree of repeatability boosts product uniformity and simplifies quality control.
Precision and Accuracy: As previously mentioned, actuators in modern automation equipment are designed for consistent, precise movement. Whether controlled by advanced PLCs or embedded control systems, these actuators maintain accuracy in each cycle, allowing for micron-level precision in processes such as micro-assembly and electronics manufacturing. Automation technologies also enable automatic calibration and real-time error correction using sensor feedback and adaptive controls. This translates into fewer defects and less material waste.
Additional Benefits: Automation facilitates scalability in production, enabling manufacturers to quickly adapt to changing market demands. Integration with ERP (Enterprise Resource Planning) and MES (Manufacturing Execution Systems) allows seamless management across the entire supply chain. Modern automated systems also support remote monitoring and predictive maintenance, reducing unexpected downtime and enhancing overall equipment effectiveness (OEE). Companies embracing automation are better positioned to achieve digital transformation and maintain a competitive edge in the global marketplace.
Considerations for Decision-Makers: When evaluating whether to automate, manufacturers should assess their specific production needs, anticipated volume, skill requirements, and long-term business strategy. Factors like system integration capabilities, upgradability, and supplier support are vital for extracting maximum value from automation investments. Engaging experienced system integrators and automation consultants is highly recommended for achieving optimal results and future scalability.
An automation system comprises a device that can receive input (such as from sensors or human-machine interfaces), a computing system (or processor), and manipulators (or actuators) that carry out the actual work. Among these components, the computing or control system is the most critical. It can be categorized into two types: open-loop and closed-loop (feedback) control. In an open-loop control system, the controller sends signals to the actuator based solely on the initial program, without considering the actual response. In contrast, a closed-loop system incorporates a feedback signal, which is generated by a sensor that measures the actuator's response, either directly or indirectly. This feedback is used by the controller to compare the actual output with the desired output, and adjustments are made to the signals sent to the actuator. This process repeats until the desired response is achieved.
The input component can be either a human-machine interface or a sensor. The human-machine interface is where the human operator interacts with the controller, entering variables or commands to adjust the desired output. A sensor, on the other hand, measures the output using various physical or electromagnetic properties such as pressure, temperature, magnetism, or radiation. The sensor converts the measured physical property into an electronic signal, which is then interpreted and utilized by the controller.
The actuator is the part that produces the actions. The actuator is composed of a driver and an assembly of joints and links. The driver provides the required force or torque used to move the links connected by joints. Drivers can be considered as electric, hydraulic, or pneumatic. Electric actuators are motors or solenoids that convert electrical energy into a mechanical output. Hydraulic and pneumatic systems operate using fluid pressure compressed on pistons, cylinders, vanes, or lobes. These systems, in their most basic concept, can be considered electric as well since the fluid is controlled by the opening and closing of solenoid valves.
The links in a mechanical system can move relative to each other based on the degrees of freedom provided by the joint. Degrees of freedom refer to the types of movement allowed for the links in three-dimensional space. There are six degrees of freedom: three for translation (up and down, left and right, forward and backward) and three for rotation (pitch, yaw, and roll). For simplicity, most joints are designed to allow only one or two degrees of freedom, as creating a highly movable arm can be complex, costly, and impractical.
The arm is the part of the system where end-of-arm tools are mounted. It consists of an assembly of links and joints, each with a fixed range of motion. A link is typically a rigid component designed to transfer force. These links are connected by joints, which are categorized into revolute or prismatic types. Revolute joints enable rotational movement, while prismatic joints allow for translational movement. The combination of these links and joints determines the degrees of freedom or range of motion of the arm. Arm configurations can be classified as follows:
Cartesian Robot: A Cartesian robot is composed of three prismatic joints. The name Cartesian is derived from the three-dimensional Cartesian coordinate system which consists of X, Y, and Z axes. This is the simplest system since it is easy to calculate the movements needed to manipulate the end effector from one place to another. This is suitable for applications that only require movement at right angles without the need for end effector rotation. An example of a Cartesian robot is a gantry machine.
Polar Robotic Arm: This type is also known as spherical robots. Its range of movement can be visualized as a sphere with the radius having the length of the link connecting the second revolute joint and the end effector. This link is allowed to be extended using a prismatic joint. Thus, this robotic arm is composed of two revolute joints and one prismatic joint.
Cylindrical Robotic Arm: This type of robotic arm consists of one revolute joint and two prismatic joints. The revolute joint is located at the base of the arm. This joint allows rotation of the links about its axis. This forms a cylindrical range of motion. The prismatic joints can extend which can be visualized as changing the height and radius of the cylinder.
Selective Compliant Articulated Robot Arm (SCARA): A SCARA is a robot that consists of an arm that is compliant or flexible horizontally in the X-Y plane but rigid vertically or in the Z-axis. This describes its "Selective Compliant" characteristic. Its "Articulated Robot Arm" is similar to a human arm composed of two links attached by a joint at their ends. This allows the robotic arm to extend or fold.
Articulated or Anthropomorphic Robot: This robot adds two more degrees of freedom to the end effector, in contrast with SCARA robots. Articulated robots have arms that are connected by a revolute joint at one end, similar to SCARA. However, they do not have a vertical linear guide. Rather, one arm is mounted into a swivel joint with a fixed base which allows more flexible movement.
End-of-arm tools (EOATs), also known as end effectors, are the components designed to interact with products or processes. Most EOATs are grippers, which handle objects by lifting, dropping, transferring, or reorienting them. Grippers can employ various methods for handling objects and are classified as impactive (mechanical jaws), ingressive (needles), astrictive (vacuum and magnetism), and contigutive (adhesion). Additionally, EOATs can be customized for specific tasks such as milling or welding.
Mechanical Grippers: These are used for basic pick-and-place robotic systems. Grippers have one to three sets of mechanical jaws that are driven typically by servo motors or pneumatic actuators. These jaws are composed of one line which is connected to the wrist by a revolute or prismatic joint. To control the gripping force when using servo motors, feedback is generated by strain gauges or the motor current. For grippers using pneumatic actuators, the gripping force can be increased without damaging the item due to the inherent compressibility of air. The jaws can be constructed as forks, fingers, parallel plates, or surfaces following the shape of the payload. A better grip is achieved by lining the surfaces with resilient, high friction materials.
Vacuum or Suction Cups: These are used for picking objects with smooth surfaces such as films, glass, and plates. A common way of producing a vacuum is through the use of a venturi supplied with compressed air. To create a larger suction force, an array of suction cups is used. Vacuum EOATs are cleaner than mechanical grippers and can allow some positional deviation. This type of EOAT is not suitable for rough, porous, or irregular surfaces. Moreover, the object can slip out of the suction cup when accelerated too quickly.
Magnetic Grippers: These types of EOATs use electromagnets for lifting ferromagnetic objects. Permanent magnets are also used since it does not continuously consume power. However, it needs a mechanical device for removing the collected object. Electromagnets are preferred due to their simple operation since the object can be lifted or dropped simply by supplying or cutting power to the electromagnet. However, aside from the limitation of its use on ferromagnetic materials, it also causes the parts to be magnetic. Also, it cannot be accelerated too quickly since the attached object can slip.
Inflatable Collars and Cylinders: An inflatable collar can be visualized as a looped elastomer tube supported by a rigid structure on its outer periphery. It grips the object by expanding the tube while releasing, which is done by deflating. These are commonly used in the two-dimensional gripping of tubular or cylindrical products.
Needle Grippers: These types perform gripping action by penetrating the object or bulk with needles or hackles. These EOATs are usually static without any moving links of joints. Needle grippers are used in handling porous or fibrous objects such as textiles, carbon and glass fibers where small penetrations are not an issue.
Adhesive Grippers: As the name suggests, these types of grippers grasp the product through surface adhesion. A special type of adhesive is coated onto the surface of a pad or plate which contacts the product to be lifted. The main advantage of adhesive grippers is their ability to operate without any air or power supply. However, they are limited to handling light objects and they tend to lose gripping effectiveness over time.
Tools (Permanent and Changeable): Tools can be fitted at the outermost link of the wrist instead of a gripper. The tool can be permanently attached or changeable. Common tools for end effectors are screwdrivers, wrenches, drills, rotating cutters, lasers, waterjet nozzles, paint spray nozzles, welding electrodes, and solders. Other specialized end effectors include inspection systems with mounted sensors. An example of this is a camera or other type of optical device which is used for non-contact testing and 3D measurements. The resulting measurements are exact in the order of tenths of a millimeter due to the intrinsic repeatability, precision, and accuracy of robotic systems.
Existing tools installed to the robotic arm can also be changed over time due to modifications brought about by new product requirements, system improvements, or part obsolescence. In deciding whether the new tool is applicable, several factors must be verified:
Anthropomorphic and Adaptive Grippers: In comparison with mechanical grippers, anthropomorphic grippers have more complicated links and joints. Mechanical grippers typically have one link connected to the wrist by a revolute or prismatic joint. Anthropomorphic grippers, on the other hand, have two or more links chained together by revolute joints. They can be configured to provide two- or three-dimensional gripping by having two or three sets of fingers. To be adaptive, each finger is actuated independently with mounted sensors for checking proximity and grip strength. Anthropomorphic and adaptive grippers are useful in applications where the objects are frequently varying such as in sorting and multiple product line packaging systems.
Actuators are components that supply force or torque to produce movement. They are connected to the links and joints via tendons, gears, chains, cams, or shafts, forming the core actuation system. Actuators are typically classified into three types: electric, hydraulic, and pneumatic.
Electric Actuators: Electric actuators are the most widely used actuators for industrial robots. The most common type of electric actuator is a servo motor energized by a DC power supply. The rotational movement of the motor can be converted into linear action by various mechanical transmission systems such as belts, cables, and chains. Electric actuators that create direct linear motion also exist in the form of linear motors and solenoids. The main types of electric actuators are summarized below:
Servo motors: This type of electric actuator operates through a closed-loop or feedback system which processes an output signal to control its position, velocity, and acceleration. The motors used in the servomechanism can be a brushed DC motor, brushless DC motor, AC motors, and even linear motors. The servomechanism has a sensor, transducer, or potentiometer called an encoder that measures the position and speed of the motor and converts it into an electronic signal. The signal, either digital or analog, is fed to an amplifier and controller which then alters the voltage or frequency of the electric power supplied to the motor.
Stepper Motors: Unlike the servomotor, stepper motors do not need a feedback loop. They operate through the continuous energization and de-energization of stator poles that pull the poles of the rotor. The stator has poles energized separately to pull the rotor poles and create a stepping or indexing rotation. The rotor is made of laminated ferromagnetic material with a different number of poles than the stator. The difference in the number of poles of the rotor and the stator allows only one set or pair of poles to be attracted at a time. A controller and amplifier power the poles according to the programmed speed of the motor. Stepper motors are simpler than servo motors but are less powerful. If the load is exceeded, the motor can slip. Since there is no built-in feedback loop, there is no way to correct the deviation.
Pneumatic Actuators: Pneumatic actuators operate using compressed air typically at pressures around 6 to 10 bars. The flow of compressed air is controlled by solenoid valves. The most common types of pneumatic actuators are cylinders or rams. A pneumatic cylinder has a piston that extends or retracts upon the application of pressure inside the cylinder. One side of the piston is connected to a rod which couples to the robot arm. Other methods of coupling are also possible such as cables and magnets. The amount of force generated depends on the pressure and the effective area of the piston.
Pneumatic cylinders can be single-acting or double-acting. A single-acting cylinder has only one inlet port in which the compressed air pushes the piston in one direction only. The return stroke is achieved by an external force such as spring force or gravity. On the other hand, a double-acting cylinder has two ports on both ends of the cylinder that acts as both inlet and exhaust ports. Compressed air is supplied on one end and is released on the other. This allows the piston to move and exert force in both directions. A less common type of pneumatic cylinder is a telescoping cylinder which is composed of nested shells that extend when compressed air is introduced. Telescoping cylinders can be single or double-acting.
For creating rotary motion using compressed air, pneumatic motors are used. Common pneumatic motors are rotary vanes and turbines. Rotary vanes operate through the positive displacement of air as it passes the rotor. Turbines create rotation using the kinetic energy of the passing air. Aside from pneumatic cylinders and motors, other types of pneumatic actuators exist such as tubes, bellows, and diaphragms. Though different in construction, they function the same way as cylinders and motors.
Hydraulic Actuators: Hydraulic actuators operate the same way as pneumatic actuators. The only differences are the magnitude of force created, the robustness of construction, its fluid circuit, and the ability to be servo-controlled. Hydraulic actuators can exert very large forces suited for carrying heavy payloads. This can be attributed to the incompressibility of hydraulic fluids or oil. Pressures can go as high as 130 bars. Because of the high pressures involved, hydraulic actuators are constructed with very thick and rigid metals. The rams and pistons are surface treated and sealed to prevent any fluid leakage.
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Pneumatic circuits are typically open where the air is not recirculated within the system. In hydraulic circuits, the fluid is returned to the pumping unit where oil is filtered and cooled before recirculation. When compressed at very high pressures, the fluid tends to heat up which can accelerate its degradation.
Another desirable characteristic of hydraulic actuators is their ability to be servo-controlled. Pneumatic cylinders are only capable of fully extending or retracting. Hydraulic cylinders, on the other hand, are capable of being servo-controlled in which their extension length and speed can be precisely controlled.
As the wave of digitalization and automation sweeps across industries, the logistics industry is bearing the brunt of the pressure to transform. From the perspective of technological development level, larger scale, higher flexibility, higher level of automation, higher efficiency, and lower cost are undoubtedly the development trend. Therefore, more and more logistics companies are trying to find a way to break through the development of enterprise through automation, intelligence, and unmanned.
Today, our article will take a deep dive into warehouse automation and explain why it is worthwhile.
Warehouse automation is an integral part of optimizing supply chains as it reduces time, effort, and errors caused by manual tasks. Here are some of the advantages that warehouse automation systems can bring to your business.
It is a huge disaster for e-commerce companies that customers receive wrong orders, and customers' trust is often lost from this moment. Warehouse automation can help us avoid this problem by reducing the number of decisions warehouse employees need to make, eliminating pick and pack errors, and improving order accuracy.
While no system can be 100% accurate, automated systems can certainly improve human accuracy. When errors do occur, automated systems can quickly identify and correct them. After all, automated systems have near-perfect precision and accuracy in the field of picking operations.
Automation does not mean that we need to replace workers with robots. The value of automation is to eliminate more mundane and repetitive tasks. Warehouse automation can improve employee satisfaction, help employees complete their work faster and better, and allow them to focus on value-added tasks. In short, warehouse automation streamlines processes in the supply chain and avoids unnecessary waste of resources.
Warehouse automation is also particularly helpful during fluctuating business demands and busy periods, such as holidays. On the one hand, automation can reduce staff turnover and recruitment costs, avoiding the need for temporary workers who must be trained and are sometimes difficult to recruit. On the other hand, when business is down, automated systems slow down and layoffs are unnecessary.
The speed and accuracy of humans are nothing compared to robots. But at the same time, humans have a cognitive power that robots cannot replace. Together, they form an effective combination for warehouse automation.
Most warehouse tasks are often repetitive and time-consuming, while automation can help to decrease touch points and ineffective tasks throughout the warehouse.
Warehouse automation systems can identify the location of all items in a particular order almost instantly, and workers can spend less time moving goods and re-picking. Even more, warehouse automation can also speed up order fulfillment when adopting automated warehouse robots and conveyor workstations.
As the entire process is speeded up and simplified, the overall productivity of the warehouse will be greatly improved.
Another benefit of warehouse automation is to speed up the process and reduce handling time. Humans cannot match the accuracy and relentless pace of robots. Warehouse process automation systems speed up the measurement process and accurately capture the dimensions, weight, and image of a package within seconds. It saves time when you need to measure thousands of parcels.
Meanwhile, automated warehouse processes allow you to use specific triggers to perform a series of tasks without human intervention. This automation makes it a valuable and necessary investment for warehouses.
Smart warehouse solutions can maximize warehouse storage space. One of the key ways automated warehouses accomplish this is by making the aisles narrower. Because machines do not require as much space as humans to operate, automated warehouses do not require additional aisle spacing to meet safety standards, which can further improve warehouse storage utilization.
At the same time, if an automated three-dimensional warehouse is used as an automated warehousing solution, its high-rise shelves can make reasonable use of space and increase the storage capacity of goods per unit area. Under the same area, the storage capacity of building an automated three-dimensional warehouse is several times or even ten times that of building an ordinary warehouse. In this way, under the same storage capacity, the automated three-dimensional warehouse can save a lot of land.
In traditional warehouses, there are a large number and variety of commodities stored, as well as various safety hazards, such as handling heavy pallets and high racks, operating in a high-traffic environment, and sometimes involving toxic products such as chemicals. Robotic picking systems avoid these problems.
First, many warehouse automation systems bring products to workers instead of workers picking them up. As a result, there is less traffic of people and equipment throughout the facility, which improves the overall safety of the warehouse.
At the same time, some automated warehouses have good sealing properties, which provide good conditions for regulating the temperature in the warehouse and improving the storage and maintenance of goods. The automated warehouse will also be equipped with alarm devices and drainage systems, which can prevent and extinguish warehouse fires in time.
Unpredictable markets, high customer expectations for faster shipping, and unstable supply chains are some of the challenges your business faces. Balancing supply and demand has become so complex that it can no longer be managed manually at costly risk.
You need an automation solution! The benefits of automated warehouse management are numerous, especially in optimizing inventory management, preventing backlogs and shortages of goods, adapting to market fluctuations, and enabling demand forecasting and just-in-time production.
Logistics automation systems can track information on specific inventory locations. The data is available on demand, making it both accurate and easy to analyze for intelligence. It can be used to transmit large amounts of relevant information to communicate with managers faster and more accurately, helping them make better and more informed decisions.
It is true that investing in warehouse automation is expensive, complex, and potentially risky. But have you evaluated the costs of an inefficient warehouse? Initially, it's zero, but in the long run, the hidden costs of out-of-stock, low service levels, and unsatisfactory customer experiences can be fatal to your business.
There is no doubt that warehouse automation projects are expensive, but they usually pay off quickly. The reason for the impressively quick ROI is that warehouse automation offers multiple new points of savings. For example, reducing staff administration and training costs, optimizing product handling and storage costs, minimizing inventory errors, and eliminating the risk of mishandling and product loss.
In an increasingly competitive industry, how to satisfy customers' purchasing experience has become an important lever of differentiation. Companies must be more proactive and deliver goods in less time than customers imagine.
With an automated warehouse, the time for order preparation and shipping is reduced, and the risk of error is almost zero. If a customer is not satisfied with an item, the return management process is also automated.
This is an important loyalty lever, as we know that customers who have a good return experience typically buy back from the same supplier. This also boosts our business accumulation. In fact, one of the main reasons why large retailers and logistics companies invest in the development of fully automated warehouse systems is to improve operational efficiency and better meet growing customer demands.
Sustainability is on the agenda of almost all businesses, and retail and logistics are no exception. In fact, while the cost advantages are fairly obvious, the long-term sustainability of warehouse automation is also a big plus point as a solution to many long-term problems, including efficiency, operating costs, and improved service.
For example, advanced automation systems ensure reduced and efficient use of energy, resulting in lower energy consumption and a smaller carbon footprint, as well as reduced operating costs. At the same time, by improving accuracy, the chance of damage is greatly reduced, which helps reduce the amount of waste each warehouse must manage.
When consumer demand changes, so do the entire warehouse operation, that is, warehouse companies need to handle more goods at a faster speed. Many companies choose to expand their existing warehouse space and establish multiple distribution centers to increase coverage, but this requires a significant investment of time and expense.
One of the great benefits of warehouse automation solutions is that you can easily scale up and down and quickly respond to changes in consumer demand. Users can re-use existing racks and totes if they fit handling specs. Automated systems can also be easily deployed in a small part of the warehouse and scaled up to a larger installation as your business grows.
Meanwhile, retailers don't need to be busy doubling their headcount or dealing with temporary workers during the holidays. Instead, employees can focus on more customer-focused activities.
Highly automated warehouses are more resilient to unexpected changes. For example, during the COVID-19 pandemic, there was a prolonged surge in demand for consumer goods and many warehouses have struggled to keep up with the dramatic growth in online shopping; new safety and sanitation measures have also hit warehouses that rely exclusively on human operations. And robotics and other emerging technologies can help make supply chains more agile and resilient by improving the accuracy and timeliness of product information.
Nowadays, more leading retailers are committed to making warehouses responsive, resilient, and reliable to adapt to the growing e-commerce market and to learn from the lessons of global pandemics.
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