Robotics Solutions Guide
The demand for highly reliable, adaptable, and high-speed automation systems continues to rise. This surge is driving significant growth in the deployment of industrial and collaborative robots (cobots), especially in small to mid-sized enterprises seeking cost-effective automation. These are data rich environments that need to communicate multiple sensor information to central CPU’s for efficient processing to support fast adaptive machine control. Optic fiber links are ideal to provide the speed and data reliability needed.
Collaborative Robotics
The cables and interfaces that connect the sensors to the core processing are not unlike the nervous system in a human body, and in robotic applications the machines nervous system must be protected from thermal stress, mechanical stress and electromagnetic interference. A machine’s efficiency is measured by its speed and its availability. If the cable infrastructure can’t handle the speed or provide the reliability then the automation is not cost effective.
Historically, industrial robots operated in isolated, caged environments due to safety concerns. However, the emergence of collaborative robots has enabled safe human-robot interaction within shared workspaces. These compact, reconfigurable systems are ideal for dynamic production environments, where traditional robotic systems were often cost-prohibitive and required specialized programming expertise.
Modern cobots leverage intuitive, kinesthetics teaching methods where operators physically guide the robot through tasks, eliminating the need for complex code-based programming. This democratization of robotics is enabling broader adoption across industries, with cobots increasingly handling repetitive, low-skill tasks, thereby freeing human workers for higher-value operations.
However, the cost-effectiveness of such systems depends on the machine being available 24-7. The same machine has to service multiple operators over several shifts. The machines don’t get a lunch break! This requires super high reliability for every component and this is where plastic optic fiber (POF) provides a cable infrastructure that has already proven reliability in other industrial sectors such as power systems and locomotive applications for over 30 years. POF brings a pedigree for reliability in compact spaces, with continuous cable flexing in challenging environments.
Challenges in Robotic Communication and Control
Cobots are typically smaller and more mobile than traditional industrial robots, often featuring fully internalized wiring to maintain compactness and flexibility. However, this design introduces significant challenges in routing high-speed communication and control signals through multiple articulating joints.
Precision motion control is critical in robotic systems. Each joint is governed by a closed-loop servo mechanism, incorporating high-resolution optical encoders, force-torque sensors, and real-time collision detection. These systems are orchestrated by high-performance industrial controllers—often ruggedized PCs—requiring robust, low-latency communication infrastructure.
Optical Communication with Plastic Optical Fiber (POF)
Comparing POF vs Copper, POF delivers the optimal balance for robotics combining robustness, electromagnetic immunity, and fast deployment without the complexity or cost overhead. Plastic Optical Fiber (POF) presents a compelling solution for robotic communication challenges, particularly in environments with tight bend radii, high EMI, and dynamic motion. Firecomms’ range of transceivers and POF-based solutions are engineered to meet the stringent demands of robotic and cobotic systems.
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Key Advantages of POF in Robotics:
- High Flexibility and Durability: POF’s mechanical robustness and tight bend radius tolerance make it ideal for routing through robotic joints without signal degradation.
- EMI Immunity: Optical transmission is inherently immune to electromagnetic interference, ensuring signal integrity in electrically noisy industrial environments.
- Electrical Isolation: No copper path, hence total galvanic isolation.
- High-Speed Data Transmission: Firecomms’ transceivers support data rates up to 250 Mbps, enabling real-time communication for motion control, sensor feedback, and safety interlocks.
- Compact Integration: The small form factor of POF components allows seamless integration into space-constrained robotic architectures.
- Lighter cabling: Versus copper cabling, POF cabling is exceptionally light
Industrial Communication Protocols and Integration
Robotic systems typically utilize industrial communication protocols such as Ethernet/IP, EtherCAT, PROFINET, Modbus-TCP, and CANOpen. Legacy systems may still rely on serial protocols (RS232/422/485, CAN) with limited bandwidth (<1 Mbps), while modern systems increasingly adopt Ethernet-based protocols offering speeds up to 125 Mbps or higher. Integrating Firecomms’ optical transceivers into these networks allows for:
- Protocol-agnostic physical layer transmission
- Reduced cabling complexity
- Improved signal reliability over long distances or in high-vibration environments
Applications in Collaborative Robotics:
- Sensor and Actuator Communication: POF enables reliable transmission of encoder data, force feedback, and actuator commands across moving joints.
- Safety Monitoring: Optical links can be used for non-invasive safety systems, such as proximity detection and emergency stop signalling, enhancing human-robot collaboration.
- Inspection and Navigation: In mobile and inspection robots, POF supports high-resolution video and sensor data transmission in confined or hazardous environments.
Firecomms Solutions
Firecomms offers a number of transceiver devices suitable for robotic & cobotic applications.
• DC-1/5/10/50 MBd low speed, serial protocols for command-and-control applications
• 125 Mbps, 250 Mbps and Gigabit for higher speed data applications.
Transceivers are available from industry standard plug type connectors to simple, bare fiber, termination. All Firecomms transceivers are EMI hardened and designed to be used and installed in harsh industrial environments.
Firecomms is the proven leader in the industrialisation of robust optical communications.
RedLink®
The form factor of the RedLink® (RL) family is compatible with the Versatile Link range of connectors and cables. We offer a range of industrial grade fiber optic transmitters and receivers (DC-1/5/10/50 MBd) in the RedLink® connector.
SMI Transceivers
Firecomms’ SMI transceivers comply to the IEEE1394b standard developed for communication over plastic optic fiber. Non-magnetic versions are available for Medical device applications.
OptoLock® Transceivers
The patented OptoLock® (OL) provides the quickest of terminations with bare POF at DC/5/10/125/250 Mbps and GigE speeds.
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Full cable offering for your robotic application
Firecomms offers a range of high quality Plastic Optical Fiber cables. SMI, LC, and RedLink® plugs, and pre-assembled patch cords in all SMI, LC and RedLink® styles. These products are suitable for use with Firecomms’ range of transceivers and other industry-standard products.
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