Designed to work alongside humans in a shared workspace, the FR10 robot arm has six rotating joints and supports a payload of 10kg, with a reach of 1400mm at ±0.05mm repeatability.

The FR10 is built on an all-metal construction and equipped with high-torque motors, harmonic drive gears, magnetic brakes and both optical and inductive encoders, with a standard protection level of IP54.

Pailton Engineering’s managing director, Dave Pound said, “This is part of a wider trend at Pailton Engineering. We’re rolling out more automation in the workshop and beyond, not to replace our valued team, but to help augment their existing skills and provide the opportunity to learn new ones.

“Over recent months, team members have noticed the digitalisation additions across the whole facility, with this cobot now learning and adapting to its role amongst the team. The goal is a collaborative environment where human expertise and robotic precision work together to drive innovation.”

The new setup also includes additional accessories and is designed for flexible automation of precision mechanical assembly and component testing, supporting improved repeatability and production efficiency.

Sebastian Schupke, sales and business development manager at FAIRINO Europe commented, “We believe collaborative robotics offers an effective way for companies to grow sustainably by helping address challenges such as labour shortages while keeping people at the centre of production.

“We truly value Pailton Engineering’s commitment to collaborative automation and greatly appreciate their excellent approach. We look forward to continuing our cooperation.”

COMAU’s in.Grid Robot Monitoring system autonomously captures production and process data, identifies performance deviations, signals anomalies, and verifies user-defined KPIs. This statistical and trend-based analysis helps IVECO’s engineering team optimise robot utilisation, reduce unplanned downtime and strengthen overall process reliability.

Aligned with the company’s comprehensive approach, COMAU supported the IVECO project through simultaneous engineering efforts that included installation of the Framing line and the Door line. Not only were both lines designed with a flexible production concept, the COMAU-supplied geogripper Framing line features a ring-shaped layout engineered to minimize non-value-added stations and maximize efficiency.

Similarly, for the Door line, COMAU applied its proprietary table-top standard during the development process. Both the Framing and Door lines utilise COMAU robots and its Versa Pallet transport system.

By integrating in.Grid within the existing automation infrastructure, IVECO has gained a unified digital environment that supports proactive maintenance and informed decision-making. The platform’s capacity to process large volumes of data directly from robot controllers ensures a detailed understanding of each robot’s status, performance, and maintenance needs.

Alongside its monitoring capabilities, in.Grid offers asset management and variable tracking functions, allowing IVECO to visualise historical trends, monitor spot-welding parameters, and improve maintenance scheduling. Furthermore, the intelligent and scalable solution supports future expansion across additional robots, lines, or plants while maintaining the same data integrity and user experience. In tandem, COMAU is working to enrich the advanced scalability of its robot monitoring solution through the enhanced integration of artificial intelligence.

“IVECO and COMAU share a long-standing partnership based on industrial excellence and innovation. As a leader in automation, COMAU has supported the evolution of our manufacturing footprint toward more digital and resilient operations,” said Giuseppe Daresta, head of advanced manufacturing solutions and ESG at IVECO Group. “The in.Grid platform is a key milestone in our digital transformation, enabling predictive maintenance, improved asset performance, and greater efficiency and sustainability across our global production network.”

“Digitalisation is a key element for improving production processes. For this reason, COMAU is dedicated to driving the development of cutting-edge technologies in this area. Our latest solution, in.Grid, provides an advanced layer of digital intelligence to the industrial setting, and we are delighted to see our technology implemented by such an innovative and longstanding partner like IVECO,” emphasised Giovanni Volpes, chief extended Europe officer. “By combining high-frequency monitoring with predictive analytics, the system helps manufacturers like IVECO increase production efficiency and achieve greater process stability.”

The in.Grid platform delivers clear operational advantages, including proactive performance monitoring and analytics that help manufacturers anticipate and resolve issues before they affect production. Its flexible architecture ensures adaptability across different plant sizes while maintaining cost efficiency through a subscription model. By improving process visibility, in.Grid reduces maintenance costs, minimises downtime, and enhances overall production reliability, extending the lifespan and performance of the robotic fleet.

The successful implementation at IVECO Valladolid reflects COMAU’s commitment to delivering intelligent, connected automation solutions that empower manufacturers to achieve measurable improvements in performance, sustainability, and operational resilience.

The IVECO factory in Valladolid is an industrial plant with more than six decades of history where both the light commercial vehicle Daily and the cabs of the heavy range are produced, consolidating itself as a benchmark for efficiency and employment in Castilla y León. In 2022 celebrated the production of the 700,000 unit of the Daily, which reflects the continuity and success of its productive activity. The plant has been recognised for its commitment to Industry 4.0 and continuous improvement, receiving several awards for its innovation and digital transformation.

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Vehicle manufacturers fit side impact beams in the car body to ensure that drivers are protected as much as possible in the event of a lateral impact. To ensure that these elongated metal reinforcements cause as little vibration and noise as possible in everyday life, they are generally coated with a damping material. In many cases, this process is automated nowadays.

In a robot cell, the side impact beams are transferred to a granulating machine and removed. A complex process, in which the precise interaction of numerous automation components is vital.

A crucial factor is, for example, the conveyor technology which supplies the side impact beams to the cell in a cycled manner and transports them away again after processing. However, finding a suitable supplier proved to be a challenge for the manufacturer of this robot cell. This is because the conveyors not only have to position the beams, which are up to 1,250 mm long, with repeat accuracy and precision so that the robot can pick them up.

They are also intended to allow for a buffer of twelve components, so that employees have more time for other activities and the line can run autonomously for a period of time. Finally, the conveying path needs to be as compact as possible and at the same time adaptable so that at the end, a seamless transfer to a customer-side conveyor offset by 90° can be achieved.

Space-saving circulation system for seamless material flow

So how was the mk expertise used to create this solution? They implemented two individually configured conveyor systems. An SPU 2040 accumulating conveyor, a 5,500 mm long and 800 mm wide, two-track chain conveyor with aluminium pallets, transports the parts into the robot cell. The pallets of the left and right tracks are connected by a beam, forming a rigid and stable connection.

In addition, the pallets are fitted with wear strips, positioning grooves and bushings as well as a drilling pattern for the customer’s workpiece holder. The corresponding sensor system allows the precise stopping, separating and positioning of the pallets at a cycle time of approximately 30 seconds.

The workpieces are manually placed on the pallets of the SPU 2040 by a worker. After removal by the robot, the pallets then travel back to the starting position on the underside of the conveyor. This creates a space-saving recirculation system that allows up to twelve side impact beams to be buffered – eight products are outside the protected area and another four inside. Additional conveying levels or complex lifting and lowering mechanisms are not necessary.

After granulation, the robot places the side impact beams on another conveyor system from mk: a ZRF-P 2040 dual-lane timing belt conveyor, 5,600 mm long and 500 mm wide, with customer-supplied workpiece holders on the top side of the timing belt. The solution boasts one special feature – at the end of the conveying path, mk has fitted a compact GUF-P Mini belt conveyor between the two lines, 400 mm long and 200 mm wide. The cross conveyor lifts the side impact beams with a pneumatic lifting device and transfers them to a belt conveyor provided by the customer. This realises the 90 degree corner transfer.

Thus, a continuous and compact material flow solution has been developed that reliably buffers the side impact beams, delivers them to the robot in a cycled manner and discharges them safely after processing. The benefits for the customer include:

• Flexible buffering: Accommodation of up to twelve components relieves the burden on employees and keeps production running smoothly.
• Precise robot supply: The SPU 2040 positions long components up to 1,250 mm in length in a precise and cycled manner.
• Space-saving feed: The recirculation system for pallets eliminates the need for additional conveying levels.

As the only UK and Ireland distributor of the mk conveyor range, get in touch with AdaptTech to see how the company can help you achieve your required solution.

The new installation marks a significant step in UFC Automotive’s digital transformation journey, facilitating continuous, robot-assisted production and delivering measurable improvements in efficiency, quality and manufacturing sustainability.

The partnership builds on more than a decade of cooperation between the two companies and reflects a shared commitment to modernising Turkish manufacturing through automation. According to The Global Economy, industry represented 25.94 per cent of Turkey’s gross domestic product (GDP) in 2024, highlighting the sector’s strategic weight and the growing need for modern, digitally driven production technologies.

UFC Automotive manufactures tractor clutch systems for both domestic and global markets as an original equipment manufacturer (OEM) and original equipment supplier (OES). Due to the critical functional role of clutch systems, the company prioritises precision, stability and traceability in its production operations.

“We’ve partnered with Tezmaksan as a reliable partner to help bring our production processes into the digital transformation era,” said Can Çetin, partner at UFC Automotive. “With Tezmaksan’s technical support and systems, we integrated the system without hesitation, and we’ve already seen an increase in productivity.”

The new CubeBOX robotic automation system continuously feeds three different CNC machines for 22 hours per day, automating a process previously requiring three operators. This transition has allowed the company to boost productivity by 35 per cent and increase cost savings by 50 per cent across its tractor clutch production.

By adopting a second CubeBOX system, UFC Automotive aims to secure higher process consistency, minimise manual handling and ensure sustainable, repeatable production quality.

“Turkish industry has enormous digital transformation potential and our work with UFC Automotive is a strong demonstration of what can be achieved with practical, well-engineered automation,” said Hakan Aydogu, Group CEO at Tezmaksan. “Our CubeBOX systems feed multiple CNC machines for extended periods, supporting efficient, operator-friendly production.”

UFC Automotive plans to continue its investment in digital transformation with Tezmaksan in upcoming projects, reinforcing its goal to increase efficiency, ensure quality and maintain competitive in both domestic and international markets.

“Collaborations like this allow us to combine our automation expertise with the real production needs of manufacturers,” explained Aydogdu. “Our goal is to make advanced CNC automation accessible to a wider range of companies and to support their transition toward more efficient, reliable and data-driven production.”

“The automotive sector is traditionally one of the strongest customer industries worldwide, accounting for around a quarter of all robot installations in 2024,” says Takayuki Ito, President of the International Federation of Robotics. “However, against this trend, the majority of EU’s car making countries cut back significantly on investment in robotics.”

Germany is the largest producer of vehicles in the EU and fourth worldwide with an output of more than 4 million units in 2024 – OICA reports. The car sector in Germany used to account for more than 40% of the annual domestic robot installations. But these shares have fallen substantially over the last four years: In 2021, it was 35%, and in 2024, it dropped to 26%, with only 6,932 units installed. This marks a reduction of 25% year-on-year.

EU’s Top 10 automotive countries

The EU’s other top 10 automotive countries cut robot investments in 2024 are: Spain as the second largest vehicle producer, installing 2,279 units in 2024, which is a decrease of 1%. The Czech Republic in third place with 1,116 units, down 28%. France in fourth place with 1,018 units, showing a 41% decrease. Slovakia on five installing 398 units, which is a 75% decrease. Italy on six, with 1,002 units and an 11% decline. Romania on seven has 248 units, down 50%.

Hungary is a remarkable statistical outlier in the EU, ranking ninth in terms of vehicle production: its automotive sector installed 3,573 industrial robots. The 305% surge is a direct result of major car industry projects, which accounted for 84% of the country’s total robot installations in 2024. Those are usually between 1,000 and 2,000 units. Poland on eight installed 742 units, unchanged. Portugal on ten installed 289 units, a 4% increase.

Industry outlook

The EU’s automotive industry is not expected to drive growth for the robotics industry in 2025. Lower-than-expected demand, particularly for electric vehicles, coupled with national and international political uncertainty, has caused companies in the industry to postpone investment projects. However, the trade and tariff agreement reached between the European Union and the United States in late July has given rise to hope. Regarding 2026, experts are widely uncertain about a return to growth. Nevertheless, there is a broader consensus that installation numbers will rise again in 2027 and 2028.

Almost 50 FANUC robots will paint both car bodies and plastic add-on parts such as bumpers. “We are managing the entire project, including installation,” says Jan Kamenicky, head of paint at FANUC Europe. “Our application technology ensures fast changeover times and minimal paint loss.”

FANUC impressed the customer with a cabin painting concept that requires fewer cabins and robots. FANUC’s paint lab near Stuttgart, Germany, also played a crucial role in securing the order. The robots will automatically open the bonnet and boot and apply multiple layers of paint, with technology provided by FANUC partner Sames Kremlin.

“Like our standard robots, our paint robots are extremely durable and benefit from unlimited maintenance,” states Jan. “This makes us an attractive partner for companies aiming for sustainable operations.”

Painting robots are essential for achieving high-quality surfaces. They apply paint evenly and efficiently, while protecting employees from health hazards. FANUC, headquartered in Japan, offers around 200 robot models, including a wide range of painting robots and paint system solutions.

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The cutting-edge technology will ramp up production during the second half of 2025 in a fully-automated and highly sustainable process that epitomizes the charismatic French brand.

“PixelPaint is increasingly being recognised by some of the world’s leading automotive designers who are seeking to create extraordinary finishes for their customers,” said Joerg Reger, Managing Director of ABB Robotics Automotive Business Line.

“Traditionally, the deep-black duo-tone paintwork of DS8 – extending from the roof, down the hood, and into the front grille – would require complex manual masking and multiple trips through the paintshop, making it both labour- and energy-intensive. PixelPaint does away with that, enhancing efficiency, saving energy, and substantially reducing emissions. And with two robots working in coordination, this precision finish can be applied without delaying the line or the need for manual intervention.”

PixelPaint consists of a paint head with more than 1,000 tiny, individually controlled nozzles, mounted on an ABB robot such as the IRB 5500 paint series. Combined with 3D vision system and coordinated by ABB’s RobotStudio planning and programming software, the head tracks very closely to the vehicle body to ensure that 100 percent of the paint is applied to the car with no overspray or airborne misting. This eliminates waste, reduces environmental treatment requirements, and makes a significant contribution to DS Automobiles’ sustainability objectives.

“DS8 redefines the French Art of Travel. Its sleek contours are an invitation to cover long distances in serene, all-electric comfort, while the extended duo-tone paintwork with its sharply-defined lines are an ultra-modern reinterpretation of historic French coachbuilding,” said Silvio Licitra, Head of Paint Process Engineering at Stellantis. “ABB’s PixelPaint enables this meeting of design and sustainability, an expression of technological excellence fused with the refined aesthetics synonymous with our avant-garde heritage.”

ABB, Stellantis and Nippon Paint announced their collaboration in Cannes at SURCAR Europe, the international conference on automotive body finishing held biennially since 1964. They were presented with the Innovation Award at the conference.

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In recognition of the importance of comfort and convenience, which are the foremost features when deciding to buy a vehicle according to a recent survey commissioned by JLR of over 2,000 luxury and premium SUV clients, the robots test a range of different foams and coverings for quality, safety and comfort.

The robots can exert forces more than 800 Newtons (N) (approximately 82kg) on each seat design 25,000 times over a period of around five days, simulating movements akin to people of varying body shapes and weights entering a vehicle and sitting in one of its seats.

But it isn’t just the act of sitting JLR tests for, as the Occubots also review the resilience of the vehicles’ heated seats. Across 20,000 cycles over 25 days, a robot reenacts actions such as sliding and twisting in the seat, applying huge forces ranging from 350N to 700N to ensure the heated seat is robust and will remain operational throughout a vehicle’s lifespan.

Integrated sensors in the robot track torque hundreds of times per second to ensure forces are maintained during different tests, while a camera communicates with the Occubots to take regular photos to operate 24/7, independently reviewing progress and investigating failures.

The robots, which also test how quickly foam recovers it shape following pressure from different body types, form part of just one of JLR’s virtual and physical testing environments dedicated to delivering the next generation of safe, reliable, luxury vehicles from the Range Rover, Defender, Discovery and Jaguar brands.

Thomas Mueller, JLR Executive Director, Product Engineering, said: “Settling into your seat is one of the first experiences when entering one of our vehicles. Comfort is critical to luxury, so it’s a make-or-break moment for our clients and they expect a consistently comfortable ride over the life of their vehicle.

“We’ve invested in robots to work alongside our expert engineers and rigorously test every aspect of our seat materials in super quick time. Automation like this is a vital part of our comprehensive vehicle quality component testing programme, which helps us review vehicle elements over a lifetime of usage and in the most extreme environments.”

JLR’s investment into virtual testing forms part of the luxury vehicle manufacturer’s wider £18bn Reimagine strategy, with Gaydon home to a wide range of testing facilities including vehicle simulators, cold weather climate chambers and a semi‑anechoic chamber.

JLR’s Gaydon head office also features 32 miles of tarmacked test track, off‑roading courses, speed bumps and manhole covers, allowing engineers to put each JLR vehicle through a range of physical testing regimes that mimic real world conditions.

The sustainable and resource-saving technology began operation in 2025 as the luxury manufacturer develops new personalised options for its most exclusive models.

“PixelPaint uses an award-winning paint head similar to an inkjet printer that can apply large areas of color as well as precise details with complete accuracy,” said Joerg Reger, Managing Director of ABB Robotics Automotive Business Line.

“In an entirely automated process that requires no manual intervention, the technology opens new possibilities for vehicle manufacturers as they look to increase personalisation in response to rising consumer demand while also reducing emissions. We’re delighted to have been able to work with Mercedes-Benz to help them make these extraordinary design visions a reality.”

PixelPaint consists of a paint head with more than 1,000 tiny, individually controlled nozzles, mounted on an ABB robot such as the IRB 5500 paint series. Combined with ABB’s 3D vision system and coordinated by ABB’s RobotStudio planning and programming software, the head tracks very closely to the vehicle body to ensure that 100 percent of the paint is applied to the car with no overspray or airborne misting. This eliminates the need for labour-intensive masking and repeat trips through the paint shop, resulting in zero waste, reduced environmental treatment requirements, and lower emissions overall.

The technology can recreate even the most intricate designs with unprecedented precision, while ABB’s 3D vision system enables a high degree of repeatability. This ensures that each painted panel appears identical to the next.

“With PixelPaint, we are setting a new benchmark in painting technology,” said Arno van der Merwe, Head of Production Planning at Mercedes-Benz AG. “The combination of the highest design and quality precision with innovative technological solutions is a milestone for the painting of our top-end models at the Sindelfingen site. This forward-looking technology raises us to a new level in individual coatings. It enables exclusive product results for our demanding customers.”

Mercedes-Benz will first use PixelPaint on the Mercedes-Maybach SL 680 Monogram Series. To further enhance the exclusivity of this model, the obsidian black hood is available upon request with an intricate Maybach pattern in contrasting graphite grey. This striking design would be impossible to achieve with a traditional process.

“The success of this project was only possible due to the close cooperation between ABB, the high-quality paint supplier, PPG, and the Mercedes-Benz project team,” said Dr. Julia Schuchardt, Head of Process Development, Coating Technology and Corrosion Protection at Mercedes-Benz AG. “With an eye on the future, we are already working to develop the application further in order to offer more colour combinations and motifs to our customers.”

PixelPaint is just one example of how ABB’s smart technologies are transforming the paint process, completing the final piece of the puzzle in digitalising automotive manufacturing. Together with solutions such as the RB1000i-S digitally-enabled atomizer – which achieves up to 99 percent transfer efficiency, meaning less paint and materials are required – ABB is making manufacturers more sustainable, efficient and competitive.

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“The United States has one of the most automated car industries in the world: The ratio of robots to factory workers ranks fifth, tied with Japan and Germany and ahead of China,” says Takayuki Ito, President of the International Federation of Robotics. “This is a great achievement of modernisation. However, in other key areas of manufacturing automation, the US lags behind its competitors.”

Robots from abroad

The majority of industrial robots are imports from overseas, as there are few robot manufacturers producing in the United States. Globally, 70% of installations are produced by four countries: Japan, China, Germany and South Korea. Within this group, Chinese manufacturers are the most dynamic, with production for their huge domestic market more than tripling in five years (2019-2023). This puts them in second place after Japan.

China’s success is based on its national robotics strategy. Its manufacturing industry installed a total of about 280,000 units per year between 2021 and 2023, compared to a total of 34,300 installations in the United States in 2024.

US versus China robot market

In China, robotics and automation are penetrating all levels of production. This is evidenced by its high robot density of 470 robots per 10,000 employees in manufacturing – the third highest in the world, surpassing Germany and Japan in 2023. The United States, on the other hand, ranks only tenth among the world’s most automated manufacturing countries with a robot density of 295 robots per 10,000 employees.

The country’s automation is heavily concentrated in the car sector: Around 40% of all new industrial robot installations in 2024 are in automotive. This is followed by the metal and machinery industry with 3,800 units representing a market share of 11%. Installations in the US electrical and electronics industry has a market share of 9% with 2,900 units sold.