Vol.07 Yamaha Motor Cobot
CHALLENGERS OF MONOZUKURI
Catch Up, Overtake, and Lead the Way
CHALLENGERS OF
MONOZUKURI
Story of New Model Development
Vol.07
Yamaha Motor Cobot
Catch Up, Overtake, and Lead the Way
Demand for collaborative robots, which offer high operational safety and flexible deployment, is expected to grow as manufacturers face labor shortages and increasing pressure to improve productivity. Responding to this, Yamaha Motor launched the Yamaha Motor Cobot, a 7‑axis collaborative robot with articulated joints designed to perform tasks in a human-like manner.
In this article, we speak with the development team that led Yamaha Motor's entry into the collaborative robot market.
Last October, Yamaha Motor released the Yamaha Motor Cobot, the company's first collaborative robot and one of the first 7-axis models introduced in the Japanese market. While 6-axis robots, consisting of three translational axes (X, Y, Z) and three rotational axes (roll, pitch, yaw), are the industry standard, this model adds an elbow axis that enables twisting motions. This allows the robot to reach into tight spaces, avoid obstacles, and approach targets from around them.
We spoke with members involved in the development process from the FA Product Engineering Division of the Engineering Section, Robotics Business Unit, Solution Business Operations. Our interviewees included MORI Shota and TSUMORI Shota, who worked on control systems and safety certifications; KOSATO Yotaro, responsible for mechanical design; IGARASHI Isamu, who handled software at the Yamaha Motor Advanced Technology Center in Yokohama; and FUJITA Takayoshi and HAYAKAWA Kei, who led the overall project.
Developing a Collaborative Robot that "Stays Close and Fits In" while Pursuing Unprecedented Technologies
In the factory automation (FA) field, the market for collaborative robots, which work alongside humans, is expected to continue growing significantly, driven by labor shortages, rising labor costs, and the need for advanced automation in new fields such as CASE. The Yamaha Motor Cobot was developed as Yamaha Motor's entry into this market. However, the collaborative robot market is already a highly competitive arena where both domestic and international manufacturers compete intensely. Furthermore, Yamaha Motor entered the field as a latecomer. "While we had single-axis robots and SCARA robots, we did not have a vertically articulated robot that mimics the movement of a human arm," explains HAYAKAWA. Nevertheless, the key to entering the market lay in how effectively the team could differentiate the product and deliver high added value. For this reason, rather than following the industry standard 6-axis configuration, the team decided to take on the challenge of developing a 7-axis collaborative robot.
"We approached the design with an emphasis on staying close to people and seamlessly fitting into everyday environments," says HAYAKAWA. The goal was to eliminate the cold, rigid image typically associated with conventional industrial robots. The product concept is "Stay Close, Fit In". At the same time, in order to "avoid commoditization," as FUJITA explains, the team aimed to create a collaborative robot unlike any previous model, both in design and performance. Development also focused on introducing new technologies, including compliance control, which enables the robot to respond flexibly to external forces.
Partnering with a Startup to Catch Up and Overtake Competitors
Adding an extra axis was far from simple. Yamaha Motor was already a latecomer to the vertically articulated robot market, and the team was taking on the challenge of developing a 7-axis model, an area with very few existing competitors. To achieve complex and delicate movements similar to those of a human arm while maintaining high productivity and stable quality, it was necessary to achieve a high level of integration across mechanics, hardware, and software. In addition, unlike conventional industrial robots, collaborative robots operate without safety fences, meaning they must simultaneously meet safety standards to work alongside humans.
Furthermore, bringing the product to market required not only advanced performance such as high-precision force control, but also high reliability through third-party certification to meet rigorous standards. Ease of use on the production floor and intuitive programming were also essential considerations.
The development team therefore began by seeking a technology partnership with a robotics startup. In the robotics business, unlike Yamaha Motor's motorcycle business where engines are developed in house from scratch, key core components are often sourced from partner companies. With this in mind, the team received a clear directive: "Find a company with technology that allows us to catch up and overtake the competition!" Acting on this mandate, they visited numerous companies in search of the right partner. Their search ultimately led them to a startup that held patents for highly advanced torque sensor technology. The technology can detect even the slightest external force with high sensitivity, enabling precise control of the robot's movements. "Collaborative robots must meet strict standards requiring them to automatically stop and limit impact force to a safe level upon contact with a human. The startup's torque sensors are both compact and highly accurate. They are installed at the joints, and when the robot makes contact, the sensors instantly detect the applied force and stop the motion," says KOSATO. The high sensitivity and rapid response of these torque sensors provided exceptional performance not only for safety, but also for impedance control, enabling the robot to maintain proper positioning while responding appropriately to external forces.
Turning Rejection into Collaboration through Persistence
When the team first approached the startup to discuss a partnership, they were turned away at the door, as the company had already received numerous offers from other companies. Nevertheless, convinced that this startup was the ideal partner, the team continued to visit repeatedly. The path was far from easy. Through repeated negotiations, Yamaha's enthusiasm, along with its commitment to and pride in Monozukuri, gradually became clear. Ultimately, the alignment between Yamaha's passion and the startup's desire to commercialize its technology led to the formation of a partnership. But the year was 2020. Just as the project was about to begin following a kick-off meeting, the COVID-19 pandemic struck. As a result, collaboration began under circumstances where the teams could no longer meet face to face.
"We couldn't travel, and it was difficult to fully grasp what was happening on each side," recalls IGARASHI. "We tried to imagine the situation and asked questions accordingly, always making sure to carefully explain the background before raising any questions." Faced with these unprecedented circumstances, the team devised new approaches to communication in order to move the project forward.
When Development Did Not Go as Planned Pursuing Mechatronic Integration through Cross-Functional Collaboration
Although the team had secured exceptional technology, the challenges were far from over. Because the partner company had already developed a collaborative robot, the team initially thought it might be possible to bring it directly into mass production. However, once development began in earnest, the reality proved quite different. "There was still a tremendous amount of work required to be done to meet our mass production standards, including durability, robustness, and ease of assembly," says HAYAKAWA. While the robot was viable as a prototype for research and development, it became evident that considerable modifications were required to meet the requirements of a mass-produced product. Although this had been anticipated to some extent, they still found themselves in a difficult situation. "Because we adapted existing technology, we found ourselves constrained by it, which made problem-solving even more difficult," says HAYAKAWA.
In addition to the challenges of commercialization and mass production, the project differed from previous robot developments because hardware and mechanical systems, which had traditionally been treated as separate specialties, had to be integrated into a single configuration. It required a cross-functional understanding of mechanics, hardware, and software. This made it essential to solve problems by bridging gaps between different areas of expertise. The team aimed for advanced mechatronic integration, which involves placing electrical components in close proximity to mechanical parts to achieve tighter integration. They worked closely together and refused to give up, eventually overcoming the obstacles.
Earning Trust and Going Further by Clearing Rigorous Certification Requirements from the Concept Phase
All members agree that obtaining third-party certification for functional safety was one of the biggest hurdles in the development process. Certification was not something to be secured only after the product was completed. Instead, it began from the concept phase. "Even if we claim that a finished product complies with the standards, that alone will not earn trust. Third-party certification is essential," says MORI. "This involved a wide range of tests, including witnessed testing and reviews. The challenge was not necessarily the technical difficulty, but coping with the sheer number of tests required. Since this was our first time obtaining functional safety certification for a collaborative robot, much of the process involved trial and error." These comments reflect how development progressed while securing certification at key milestones along the way. Depending on the item, the team was also required to bring the robot to testing facilities designated by the certification body. Managing these demanding requirements during the COVID-19 pandemic and within a tight development schedule required extensive effort and coordination. Those efforts ultimately paid off with the acquisition of certification, enabling the product to earn a high level of trust and reliability.
A Controller Gaining Industry Attention through a Combination of User-Friendly Functionality and Aesthetic Design
Achieving a compact design was another development goal to ensure product differentiation. Considering the flexibility and ease of handling required on production floors where collaborative robots operate, the team aimed to minimize the controller size as much as possible. While conventional controllers are said to be roughly the size of a refrigerator for a single-person household, this model achieved an industry-leading compact form of 374 mm (w) x 325 mm (d) x 155 mm (h). "We designed everything from the circuit boards up, but it was difficult to fit everything into the target size, and I was close to giving up," recalls TSUMORI. "That was when my supervisor told me to pour water into the housing. He said that if water could still fit inside, there was room to make it smaller. That pushed me to keep going," he says with a laugh. As a result, the team meticulously rethought the components and their layout and succeeded in fitting everything into the target size.
Furthermore, recognizing that collaborative robots and their controllers are frequently mounted on Autonomous Mobile Robots (AMRs) and Automated Guided Vehicles (AGVs), the team focused on battery power as the primary power source. Since these systems operate on DC power, the controller was designed to run on 48V DC. This specification contributes significantly to factory automation. This approach demonstrates a commitment to designing from the user's perspective.
In addition, the controller was designed with careful attention to functionality and user interface, enabling simple and intuitive operation regardless of the operator's level of experience. As with the collaborative robot itself, particular emphasis was placed on the design of the housing, which visually embodies the concept of "Stay Close, Fit In."
Challenging Market Conventions with a Fresh Design Approach through Collaboration with a Home Appliance Designer
In fact, both the collaborative robot and its controller are the result of a unique design approach. "This is the first product in our FA development work that we created by working with a designer from the concept stage," says HAYAKAWA. Moreover, the team deliberately held a design competition that included designers from outside the FA and robotics fields. To everyone's surprise, a home appliance designer was selected and joined the project. "I wanted to break new ground. By incorporating fresh elements that aren't typical for robots, I also wanted to achieve differentiation through visual impact," says HAYAKAWA. This approach resulted in an unprecedented look for the product. Composed of smooth curves and finished with a matte coating, the collaborative robot has a sense of softness and warmth perfectly suited for a robot that works alongside humans. Because the designer did not come from an industrial design background, the team encountered challenges related to structure and functionality along the way. Nevertheless, the members agree that these efforts resulted in a product that clearly differentiates itself through its appearance. Some people have even compared it to an adorable, lovable character. Once you see the collaborative robot in person, you will certainly understand why.
Seeing the Project through to the End No Matter What, with Mutual Respect and Gratitude among Team Members
To reiterate, developing a collaborative robot was a first for the company, and Yamaha Motor entered the market as a latecomer. The pressure on the team, tasked with catching up and overtaking competitors in a short period of time, was enormous. Moreover, the project coincided with the start of the pandemic, imposing severe constraints from the earliest stages of development. Some voices inside and outside the company even questioned whether the project would succeed at all. Nevertheless, FUJITA remained committed to two guiding principles: finish the project no matter what others say, and maintain gratitude and respect among team members. "As these ideas spread among the team members, they gradually became embedded in the atmosphere of the entire project," FUJITA reflects. "This shared mindset not only unified the development team but also fostered cooperation from many stakeholders, including those in sales, procurement, and manufacturing."
Such an approach represents a fundamental principle of effective collaboration among people. It may well have been one of the key factors that enabled the successful development of this highly complex collaborative robot.