Enhance the safety of autonomous mobile robots
Date：September 7, 2025 Views：11
Source: ON Semiconductor Author: Theo Kersjes (Systems Engineering Manager)
Nowadays, robots have been introduced into industrial facilities to help increase productivity and improve efficiency. During the transition from Industry 4.0 to Industry 5.0, industrial manufacturers have been actively leveraging advanced technologies such as artificial intelligence to enhance their competitiveness, while focusing on people-oriented strategies and sustainable development. In pursuit of higher efficiency and quality, enterprises are seeking to enhance human-computer interaction one after another. This trend has greatly promoted the wide application of autonomous mobile robots (AMRs).
AMR requires a comprehensive software and hardware system to work in coordination with operators in modern manufacturing or warehousing facilities. Robots can generate considerable impact force and move at a relatively high speed, thus possibly posing certain risks, such as causing workers to get injured in accidental collisions. We must manage such risks carefully. Not only should we formulate relevant operation procedures, but also pay attention to the design of the robots themselves.
Figure 1: Today's robots work in coordination with operators in modern factories
What key elements need to be considered when designing an AMR system that can collaborate safely and effectively with humans? This article conducts a discussion. We will analyze how onsemi's advanced solutions serve as the fundamental building blocks of the AMR subsystem, providing designers with powerful tools that enhance productivity without compromising security.Automation grows side by side with humanity
The wide application of industrial robots began in the computer age of the 1960s. Over the past two decades, advancements in digital technology have given rise to collaborative mobile robots capable of navigating in complex environments and collaborating with teams to complete tasks.
As industrial automation progresses from Industry 4.0 to Industry 5.0, the level of human-machine interaction will further drive the demand for AMR.
AMR is cost-effective, easy to deploy, and can work in collaboration with operators to achieve better results than working alone. For instance, collaborative robots excel in speed, accuracy and consistency, making them an ideal choice for repetitive tasks such as welding and assembly line work, thus enabling workers to focus on more complex tasks that require higher cognitive skills.
Traditional fixed robots can be physically separated from humans to prevent injuries. However, after the concept of shared workspaces was introduced, new challenges emerged. The AMR must be capable of sensing sudden external forces and stop moving quickly when necessary. Although collisions with people and objects in the workplace are inevitable, robots must be able to reduce the impact to prevent injuries to personnel and damage to items. In this regard, robot designers can leverage advancements in sensing technology and visual systems to overcome these challenges and more closely integrate the power and precision of robots with human creative problem-solving abilities.
The key subsystems in AMR
AMR Interacts with the environment using multiple sensors, artificial intelligence and advanced algorithms to make decisions, detect obstacles and collaborate safely with operators and other machines.
The functional block diagram below (Figure 2) shows the typical design of the AMR system, in which the basic subsystems include motion control, sensing, lighting, power supply, charging and communication.
In this article, we will focus on the sensing, motor control and lighting subsystems.
Figure 2: Typical Design of the AMR system
Sensing subsystemSensors enable robots to adapt to their operating environment and make decisions based on real-time data. There are various types of sensors, including imaging, ultrasonic, infrared, inductive and inertial sensors, which are designed to enhance the navigation ability and safety of robots. To deal with complex environments such as loading ramps, various types of sensors may be needed. At this time, sensor fusion is required to merge the data of multiple sensors.
On Semiconductor's AR0234CS is an advanced global shutter image sensor that can generate very clear and sharp digital images. This sensor has been optimized and adopts an innovative pixel design, capable of accurately and quickly capturing moving scenes at a speed of 120 frames per second, and generating clear low-noise images in both low-light and high-light scenarios. The AR0234CS is capable of capturing video streams and single frames, making it an ideal choice for a wide range of industrial applications such as AMR.
The AR0234C is just one of many advanced sensors from ON Semiconductor. On Semiconductor's extensive product portfolio also includes the ARRAYRDM-0112A20-QFN, a quasi-one-stop solution for single-point LiDAR systems. The NCV75215 ultrasonic sensor adopts low-cost ToF measurement technology, with a measurement range of 0.25 meters to 4.5 meters, making it an ideal choice for AMR applications.
Motion control subsystem
Robots must be capable of performing repetitive and precise movements. Most moving parts (including robotic arms and traction systems) rely on brushless DC (BLDC) motors controlled by complex algorithms. Typically, BLDC is controlled by a variable frequency driver (VFD), which uses discrete components such as MOSFETs, IGBTs, gate drivers and diodes. Power integration modules (PIM) and intelligent power modules (IPM) offer higher integration, reduce the number of components and save space.
On Semiconductor offers a wide range of discrete components and modules, including the NCD83591 motor driver, which is an easy-to-use 60V multi-purpose three-phase gate driver with a high-gain bandwidth current-aware amplifier, making it ideal for robot motor control. This gate driver adopts a small QFN28 (4x4mm) package, featuring high integration and is particularly suitable for overall BOM optimization.
The inductive position sensors NCS3210 and NCV77320 provided by ON Semiconductor are used in motion control systems to measure the rotation of wheels or other moving parts.
Lighting subsystem
Lighting technology is used to illuminate paths, assist AMRs in navigation and operation, and indicate their status and intentions by sending signals and indicator lights, thereby communicating with other personnel and equipment. The reason for choosing LED lighting technology lies in its excellent performance in terms of brightness, color temperature and power consumption. LED lighting solutions can be constructed using a variety of components, including but not limited to LED drivers, buck or boost converters, and power MOSFETs.
The LED controller and driver assembly is responsible for monitoring the current within the LED, enabling it to emit light of specific intensity and wavelength. The LED driver circuit uses high-side and low-side power MOSFETs to turn on or off the LED current and protect the LED from overvoltage and overcurrent conditions, thereby ensuring the stability of the LED driver circuit. The NCV7685 features 12 linearly programmable constant current sources, using the same reference voltage, and supports 128 different adjustable PWM duty cycle levels. This linear LED driver is used for the regulation and control of leds and is highly suitable for AMR and automotive applications.
On Semiconductor's comprehensive support for robotics technology
The application of robots is evolving rapidly. Whoever is the first to introduce innovative robot solutions is expected to reap rich rewards. On Semiconductor is well aware of the challenges that enterprise customers face in the current rapidly changing market. With our profound technical capabilities and professional knowledge, we provide dedicated support to the market.
On Semiconductor has a leading edge in sensing and robotics technology, which is attributed to our strong global infrastructure and our capabilities in design, manufacturing and solution engineering. Our extensive product portfolio encompasses a variety of technologies, such as BLDC motor control kits, battery charging and power conversion solutions, sensor fusion solutions, communication solutions, and LED lighting drivers, among others. On Semiconductor has profound knowledge in the industrial and automotive markets, capable of providing system-level support to customers, while offering flexible and scalable products and solutions for robot systems.
Conclusion
Unlike the robots that were separated from people in the past, the latest generation of robots must be able to collaborate safely with people and prevent injuries to personnel and damage to items. The new generation of robot solutions is transforming numerous industries, including manufacturing, e-commerce, healthcare and transportation. These industries are under tremendous competitive pressure and must enhance efficiency while ensuring that quality and safety are not compromised. The new generation of flexible and customizable robots is designed to collaborate with humans, perform repetitive tasks with precision requirements, and help people focus on higher-value activities instead.
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