What image do you have in mind when you think of automation? Perhaps a production line at a large car manufacturer or a packaging sorting system in a large-scale warehouse? You might also think of sophisticated software and large-scale robotic systems that function almost without human intervention. With this picture in mind, it is hardly surprising that only large companies seem to be able to afford the costs of automation equipment and processes.

But automation is also worthwhile for medium-sized production facilities or laboratories. The fact that the components, systems and software required for this are becoming more financially attractive and flexible expands the range of applications for smaller companies. Innovations in the field of miniaturization, modular design and the growing range of cost-effective robot solutions and collaborative robots, so-called cobots, are making a significant contribution to this development.

Trend towards miniaturization

For medium-sized production facilities and warehouses, optimizing the available operating space is the be-all and end-all. As a rule, fixed building costs are among the largest operating costs, which is why expanding the floor space is often out of the question for cost reasons. A dense automation layout helps to make the best possible use of a smaller production environment, but the design of the machines must also be adaptable accordingly. In addition, space savings should not be at the expense of performance.

The demand for more performance and reliability in smaller sizes has driven incredible innovations and effects in the field of industrial manufacturing, especially when it comes to the miniaturization of components.
For example:

• Lightweight, complex circuit boards that meet desired operating speed requirements,
• smaller, lighter and energy-saving relays that support heat dissipation,
• increasingly compact cables and connectors that still meet the requirements of the harsh industrial environment,
• control units with smaller connectors that manage the high power, signal and data requirements.

Modular design

Another key requirement of medium-sized companies when optimizing their production facilities, in addition to optimal use of space, is flexibility. These companies often manage 'high mix low volume' production, rather than mass production of standardized products. The more customized the production, the higher the demand for flexible production and machine layout for quick and easy configuration adaptation to manufacture and assemble different products.

© TE Connectivity

Modular design allows manufacturers to quickly scale and adapt their production with minimal downtime, supporting the need for greater flexibility.

The principle of modular design for flexible manufacturing applies not only to production equipment and systems, but also to the corresponding connection solutions. Today, input/output connectors are also designed modularly to ensure a secure and reliable connection - often with a unique locking system to significantly reduce misconnections or unintentional disconnection due to shock or vibration. At best, connectors are compact, one-piece, pre-mated with contacts and have a space-saving and easy-to-install design that gives engineers more design flexibility.

Control cabinets can also benefit from innovative modular design. The move towards specific, application-based enclosures allows manufacturers to quickly scale up and customize enclosure options using standardized parts that can even be reused when needed. The aim is to reduce complexity in specific application areas by designing for part limitation and simpler operation and support - while meeting all performance requirements.

Modularity enables mid-sized companies to retool their production lines faster and more efficiently to meet their daily production requirements and ever-changing manufacturing goals.

Cost-effective robot solutions and cobots

The increasing demand for flexibility and miniaturization has also brought more and more cost-effective robotic solutions and cobots to the market - with significant benefits for small and medium-sized businesses and warehouses. Thanks to their smaller size and easier integration compared to large robot systems, they are increasingly becoming an option for manufacturing operations of all sizes.

A low-cost robot solution usually refers to any robot model with a maximum load capacity of 20 kg. They are equipped with connectors, cables and other components, have a compact design and are suitable for harsh environments. Therefore, although these robot systems have a lighter construction, they offer the sustainable robustness required for industrial applications. They also enable the automation of repetitive, time-consuming tasks with a smaller footprint and often at a lower cost. As an entry-level solution, these cost-effective robot systems are an attractive option for managers who want to test a partial automation solution for their production facilities and warehouses.

Collaborative robots or cobots are also easier to integrate into a production facility due to their compact size. Cobots are designed in such a way that they can share a workspace with humans without additional protective equipment. In addition, the collaborative cooperation between humans and cobots brings further flexibility to the manufacturing process by allowing production managers to combine the efficiency and precision of cobots with the skills of their employees, especially for more complex processes.

Integration into existing systems

The integration of robots into production lines used to require an enormous amount of time and a high level of technical expertise. However, current innovations in the field of robotics enable much faster integration, in some cases in just a few hours. In addition, those who operate the robots benefit from advances in sensor technology, machine monitoring and software, enabling them to reposition and program robots much faster than before.

These developments in robotics and modular, miniaturized automation solutions are just the beginning: further innovations will make devices and systems even smarter, faster and more tangible. Thanks to new, improved automation technologies, large, small and medium-sized companies alike will discover new ways to increase efficiency, manage a wide variety of scenarios, optimize their customer service and better support their employees.

We would like to emphasize that we cannot imagine a discussion about the future of automation without taking small and medium-sized businesses into account.