Rethinking Robotics in Manufacturing: The Realtime Robotics Revolution
Introduction to Realtime Robotics
Based in Boston and founded in 2016, Realtime Robotics is reshaping how the manufacturing industry perceives and utilizes robotics. Specializing in path planning software driven by artificial intelligence (AI), the company is dedicated to optimizing industrial robot paths in real-time—a crucial development for the automation of integration processes.
Insights from Automate 2025
At the Automate 2025 event in Detroit, Michigan, Ville Lehtonen, the vice president of product at Realtime Robotics, highlighted how early adopters within the manufacturing sector are leveraging the company’s cloud-based Resolver platform. Remarkably, users of this platform can enhance their operational efficiency by outperforming human counterparts in terms of speed, achieving improvements of up to 20%.
Traditionally, simulation engineers or integrators engaged in lengthy and often costly processes to optimize workcells, the areas where robots operate. These lengthy simulations required various tools and significant human labor, sometimes taking hundreds of hours to finalize effective configurations.
The Speed of Resolver
Lehtonen demonstrated how the Resolver software radically accelerates path planning. While conventional methods could stretch over several weeks, Resolver can solve complex workcell problems in mere hours. For instance, in a notable welding application involving over 20 robots, Resolver created an efficient path that reduced the cycle time from 41.47 seconds to just 32.04 seconds, drastically enhancing throughput.
This efficiency is achieved without compromising safety. The program not only formulates collision-free paths but also incorporates mandatory safety interlocks—components designed to prevent operation under unsafe conditions.
The Power of Cloud Computing and AI
The efficiency of Resolver stems from its use of cloud computing, which dramatically accelerates computations compared to traditional simulations run on local systems. Utilizing AI, the software can learn from various scenarios, continuously optimizing and improving processes over time. This combination of powerful cloud infrastructure and AI adaptability allows manufacturers to think beyond the current limitations of their robotics systems.
Implications for Integrators
Despite advancements, many top-tier manufacturers still rely on integrators for setting up new workcells. Lehtonen has engaged with a wide array of manufacturers, highlighting a critical issue: for companies engaged in high-mix, low-volume production—those requiring frequent switchovers—there is a pressing need to embrace these new AI capabilities.
He illustrated a future where production lines can effortlessly switch between complex tasks, such as manufacturing cruise missiles and torpedoes, with just a click of a button. Such shifts necessitate a change in mindset throughout the industry.
Encouraging Big Picture Thinking
Lehtonen emphasizes the need for manufacturers to think bigger about their operational capabilities. He noted the U.S. currently has about 270 robots for every 10,000 manufacturing workers, primarily concentrated within the automotive sector. This disparity raises a fundamental question: why aren’t more manufacturing processes automated?
The answer, as Lehtonen puts it, often relates to the complexity and challenges involved in setup. He references a recent report from the International Federation of Robotics (IFR), which recorded a total of 381,964 industrial robots actively utilized in U.S. factories—a 10% increase from the previous year. Even though 2023 saw a slight downturn in annual installations, these figures still represent the third-best performance in history.
Lehtonen calls for a "democratization of robotics," advocating for the sale of millions of robots instead of the mere thousands currently seen. As he points out, U.S. manufacturing risks stagnation without ambitious visions, especially when compared to countries like China which are rapidly investing in advanced manufacturing.
Innovations at Automate 2025
Inbolt: Vision for Enhanced Automation
Another notable highlight from Automate 2025 was Inbolt, co-founded by Albane Dersy. Inbolt aims to reduce automation costs by enabling robots to utilize advanced vision systems. This technology allows for real-time part mobilization; if a part shifts during a task—like laying adhesive—the robot can adjust its movements accordingly. Such flexibility promises to simplify setups and accelerate engineering processes.
Dirac: Streamlining Work Instructions
Dirac introduced BuildOS, a tool designed to automate the creation of digital work instructions tailored for manufacturing engineers. By providing interactive models, annotated photographs, and video guides, this tool aims to uplift less-skilled operators, thus addressing a widespread challenge of “tribal knowledge” in the manufacturing sector.
Olis Robotics: Remote Monitoring Solutions
Olis Robotics is revolutionizing industrial automation with a mobile app that serves as a real-time monitor for automation cells. This solution synchronizes video feeds with system logs, enabling engineers to troubleshoot remotely and maintain production efficiency. Described as a "ring camera for industrial automation," the app promises quick installation even alongside legacy systems.
Looking Ahead
As we observe the innovations emerging in robotics and automation, it becomes crucial for manufacturers to embrace these advanced technologies. With companies like Realtime Robotics leading the charge, the landscape of manufacturing is poised for significant transformation, driven by AI and a reallocation of how we think about and utilize industrial robots.