(Source: Gorodenkoff/stock.adobe.com)
One of the defining features of Industry 5.0 is the widespread adoption of advanced technologies that create a more efficient, sustainable, and effective manufacturing cycle. Some of the technologies with the greatest potential to impact the industrial sector include augmented reality (AR), robotics, exoskeletons, and drones.
While each of these technologies brings different distinct benefits, their individual integration and synergistic overlap—and interaction with the operator—are expected to be the backbone of Industry 5.0. This article discusses how each of these technologies will be employed in the next wave of industrial automation and how the manufacturing sector stands to benefit from such advances.
AR is considered one of the key technological advancements driving Industry 5.0. AR technology uses a confluence of advanced hardware, optics, processing, and software to merge digital elements with the physical environment. This technology enhances the capabilities of factory operators and improves industrial processes through real-time data collection and interactive feedback systems.
One of AR's primary impacts in Industry 5.0 is in the domain of quality control, as it stands to transform inspection processes. Traditionally reliant on human observation, these processes are being revolutionized by AR’s ability to provide enhanced visual inspections. For instance, AR can overlay digital markers on physical objects to indicate tolerance levels, defects, or assembly instructions. This accelerates the inspection of incoming materials and ensures higher accuracy by highlighting deviations from expected standards.
In assembly operations or maintenance procedures, AR can guide operators through complex manufacturing tasks by displaying step-by-step instructions directly in their field of vision. This results in fewer errors, streamlined training, and significantly increased operational efficiency.
However, integrating AR into industrial operations is challenging. The main hurdle lies in developing robust software that can integrate seamlessly with AR hardware to process and display complex industrial data effectively. Software must be intuitive and tailored to specific industrial applications to ensure that the information presented is relevant and actionable.
Since its inception in the 1960s, robotics has been a fundamental automation tool in manufacturing. Now, with the rise of Industry 5.0, robotics is positioned to adopt new roles.
Today, robots are equipped with specialized end-of-arm tools such as grippers, suction cups, cutters, and tools for soldering, painting, or applying adhesives. These modern robots can perform complex assembly tasks with high precision, creating avenues for automation that were not previously possible.
Robots have also diversified in size and capability, which is matched by advancements in actuation technology. While large robots often rely on hydraulic systems, mid-sized models may use pneumatic actuators, and most modern robots employ electric actuators. In the context of Industry 5.0, electric actuators are particularly beneficial because they easily integrate with the Internet of Things (IoT) to enhance connectivity, human transparency, and control.
The most transformative aspect of robotics in Industry 5.0 is the rise of collaborative robots, commonly known as cobots. Cobots are designed to work alongside human operators by sharing tasks and responsibilities (Figure 1). For example, cobots can handle heavy or repetitive tasks on manufacturing lines, allowing humans to focus on fine-tuning and quality assurance.
Figure 1: Cobots align with Industry 5.0’s human-centric approach to automation by enhancing productivity through collaboration. (Source: gumpapa/stock.adobe.com)
As we advance further into Industry 5.0, the interaction between humans and robots will likely evolve into more integrated and intelligent systems. Robots will share tasks as well as sensory inputs and decision-making processes, blurring the lines between human and machine capabilities. Ultimately, this synergy will enhance efficiency, reduce human error, and foster environments where human-robot interactions optimize creative and analytical tasks.
With respect to human safety and performance, exoskeleton technology is poised to be transformative for Industry 5.0. Exoskeletons are wearable devices that support and augment the user’s strength and endurance. Active exoskeletons, equipped with motors and battery packs, assist operators by providing additional strength to perform tasks that exceed typical human capacities. This capability allows workers to handle heavier loads or perform repetitive tasks without fatigue, thereby increasing operational efficiency and reducing the risk of injury.
One significant benefit of exoskeletons in Industry 5.0 is their potential to democratize physically demanding jobs. By augmenting human strength, exoskeletons can make physically challenging tasks accessible to a broader range of people. With greater job inclusivity, industries can tackle labor shortages and increase workforce diversity.
However, several challenges must be addressed to realize the full potential of exoskeletons. The comfort and ergonomics of these devices are crucial. Current exoskeleton models often require considerable adjustment to fit comfortably and allow for natural movement. Improvements in design and the use of lightweight materials like carbon fiber stand to make exoskeletons more user-friendly and less cumbersome.
Another hurdle is the technology’s responsiveness and intuitive control. Operators need exoskeletons that can interpret their movements and intentions accurately without delay. Advanced sensors and artificial intelligence algorithms are required to integrate human intent with mechanical action, ensuring that the exoskeleton acts as a true extension of the human body.
In Industry 5.0, drones are expected to significantly impact inventory management, safety, and quality control. Traditional methods of inventory management are struggling to keep pace with the high demands of modern warehouses, which may contain hundreds of boxes and crates in difficult-to-reach locations. Instead, drones equipped with advanced sensors and imaging capabilities that can identify smart tags and QR codes can offer a new means of navigating these vast warehouse spaces (Figure 2). These systems can efficiently track and manage inventory location and status in real time. Compared to traditional inventory management, drones reduce the need for human intervention in unsafe zones and allow for faster, more detailed, and more accurate data collection.
Figure 2: Drone technology enables manufacturers to perform quality control inspections and inventory management with efficiency never seen before. (Source: Creative_Bringer/stock.adobe.com, generated with AI)
For the automotive industry, drones can also play a role in enhancing quality control by conducting aerial inspections of vehicles during various production stages. For instance, drones equipped with high-resolution cameras and sensors can inspect car bodies for defects such as dents, scratches, or inconsistencies in paint applications.
The real-time data collected by drones can be coupled with an advanced quality control system, in which advanced algorithms analyze the images to detect irregularities or imperfections. This process increases the accuracy and safety of inspections by eliminating oversights while significantly accelerating the quality control process.
As Industry 5.0 gains momentum, AR, robotics, exoskeletons, and drones are poised to be mainstays. By collectively enhancing production efficiency, decreasing human error, and creating a safer environment for workers, each of these technologies is well aligned with Industry 5.0's goals and constitutes the key pillars of the future of smart factories.
Hector Barresi is an award-winning Industrial Technology Advisor, Consultant, and Public Speaker specialized in Industrial Automation, Smart Manufacturing, and Digitalization. He has held executive positions at Honeywell, Danaher, IDEX and General Electric, and he is renowned for shaping top-tier Product Innovation organizations globally. Notably, he pioneered the Honeywell XYR5000, the first industrial wireless sensor family on the market, and the groundbreaking Tintelligence smart tinting platform, revolutionizing the paint industry.