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The Rapid Evolution of Industrial Robots and Cobots
Industrial automation continues to accelerate as manufacturers pursue higher productivity, consistency, and workforce safety. While popular culture often labels autonomous cars or software agents as “robots,” industrial robots are precisely defined as programmable manipulators with three or more axes, designed for physical tasks in manufacturing environments.
Traditional industrial robots have seen steady global adoption, but collaborative applications are reshaping expectations. Cobots are no longer a niche concept—they are becoming a strategic tool for factories seeking flexibility without sacrificing safety.
Traditional Robots vs. Collaborative Applications
Conventional industrial robots are built for speed, strength, and precision. They excel at welding, painting, assembly, and material handling, but they typically operate behind physical guarding to isolate humans from risk.
Cobots, by contrast, are optimized for proximity to people. They feature lower mass, reduced speeds, and force-limiting capabilities, allowing them to share workspaces with operators. In my experience, their real value is not just safety—but redeployability. A single cobot can serve multiple processes across shifts with minimal reprogramming.
A Major Shift in Safety Standards: ISO 10218 (2025 Update)
Historically, robot safety was governed by ISO 10218 for industrial robots and ISO/TS 15066 for collaborative robots. The 2025 revision of ISO 10218 fundamentally changes this structure.
The updated standard removes the rigid distinction between “robots” and “cobots.” Instead, it focuses on collaborative applications. Any system in which humans and robots share space must now be evaluated as a collaborative system—regardless of robot size or marketing label.
This is a critical shift: compliance is no longer about what the robot is, but how it is used.
Robot Class I and Class II: A Practical Classification
The revised ISO 10218 introduces two robot classes:
- Robot Class I
Designed for manipulators ≤10 kg, ≤50 N force, and ≤250 mm/s speed. These robots may perform limited collaborative tasks without additional safety technologies, depending on risk assessment. - Robot Class II
Any robot exceeding one or more Class I limits. These systems require additional protective measures for collaborative use.
From a system integrator’s perspective, this classification simplifies early design decisions while reinforcing the importance of application-specific risk analysis.
Mandatory Safety Technologies for Collaborative Operation
For Class II robots, collaborative use requires at least one of the following safety strategies:
- Speed and Separation Monitoring (SSM) using safety scanners or sensors
- Power and Force Limiting (PFL) to reduce injury risk on contact
- Hand-Guided Control (HGC) with hold-to-run functionality
Regardless of class, emergency stops and hardwired safety circuits remain non-negotiable. Larger robots still demand protective devices such as interlocks, light curtains, and presence-sensing devices.
Teaching Pendants and the Role of Enabling Switches
Teach pendants are often overlooked as safety devices, but under the new standard, their design is critical—especially in manual or maintenance modes.
For Class II robots, a three-position enabling (3PE) switch is mandatory. These switches ensure motion occurs only when the operator consciously holds the pendant in a safe mid-position. Releasing or gripping too tightly immediately stops the robot.
For Class I robots, a 3PE switch may not be strictly required, but in my professional judgment, integrating one is often the most robust and defensible way to pass a risk assessment—especially for troubleshooting or hand-guided tasks.
Modern HMI Design: Tablets Meet Industrial Safety
OEMs face a challenge: how to deliver modern, intuitive interfaces while meeting stricter safety requirements. Redesigning custom pendants can be costly and time-consuming.
An emerging solution is the integration of consumer-grade tablets within industrial safety-rated holders that provide:
- Hardwired emergency stop and 3PE switch
- Wired power and networking
- Mode selectors and reset controls
- Environmental protection and drop resistance
This approach bridges the gap between advanced visualization and certified safety—something I believe will become standard practice in the next generation of robot HMIs.
Why These Changes Matter for OEMs and End Users
The evolution of ISO 10218 should not be seen as a regulatory burden. Instead, it is an opportunity to build safer, smarter, and more flexible robotic systems.
OEMs who embrace standardized safety components and modular HMI concepts can reduce development risk, accelerate compliance, and deliver greater value to end users. In a market where differentiation is increasingly difficult, safety-driven design excellence is becoming a competitive advantage.
