Selecting Batteries for Collaborative Robots (Cobots)

You face many decisions when choosing batteries for collaborative robots. Matching battery specs like voltage, capacity, and discharge rate to cobot needs helps you achieve reliable automation. Lithium-ion batteries and lithium iron phosphate stand out as high-performance batteries for robotics batteries. You benefit from advanced battery technologies that support energy storage, safe charging, and efficient battery management systems. Rechargeable options fit most applications. Solid-state batteries promise future improvements. Recycling remains one of the challenges facing the robotics battery market.

Key Takeaways

• Choose the right battery voltage and capacity to ensure efficient operation of collaborative robots and avoid damage.

• Select batteries with appropriate discharge rates to meet peak power demands and prevent overheating.

• Prioritize safety features like thermal protection and advanced battery management systems to protect robots from hazards.

• Consider the weight and size of batteries to maintain the mobility and efficiency of collaborative robots.

• Regularly monitor battery health and follow a strict maintenance schedule to extend battery lifespan and reduce downtime.

Part 1: Battery Selection Criteria

1.1 Voltage and Capacity

Selecting the right voltage and capacity for batteries in collaborative robots is essential for reliable automation. You must match battery specifications to the motor requirements and operational needs of your cobots. When you choose batteries with the correct voltage, you ensure that the robot’s motors run efficiently and avoid damage from under- or over-voltage. Capacity determines how long your cobot can operate before needing a recharge, which directly impacts productivity in your facility.

Tip: Always check the manufacturer’s recommended voltage and capacity ranges for your robotics batteries. This helps you avoid downtime and maximize energy storage.

Here is a table showing recommended specifications for collaborative robots:

Matching battery voltage and capacity to your cobot’s requirements improves operational efficiency. High-current DC charging transforms robots from scheduled tools to continuous collaborators in smart production environments. System designs must handle voltage/current profiling for various chemistries like LiFePO4, NMC, LCO, LMO, LTO, and solid-state batteries using CC/CV logic. Integrating battery management systems allows real-time parameter adjustment, which optimizes performance and efficiency.

Charging stations should exchange battery state of charge (SoC), temperature, cycle count, charging rate, estimated time to full, fault codes, contact quality, and temperature alerts. This exchange keeps your robots operating under optimal conditions and supports continuous automation.

1.2 Discharge Rate (C/E Rates)

Discharge rate, often shown as C-rate or E-rate, tells you how quickly a battery can deliver energy. You need to select robotics batteries with a discharge rate that matches your cobot’s peak power demands. If the discharge rate is too low, your robot may lose power during heavy tasks. If it is too high, you risk overheating and reducing battery lifespan.

Note: Always review the discharge current requirements for your applications. For collaborative robots, a nominal discharge current of at least 27A and a maximum discharge current of 47A are typical for high-performance batteries.

Advanced battery technologies like LiFePO4 and NMC offer stable discharge rates and support fast charging, which is vital for automation in industrial settings.

1.3 Weight and Size

Battery weight and size influence the design and mobility of collaborative robots. You must balance battery capacity with the need for lightweight, agile cobots. Increasing battery capacity adds weight, which impacts mobility and energy consumption. Design trade-offs are necessary to balance battery capacity and robot mobility.

Here is a table showing how payload capacity relates to application areas and key features:

• The lightweight design of lithium batteries significantly enhances the mobility of robots.

• By reducing overall weight, these batteries improve maneuverability and energy efficiency.

• This is especially important in applications that require frequent movement, such as healthcare assistance or industrial inspections.

Energy-aware strategies are being researched to enhance efficiency in the robotics battery market.

1.4 Safety Features

Safety features in batteries protect your collaborative robots from thermal runaway, fire, and other hazards. You should look for improved battery pack designs that minimize heat buildup and thermal propagation. Proper spacing, thermal insulation, and heat dissipation mechanisms are essential.

Advanced battery management systems monitor voltage, current, and temperature. These systems take action to prevent conditions that could lead to thermal runaway. Safer battery chemistries, such as LiFePO4, offer higher thermal stability and lower risk of fire.

• Gas sensors provide early detection of thermal runaway.

• Thermal runaway detection systems alert you before failures occur.

• Solid-state batteries replace liquid electrolytes with non-flammable solid materials, improving safety.

You can learn more about sustainability and safe battery practices in the robotics battery market here.

1.5 Durability and Lifespan

Durability and lifespan are key factors in selecting robotics batteries for collaborative robots. Most robot batteries provide between 4-10 hours of runtime per charge. The lifespan of a robot battery typically ranges from 500 to 3,000 charge cycles. You should choose high-performance batteries that offer long cycle life and stable performance.

• The cost of high-performance robot batteries is significant, which can restrict their use, especially for smaller businesses.

• Robot batteries have a finite lifespan and require regular replacement, contributing to the total cost of ownership.

• Safety issues related to battery failures can increase operational costs and complicate the adoption of collaborative robots.

Recycling batteries at the end of their life helps reduce environmental impact and supports sustainability in the robotics battery market.

1.6 Brand and Cost

Brand reputation and cost play a major role in your battery selection process. You should choose brands known for quality, reliability, and support in the robotics battery market. While high-performance batteries may cost more, they offer better durability, safety, and efficiency. Investing in advanced battery technologies and rechargeable options can lower your total cost of ownership over time.

Tip: Compare brands based on warranty, support, and proven performance in automation and collaborative applications.

You should also consider the availability of recycling programs and the brand’s commitment to sustainability.

Part 2: Types of Robotics Batteries

2.1 Lithium-Ion Batteries

You find lithium-ion batteries at the center of the robotics battery market. These batteries deliver high energy density and lightweight design, which makes them ideal for collaborative robots. Lithium-ion chemistries such as NMC, LCO, LMO, and LTO support platform voltages from 3.6V to 3.7V per cell. You benefit from long cycle life, often reaching 1,000 to 2,000 cycles. Fast charging and reliable performance help you maintain automation in demanding environments. Lithium-ion batteries remain the preferred choice for most robotics batteries due to their balance of power and efficiency.

2.2 Lithium Iron Phosphate

Lithium iron phosphate (LiFePO4) batteries stand out for their safety and durability. You gain robust performance under high temperatures and challenging conditions. LiFePO4 batteries offer stable chemistry and do not burn or explode under damage. These batteries provide platform voltages around 3.2V per cell and cycle life exceeding 2,000 cycles. You also support sustainability, as LiFePO4 batteries are non-toxic and do not contain heavy metals. Their long cycle life and resistance to thermal runaway make them a top choice in the robotics battery market.

Tip: LiFePO4 batteries help you reduce risk and improve reliability in collaborative robot applications.

• LiFePO4 batteries are recognized as green batteries in the market.

• You can learn more about sustainability and recycling in robotics batteries here.

2.3 NiMH and Lead-Acid

You may encounter NiMH and lead-acid batteries in legacy systems. NiMH batteries offer affordability and safety, but they have lower energy density and shorter lifespan. Lead-acid batteries provide reliable and cost-effective solutions, but they are heavier and have shorter cycle life. These types are less common in modern robotics batteries due to limitations in energy density and weight.

2.4 Pros and Cons Comparison

Here is a table comparing the main types of batteries used in the robotics battery market:

You should select batteries based on your application needs, safety requirements, and total cost of ownership. Rechargeable batteries with advanced battery technology support automation and sustainability in the robotics battery market.

Part 3: Collaborative Robots Application Needs

3.1 Work Environment

You must consider the work environment when selecting batteries for collaborative robots. Cobots operate in diverse settings, including medical facilities, industrial plants, security systems, transportation infrastructure, and consumer electronics assembly lines. Each environment places unique demands on lithium battery packs. For example, medical applications require clean, quiet operation and reliable energy storage. Industrial sectors need batteries that withstand dust, vibration, and temperature changes. Security systems depend on stable power for continuous monitoring. Transportation infrastructure calls for robust batteries that support mobility and automation in trains or smart traffic systems. You should match battery chemistry, such as LiFePO4 or NMC, to the specific requirements of your application.

Tip: Choose batteries with advanced safety features and thermal management for environments with high temperature or risk of fire.

3.2 Usage Patterns

Usage patterns affect battery degradation and overall performance. You must monitor how often cobots charge, discharge, and operate under heavy loads. Data analytics and cell monitoring help you predict maintenance needs and optimize battery life. The table below shows how different aspects impact battery health in collaborative robots:

You can extend battery lifespan by using smart charging strategies and monitoring systems. These practices support sustainability in robotics batteries.

3.3 Mobility and Integration

Mobility and integration present challenges when deploying batteries in collaborative robots. You must balance energy storage with lightweight design to ensure cobots move efficiently in applications like medical delivery, industrial inspection, and consumer electronics assembly. Integration of lithium battery packs requires attention to cost, logistics, and safety:

• Cost: The initial expense of lithium-based batteries can hinder the adoption of mobile robots.

• Logistics: Transportation of these batteries requires strict safety measures due to risks of fire and thermal runaway.

• Safety Concerns: Issues such as short circuits, overvoltage, and overheating must be managed to ensure safe operation.

You should select batteries that support seamless integration with automation systems and robotic controllers. Advanced lithium chemistries, such as LiFePO4 and NMC, offer reliable performance for mobile cobots in demanding environments.

Part 4: Safety and Compliance

4.1 Industry Standards

You must follow strict industry standards when selecting batteries for collaborative robots. Standards such as IEC 62133, UL 2054, and UN 38.3 set requirements for lithium battery packs used in automation and industrial applications. These standards address electrical, thermal, and mechanical hazards. You ensure compliance by choosing batteries tested for short-circuit, overcharge, and drop scenarios. Manufacturers in the market provide documentation that confirms adherence to these standards. You also need to review your supplier’s conflict minerals statement to support ethical sourcing. Read the conflict minerals statement.

4.2 Handling and Storage

You protect your collaborative robots by following best practices for handling and storing batteries. Risk assessment covers the entire life cycle, from installation to end-of-life. Hazards can arise even when robots are not in operation. You should:

• Disconnect, remove, or drain batteries before storage or transport.

• Store batteries separately from robots in ventilated, temperature-controlled containers.

• Follow hazardous materials regulations for lithium battery packs.

You maximize safety by keeping batteries away from heat sources and moisture. You also support sustainability by recycling batteries at the end of their life. Learn more about sustainability in battery management.

4.3 Risk Management

You manage risks by identifying hazards and applying mitigation strategies. Common hazards include electrical (short-circuit, overcharge), thermal (fire, elevated temperature), mechanical (crush, drop), and system failures. You reduce risk by:

1. Keeping batteries charged or replacing them as needed.

2. Maintaining separation between robots and obstacles.

3. Ensuring a safe robot form factor.

4. Using stable ground surfaces.

5. Limiting speed and force/torque.

6. Activating automatic brakes if control is lost.

You improve safety and reliability in the market by using advanced lithium chemistries like LiFePO4 and NMC. These batteries support automation and meet the demands of industrial applications.

Part 5: Maintenance and Replacement

5.1 Monitoring and Diagnostics

You need to monitor battery health to keep collaborative robots running efficiently in your facility. Predictive monitoring systems use data from battery management systems (BMS) to track performance and detect issues early. These systems work for individual robots and fleets, helping you manage multiple units across your operations. Manufacturers offer multi-robot management platforms that integrate with BMS for better diagnostics. You can learn more about BMS features and integration here.

• Predictive monitoring systems analyze voltage, temperature, and cycle count.

• Multi-robot management tools help you optimize energy storage and reduce downtime.

• Early detection of faults allows you to schedule maintenance before failures occur.

Tip: Regular diagnostics improve battery lifespan and support sustainability in the market.

5.2 Maintenance Schedule

You should follow a strict maintenance schedule to ensure optimal performance of lithium battery packs. Routine checks and timely replacements prevent unexpected failures and costly downtime. Here is a recommended schedule for collaborative robots:

• Scheduled battery replacement keeps your robots aligned and ready for production.

• Neglecting maintenance can lead to loss of positional data and extra recalibration work.

5.3 Replacement Guidelines

You must replace batteries according to manufacturer recommendations to maintain reliability in the market. Proper execution of battery replacement is crucial. If you skip or delay replacement, you risk losing critical data and increasing downtime.

• Replace batteries annually or after 3840 hours of operation.

• Change backup batteries every 1.5 years (5760 hours) to maintain factory settings.

• Always follow the correct procedure to avoid losing positional and alignment data.

Note: Regular replacement supports energy storage efficiency and keeps your robots operating at peak performance.

Part 6: Batteries Selection Checklist

6.1 Step-by-Step Process

You can streamline your battery selection for collaborative robots by following a clear process. This approach helps you match technical needs with operational goals:

1. Select Chemistry: Identify the best battery chemistry for your application, such as LiFePO4, NMC, or NiMH. Consider safety, energy density, and cycle life.

2. Check Nominal Voltage: Choose a battery with the correct nominal voltage to ensure optimal motor performance.

3. Determine Capacity: Calculate the required capacity so your robot operates for the desired period without interruption.

4. Verify Charging Compatibility: Use a smart charger that matches your chosen battery chemistry and configuration.

5. Assess Discharge Rate: Confirm the battery can handle your robot’s continuous discharge needs.

Tip: A structured process reduces risk and improves reliability in your automation projects.

6.2 Supplier Questions

When sourcing batteries for collaborative robots, you should ask suppliers targeted questions to ensure quality and support:

• What experience do you have with lithium battery packs for automation?

• How do you optimize product designs for manufacturability?

• Can you help improve production efficiency and reduce costs?

• What certifications and safety standards do your products meet?

• How do you support sustainability and recycling initiatives?

  For more on sustainable battery management, see our approach to sustainability.

6.3 Documentation

You need comprehensive documentation to ensure compliance and traceability:

• System specifications with voltage, current, capacity, and operational parameters

• Circuit diagrams showing all electrical connections and protection devices

• Thermal management plans detailing heat generation and cooling systems

• Mechanical drawings with housing materials and mounting details

• Safety analysis reports covering failure modes and mitigation

• Bill of materials with component certifications

• Software specifications for battery management systems

• Electromagnetic compatibility assessments

• Version-controlled documents signed by qualified engineers

• Digital Product Passport (DPP) with a unique product ID, following ISO/IEC 15459:2015, and machine-readable data for supply chain transparency

Note: Proper documentation supports regulatory compliance and builds trust with stakeholders.

You need to focus on voltage, capacity, and safety when selecting batteries for collaborative robots. The checklist helps you make confident choices for your automation projects. Lithium-ion and lithium iron phosphate offer strong performance and reliability for collaborative robots in industrial settings. You should consult suppliers for tailored solutions and review sustainability practices in battery management.

FAQ

What is the best battery chemistry for collaborative robots?

You should choose LiFePO4 or NMC for most collaborative robots. These chemistries offer high safety, long cycle life, and reliable energy density. LiFePO4 provides stable performance in demanding environments. NMC supports lightweight designs and fast charging.

How often should you replace lithium battery packs in cobots?

You should replace lithium battery packs annually or after 3840 hours of operation. Regular replacement keeps your robots running efficiently and prevents unexpected downtime. Always follow manufacturer guidelines for best results.

What safety features should you look for in robotics batteries?

You should look for advanced battery management systems, thermal protection, and stable chemistries like LiFePO4. These features help prevent overheating, fire, and electrical faults. Proper safety features protect your robots and your facility.

How do you ensure sustainability when selecting batteries?

You should choose batteries with long cycle life and recyclable materials. Ask suppliers about recycling programs and environmental certifications.

Can you compare lithium battery chemistries for cobots?