Applications of intelligent mobile robots and image sensor solutions

Industry 5.0 focuses on the integration of human and machine intelligence

ndustry 5.0 is the next-generation industrial development concept following Industry 4.0, emphasizing Human-Centric Collaboration, Sustainability, and Resilience. Compared to Industry 4.0's focus on automation and digitalization, Industry 5.0 places greater importance on the integration of human intelligence and machine intelligence. In this transition, the role of intelligent mobile robots has become more critical and is profoundly impacted.
 
As the industrial sector gradually approaches Industry 5.0, the next phase of manufacturing digitalization, the demand for human-robot interaction and robotics technology improvements is growing. The variety of intelligent robots is vast, ranging from robotic arms to wheeled autonomous delivery robots, to fully walking humanoid robots. Intelligent robots differ from traditional industrial robots in their use of various sensors, artificial intelligence, and advanced algorithms to interact with the environment, detect obstacles, and collaborate with humans and other machines.
 
Industry 5.0 no longer pursues complete unmanned operations but emphasizes "Human-Machine Synergy." Therefore, intelligent mobile robots require higher-level perception capabilities and behavior prediction, utilizing technologies such as 3D vision sensors, LiDAR, ultrasonic sensors, and AI behavior recognition to ensure safe movement and collaboration within human workspaces.
 
Robots need to possess greater autonomous decision-making and environmental adaptation capabilities. They must be able to navigate autonomously and adjust tasks in dynamic, unstructured factory environments. This requires them to be equipped with Edge AI and Self-learning Algorithms to determine the optimal path and operational strategy in real-time.
 
Industry 5.0 also emphasizes green manufacturing. Intelligent mobile robots need to adopt efficient power management, energy recovery mechanisms, and be driven by renewable energy sources. Simultaneously, there is a pursuit of recyclable materials and low-carbon footprint in module design. They also require modular and highly flexible deployment to meet diverse production needs. IMRs need to support modular structures and Software-Defined Control architectures to quickly switch between tasks such as material transport, inspection, assembly, or maintenance assistance.
 
In the smart factories of Industry 5.0, robots must exchange data in real-time with other equipment, systems, and personnel through Industrial IoT (IIoT), 5G/6G communication, and Cloud-Edge Collaboration technologies, forming "Collaborative Intelligence." Industry 5.0 will promote the upgrade and integration of robotics technology, driving the combination of robots with AI, Sensor Fusion, and Digital Twin technologies, enabling them to predict, simulate, and optimize operations in integrated virtual-physical environments.
 
Intelligent mobile robots are no longer just performing repetitive tasks; they can dynamically adjust their work based on production conditions and human needs, such as proactively assisting operators or self-assigning tasks. Robots will assume the role of "Intelligent Assistants," working alongside personnel to complete innovative and complex tasks, enhancing work flexibility and the humanized experience. To achieve cross-platform collaboration, robots need to adhere to unified communication protocols and data interfaces, promoting the integration of software and hardware ecosystems and the development of Open Robot Architectures.
 
Industry 5.0 elevates intelligent mobile robots from "execution tools" to "collaborative partners." Future IMRs will combine AI, sensing, communication, and energy innovation technologies. They will not only improve production efficiency but also realize the vision of human-robot integration, flexible manufacturing, and sustainable smart factories.

Artificial intelligence drives rapid development of the global intelligent robot market

Thanks to advancements in Artificial Intelligence (AI), the global intelligent robot market is undergoing significant expansion. Progress in AI enables the construction of more sophisticated autonomous robots that can be deployed not only in warehouses but also outdoors and in less controlled environments. The autonomous robot segment offers solutions for various industries such as e-commerce, manufacturing, and healthcare, and can be highly customized.
 
The existing collaborative robot segment is projected to grow at a Compound Annual Growth Rate (CAGR) of 32% from 2023 to 2030, and there are still many new, innovative, and more complex use cases. For instance, self-driving forklifts are expected to lead market growth in the e-commerce sector in the coming years. Other established robot types include warehouse robots (forecasted CAGR of 19% from 2023-2030) and delivery robots (forecasted growth of 30.3%).
 
Deploying intelligent robots requires substantial upfront investment, which hinders potential customers from utilizing and benefiting from autonomous robotics. Companies still need to invest in training their employees to collaborate effectively with robots, thereby improving work efficiency.

Enabled by advancements in information technologies such as artificial intelligence, automation, big data analytics, the Internet of Things (IoT), machine learning, and robotics, Industry 5.0 can create higher-value jobs. By automating manufacturing processes, human workers can dedicate more time to creative tasks, efficient business solutions, and value-added activities, which not only boosts productivity but also enhances motivation. The increasing focus on sustainability and resilience means businesses can become more agile and flexible, while also positively impacting society.
 
To build intelligent mobile robot solutions, onsemi offers a wide range of products applicable to various modules within robot applications. A robotic system consists of several interconnected sub-modules. Key sub-modules include battery management, motion control, sensing, and CPU. The sub-module solutions are highly dependent on the specific application, meaning a robot operating only indoors requires fewer sensors, while a robot with a robotic arm needs more motor inverters. Given the extensive number of modules and products in intelligent mobile robot solutions, this article will focus specifically on the application of image sensors.
 
Indirect Time-of-Flight (iToF) technology calculates distance precisely by measuring the phase shift of modulated light pulses. This method enables accurate 3D imaging and depth perception, making it ideal for various industrial applications. These sensors can be used alone or complement other depth sensing technologies to improve data accuracy. In robotic systems, they can be used to calculate the depth required for a robotic arm to grasp and manipulate objects. Other potential applications include creating environmental maps used for floor navigation.
 
onsemi's Hyperlux ID depth iToF sensors are designed to enhance machine vision applications with their advanced depth sensing capabilities, covering distances up to 10 times greater than other iToF solutions. Hyperlux iToF sensors offer several advantages, providing high depth accuracy crucial for tasks requiring precise 3D mapping and object detection. Their ability to operate at high frame rates ensures reliable performance in dynamic environments, easily capturing fast-moving objects. Furthermore, these sensors are optimized for low power consumption, making them suitable for battery-powered and multi-sensor systems.
 
Hyperlux ID depth iToF sensors maintain robust performance even under challenging conditions like low-light and high dynamic range environments, ensuring reliable operation across diverse industrial settings. This makes them an excellent choice for improving the efficiency, accuracy, and safety of machine vision applications.
 
Resources required for depth calculation include an FPGA or MCU, frame memory, and a high-speed interface (>1MP). Outputting the depth map directly from the sensor allows for the use of fewer external components, lower computational load and power consumption, and relaxed interface speed requirements.

Image sensors designed for exceptional depth sensing and imaging

Taking the AF013X family of Smart Indirect Time-of-Flight (iToF) 1.2-megapixel CMOS sensors launched by onsemi as an example, these are designed for exceptional depth sensing and imaging. These sensors feature a 1/3.2-inch optical format and BSI CMOS global shutter technology, incorporating a 1.2 MP CMOS Smart iToF sensor with advanced 3.5 µm pixel stacked BSI technology, superior low-light and ambient light performance, enhanced Near-Infrared (NIR) response at 850 nm and 940 nm wavelengths (Quantum Efficiency (QE) > 40%), dual-laser operation for extended depth range, and laser eye safety monitoring.
 
Key features of the Hyperlux ID depth iToF sensors include high accuracy, providing precise distance measurements crucial for tasks requiring exact 3D mapping and object detection, and high frame rates, enabling the capture of fast-moving objects (60-100 fps) to ensure reliable performance in dynamic environments.
 
Furthermore, the AF013X image sensors feature low power consumption, optimized for energy efficiency, making them suitable for battery-powered and multi-sensor systems. They also maintain stable performance under demanding conditions, excelling in low-light and high dynamic range environments to ensure reliable operation across various industrial settings.
 
The AF013X image sensors support on-chip dual laser driver control and modulation frequencies up to 200 MHz, providing precise and reliable depth measurements. They also include on-chip laser eye safety thresholds, ensuring safe operation in all environments.
 
The AF0130 sensor is equipped with an on-chip depth processing ASIC, which calculates depth, confidence, and intensity maps at high speed from laser-modulated exposures. This makes it ideal for applications requiring fast and accurate depth data. The AF0131 sensor offers the same high performance but without the on-chip depth processing functionality. This version is perfectly suited for solutions that prefer off-chip depth calculation, providing flexibility for custom processing requirements.
 
To accelerate application development with the AF0130 sensor, onsemi offers the AF0130 Evaluation Kit – AF0130CSSM30SMKAH3-GEVK. It utilizes onsemi's innovative Indirect Time-of-Flight (iToF) sensor with a 1.2MP 1/3-inch BSI Global Shutter, working in conjunction with a laser driver board to program the modulation settings of the VCSELs for illumination. The AF0130 sensor board can interface with the Demo3 Evaluation Board. This kit uses onsemi's popular DevSuite software to configure the system. The software provides a comprehensive setup interface and flexibility for evaluating the sensor's characteristics and capabilities.

Conclusion

Driven by industrial automation and Industry 5.0, the role of intelligent mobile robots has evolved from simple material handling and navigation to intelligent systems capable of autonomous decision-making, environmental perception, and human collaboration. Image sensors, serving as their "visual core," play a vital role in this transformation. Through the combination of high sensitivity, high resolution, and AI image processing technology, image sensors not only enhance the robot's positioning accuracy, obstacle identification, and quality inspection capabilities but also ensure stable operation in complex and dynamic industrial environments. In the future, with the further integration of sensing technology and edge computing, the image sensors introduced by onsemi will assist intelligent mobile robots in achieving higher levels of autonomy and human-robot collaboration, becoming a core driving force for smart factories, logistics warehouses, and service robot applications.