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Robotics

Robotics workflow challenges

Section titled “Robotics workflow challenges”

Coordinating robot systems with human teams is hard. Industrial and commercial robots run on proprietary control systems and communication protocols - connecting them to business workflows requires middleware, protocol translation, and careful architecture planning.

Common communication protocols

Section titled “Common communication protocols”

OPC UA (Open Platform Communications Unified Architecture)

Section titled “OPC UA (Open Platform Communications Unified Architecture)”

Industry standard used by major manufacturers (ABB, KUKA, FANUC, Siemens). It provides secure machine-to-machine communication with built-in data modeling.

ROS/ROS2 (Robot Operating System)

Section titled “ROS/ROS2 (Robot Operating System)”

Open-source robotics middleware common in research and collaborative robots. ROS2 uses DDS (Data Distribution Service) for real-time communication between nodes.

MQTT (Message Queuing Telemetry Transport)

Section titled “MQTT (Message Queuing Telemetry Transport)”

Lightweight publish-subscribe protocol built for IoT devices. Used for robot telemetry and event-driven communication, with lower bandwidth needs than OPC UA.

Proprietary protocols

Section titled “Proprietary protocols”

Many manufacturers use proprietary communication methods that need vendor-specific SDKs or edge devices to translate into standard protocols.

Integration architecture

Section titled “Integration architecture”

Network topology

Section titled “Network topology”

Robot systems typically need network segregation between operational technology (OT) and information technology (IT) networks. Integration points usually happen through:

  • DMZ (demilitarized zone) with controlled access
  • Edge computing devices bridging OT and IT networks
  • API gateways with rate limiting and authentication
  • Message queues for asynchronous communication

Security requirements

Section titled “Security requirements”

When connecting robots to external systems, you’ll need:

  • Network isolation between robot control and business networks
  • Authentication and authorization for all API calls
  • TLS encryption for data in transit
  • Fail-safe mechanisms if connectivity drops
  • Air-gapped operation for safety-critical systems

Human-robot collaboration workflows

Section titled “Human-robot collaboration workflows”

Modern industrial settings increasingly mix automated and manual work. Coordinating these workflows means connecting robot control systems with human task management.

Common patterns

Section titled “Common patterns”

Assembly operations - Robots handle heavy lifting and precise positioning while humans manage delicate components that need dexterity.

Quality inspection - Automated measurement systems run initial checks, routing exceptions to human inspectors.

Maintenance workflows - Diagnostic routines generate data that maintenance teams use for troubleshooting and repair.

Safety and compliance

Section titled “Safety and compliance”

Industrial robot deployments must follow relevant safety standards:

  • ISO 10218 (Safety requirements for industrial robots)
  • ISO/TS 15066 (Collaborative robots)
  • ANSI/RIA R15.06 (North American industrial robot safety)

Audit trails help demonstrate compliance during safety assessments.

Planning your integration

Section titled “Planning your integration”

Technical requirements

Section titled “Technical requirements”
  • API access and authentication
  • Network connectivity and bandwidth
  • Protocol translation capabilities
  • Edge computing or middleware needs
  • Data sync and latency requirements

Organizational readiness

Section titled “Organizational readiness”
  • IT and operations team collaboration
  • Clear ownership of robot systems
  • Change management processes
  • Training for maintenance staff
  • Incident response procedures

Industry applications

Section titled “Industry applications”

Manufacturing

Section titled “Manufacturing”

Automotive assembly, electronics production, material handling, CNC coordination, quality inspection systems

Logistics and warehousing

Section titled “Logistics and warehousing”

Autonomous mobile robots (AMRs), automated guided vehicles (AGVs), picking and packing systems, inventory management

Healthcare

Section titled “Healthcare”

Laboratory automation, pharmacy dispensing, sample tracking, diagnostic equipment coordination

Food and beverage

Section titled “Food and beverage”

Packaging lines, batch processing, cleanroom operations, quality control systems

Common challenges

Section titled “Common challenges”

Protocol complexity - Translating between industrial protocols and business systems needs specialized middleware and expertise.

Network security - Keeping proper OT/IT segregation while enabling data flow.

Latency sensitivity - Real-time robot control and asynchronous workflow updates need different architectural approaches.

Legacy systems - Older robot controllers may lack modern connectivity options.

Vendor lock-in - Proprietary systems can limit integration flexibility.

Documentation and knowledge management

Section titled “Documentation and knowledge management”

Organizations managing robot fleets often struggle with:

  • Keeping operational procedures up to date
  • Sharing improvements across multiple robot installations
  • Tracking which procedures were followed for compliance
  • Managing procedure versions as operations evolve
  • Coordinating human and automated tasks

Vendor resources

Section titled “Vendor resources”

Each vendor page below covers workflow management considerations for that robot platform:

Note: Implementation details depend on your organization’s requirements, robot configurations, and network architecture.

Important disclaimer

Section titled “Important disclaimer”

Information currency: This documentation covers general robotics workflow integration concepts. The robotics industry evolves rapidly, with frequent changes in:

  • Vendor product capabilities and APIs
  • Communication protocols and standards
  • Safety regulations and compliance requirements
  • Market positioning and company ownership

Verification required: Before making technical or business decisions:

  • Check current vendor capabilities through official documentation
  • Consult robot manufacturers for specific integration requirements
  • Review current safety standards and compliance obligations
  • Assess your organization’s specific needs

No guarantees: This documentation doesn’t constitute:

  • Promises of specific integration capabilities
  • Technical specifications or service level agreements
  • Endorsements of particular vendors or products
  • Professional advice for your specific situation

Contact Tallyfy support to discuss your robotics integration requirements and current capabilities.

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