As a key equipment in modern industrial automation, industrial robots play a pivotal role in improving production efficiency, enhancing product quality, and reducing labor costs. However, the high procurement cost often becomes a major barrier for enterprises looking to adopt industrial robots. Many may assume that the complex body structure of industrial robots leads to high manufacturing costs. In reality, the body structure accounts for only about 10%-28% of the total cost. What truly determines the price of industrial robots are their core components: the reducer, servo motor, and controller. Together, these three core components make up approximately 70% of the total cost, serving as the key factors in robot performance and the most technologically challenging aspects.
The controller is the core control system of an industrial robot, functioning like a human brain. It receives and processes sensor data, executes motion planning, and coordinates the movement of each joint. An excellent controller must possess the following key characteristics:
• High Computational Power:
Industrial robots need to process vast amounts of sensor data in real time and perform complex kinematic and dynamic calculations, requiring powerful computing capabilities.
• Real-Time Performance:
The controller must respond quickly to external commands and sensor feedback to ensure real-time and precise motion control.
• Stability & Reliability:
Operating in harsh industrial environments, the controller must maintain high reliability and stability for continuous operation.
• Support for Advanced Motion Control Algorithms:
Modern industrial robots execute complex motion trajectories (e.g., linear interpolation, circular interpolation), necessitating controllers that support sophisticated algorithms.
The complexity of controller technology lies in hardware design, software development, and algorithm optimization. High-performance processors, precision sensor interfaces, and advanced control algorithms all contribute to the high cost. Additionally, controllers involve intellectual property and licensing fees, further adding to the cost structure.
The reducer is the core component of an industrial robot’s joints, responsible for converting the motor’s high-speed rotation into low-speed, high-torque output while ensuring motion precision and stability. It critically impacts the robot’s load capacity, speed, and positioning accuracy.
The high cost of reducers stems from:
• Extreme Manufacturing Precision:
Particularly for harmonic drives and RV reducers, internal gear machining requires micron-level precision, demanding expensive equipment and strict quality control.
• Complex Manufacturing Processes:
Reducer production involves multiple steps—grinding, heat treatment, assembly—each requiring skilled craftsmanship and expertise.
• High Material Standards:
Reducers must endure high torque and impact forces, necessitating high-strength, wear-resistant materials, which are costly.
Among various reducer types, harmonic drives and RV reducers are widely used in robot joints due to their high precision, rigidity, and torque density. However, their manufacturing difficulty also makes them the most expensive.
The servo motor acts as the "power source" of industrial robots, providing motion control with precise positioning, speed, and torque adjustments. Unlike standard motors, servo motors enable accurate motion execution based on control signals, ensuring robots follow predefined trajectories.
The high cost of servo motors is attributed to:
• High Responsiveness:
Must rapidly adjust to control signals for high-speed and precise movements.
• Exceptional Precision:
Requires high-accuracy position, speed, and torque control for smooth robot motion.
• Reliability in Harsh Conditions:
Must withstand high temperatures, vibrations, and dust in industrial settings.
To meet these demands, servo motors use high-performance magnetic materials, precision sensors, and complex control algorithms, all contributing to their elevated cost.
The high cost of industrial robots does not stem from their body structure but rather from their core components—reducers, servo motors, and controllers. These three elements are not only critical to robot performance but also represent the highest technological barriers in the industry.
