Automation has long since become an integral part of industry, but until now specialised machines and industrial robots have dominated production halls. Today, however, humanoid robots represent the next stage of development in the focus of research and industry. With a human-like appearance, advanced sensor technology and artificial intelligence, they are designed to be flexible in their application and to work together with human workers.
But how far off is this technology really? Are humanoid robots already being used productively or are they still a long way off? A study by the Fraunhofer Institute for Production Technology and Automation (IPA) shows that German industry is open to the use of humanoid robots. At the same time, the technical, economic and organisational framework conditions are under intense discussion.
Malte Janssen, Product Manager at reichelt elektronik, sheds light on the potential of humanoid robots in industry, highlights current developments and provides an outlook on their potential effects on the working world.
What makes a robot “humanoid”?
Humanoid robots are machines whose design and range of motion are based on human anatomy. Arms, legs, hands and head are not only used for the human-like appearance, but above all for function: They enable movements, gripping and interaction skills that are based on human working methods.
Unlike traditional industrial robots, which usually operate on stationary axes, or “cobots”, which are optimised for specific assistance tasks, humanoid robots are designed to have a wide range of applications. They can move, use tools and work in different production environments — similar to human colleagues.
Technological basis: Three levels of progress
The development of humanoid robots is based on a combination of different technologies. Advanced drive systems, highly flexible joints and precise grippers enable fine movements and stable locomotion. Sensors for balance and environmental detection ensure that the robots can operate safely even in dynamic environments.
Artificial intelligence forms the basis of the control system. It allows complex tasks to be handled flexibly, processes to be optimised and new situations to be responded to. Machine learning allows algorithms to adapt continuously based on data and become more precise.
Modern humanoid robots also increasingly understand language and gestures. This reduces initial difficulties regarding operation and cooperation and is an important factor for their acceptance in mixed teams of people and machines.
Areas of application: From the lab to real life
The fields of application of humanoid robots are diverse, and some models are almost ready for everyday industrial use.
Atlas from Boston Dynamics is considered the most advanced humanoid robot in the world. Originally developed for research and test environments, it demonstrates impressive abilities in balance, agility and complex movements. Even though it is not currently in mass production, its tests illustrate the potential of humanoid robots in dynamic industrial environments.
Future humanoid robots will be able to move independently in complex and changing environments without having to rely on pre-programmed routes. This would enable them to adapt spontaneously to new situations, to avoid obstacles and to independently find the most efficient way to achieve their objectives. Their ability to work with existing tools, machines and infrastructures opens up a wide range of applications — from logistics and production to rescue and disaster operations. In contrast to stationary industrial robots, they bring genuine mobility and flexibility to a wide range of work areas.
In Germany, Neura Robotics is working towards industrial implementation. The company from Metzingen presented the 4NE-1 humanoid robot at the IFA in Berlin, causing quite a stir. Its plan is as follows: Series models for broader use, including in industry, are expected to be available within two years. Target industries are mainly assembly, production and logistics, where flexible automation is in particularly high demand.
At the automotive supplier Schaeffler, humanoid robots are already being tested in practice. In assembly processes, they take on work steps that require precision and relieve the workload on employees. Initial results show that the targeted use of humanoid robots significantly reduces ergonomic strain, for example, as the robots can take on difficult or cumbersome tasks. This has a positive effect on health, reduces illness-related absences and increases both productivity and employee satisfaction in the long-term.
Benefits for industry
The use of humanoid robots promises a significant increase in adaptability in production environments. Since they are based on humans in terms of form and function, they can be used in existing workplaces without the need for costly structural changes.
Another advantage is efficiency. Humanoid robots work with consistent precision, regardless of shift length and without fatigue, and thus meet high quality requirements. At the same time, they relieve employees of physically strenuous or monotonous tasks, which not only promotes health, but also reduces the error rate.
These factors make humanoid robots an interesting building block for flexible production — especially in industries that have to quickly respond to changing requirements.
Challenges and limitations
Despite their potential, humanoid robots still face a few hurdles. One important point is energy consumption. Models like Atlas are indeed impressive in terms of their mobility, but they require a lot of energy to operate stably and sustainably. The speed of movement and stability are still not at the level of specialised machines already used in high-speed production lines.
Last but not least, the cost-benefit aspect remains decisive. The acquisition costs are currently still high. However, series production such as the planned production of the 4NE-1 could significantly ease the burden in the near future. Maintenance also plays a central role: Humanoid robots require regular inspections, software updates and the replacement of wear-prone components to ensure their reliability and safety. Advances in modular design and remote diagnostics could significantly reduce maintenance costs and minimise downtime in the future, which further improves their cost-effectiveness.
Outlook: From pilot project to series solution
The coming years will determine how quickly humanoid robots find their roles in industry. Advances in AI, sensor technology and control technology as well as falling production costs will facilitate their introduction.
For companies, humanoid robots could become a crucial component in Industry 4.0: flexible, mobile and universally applicable. For the world of work, this does not mean replacing humans, but rather expanding the possibilities — moving away from monotonous tasks and towards more challenging work in programming, maintenance and system integration.
One thing remails clear: Humanoid robots are no longer a distant vision of the future. They are on the verge of becoming part of industrial reality and offer German industry the opportunity to play an active role in shaping this change.
Images: Adobe Stock
