The classic idea is that a vehicle follows predefined routes, transports goods from A to B and interacts only minimally with its surroundings. It is impossible to imagine modern intralogistics without such systems; they are reliable, safe and well-regulated.

However, the wave of innovation in recent years is fundamentally changing this picture. Mobile platforms are increasingly being equipped with manipulators (robots), turning them into autonomous, multifunctional robotic units. Instead of 'just' driving, they can grip, sort, assemble or inspect flexibly at different locations within a factory.

From the transportation task to mobile production support

This development opens up completely new fields of application:

• Assembly support: Mobile manipulators bring workpieces directly to the assembly station and carry out work steps.
• Machine loading: They load and unload machining centers without permanently installed feed systems.
• Quality assurance: Sensor-equipped robot arms on mobile platforms carry out flexible inspections on different production lines.
• Order picking in the warehouse: The combination of autonomous navigation and gripper function replaces manual pick-and-place tasks.

The key idea behind this is increased flexibility. A system that is mobile and can work actively at the same time increases capacity utilization and reduces downtimes.

New degrees of freedom, new security issues

However, these extended capabilities give rise to new risks. While classic AGVs/ AGVs move in controlled paths and their movements are relatively easy to predict, the complexity of mobile manipulators increases significantly. This increases the freedom of movement, as the robot arm can operate beyond the platform, move in all directions and reach areas that lie outside the original safety zone. In addition, mobile manipulators often operate in areas where people are working at the same time. This means that unpredictable movements or rapid arm movements can be dangerous. Furthermore, the task profiles are dynamic: processes can no longer be strictly planned, as the robot can switch tasks during a journey, for example from transporting to gripping. And last but not least, there is a combination of risks in that both the movement and the arm movement must be taken into account in terms of safety, often in real time under variable conditions.

Standards landscape and regulatory framework

The safety of mobile robotic systems is currently covered by several standards:

• ISO 3691-4 Safety of automated guided vehicles
• ISO 10218-1/-2 Safety of industrial robots
• ISO/TS 15066 Cooperation between humans and robots
• ISO 13849/ IEC 62061 Functional safety of control systems

The challenge is that mobile manipulators fall into several categories at the same time. The platform is subject to the standards for AGVs, the robot arm to the standards for stationary industrial robots, and the combination of the two has not yet been sufficiently standardized. The work of ISO/TC 299 therefore aims to create uniform standards for Industrial Mobile Robotics (IMR). Humanoid robots and complex mobile manipulator systems are also taken into account here.

Technological solutions for security

Technical measures are used to meet the new safety requirements:

• Multi-sensor fusion: Combination of lidar, 3D cameras, ultrasound and force-torque sensors.
• Dynamic protective fields: Real-time adaptation of safety zones depending on speed, arm position and surroundings.
• Collision avoidance through AI: Predictive trajectory planning to prevent dangerous movements.
• Integrated control safety: Platform and arm control communicate at a functionally safe level.
• Virtual barriers: Digital 'geofences' define action areas for the robot arm.

Cybersecurity as an integral component

Flexible, autonomous production assistants instead of 'moving transport boxes' © Kuka Group

Mobile robotic systems are usually networked, for example with warehouse management, production control systems or cloud platforms. Such networking has both advantages and risks, as cyber attacks can cause direct physical damage.

With the Cyber Resilience Act (CRA), the EU is creating binding requirements for the cyber security of networked products for the first time.

• Security by design: Protection mechanisms must be integrated into hardware and software from the outset.
• Vulnerability management: Security gaps must be identified and closed over the entire life cycle.
• Updates and patches: Timely security updates must also be provided for embedded systems.
• Transparency obligations: Security features must be disclosed.

For mobile robotics, this means that the platform control, manipulator control and fleet management software must all be CRA-compliant.

New machinery regulation (EU 2023/1230)

The new Machinery Directive integrates cyber security aspects directly into machinery safety:

Jens Müller is an ISO/IEC 17024 certified expert for machine safety, robots and handling systems and a BDSF-certified expert for occupational safety, CMSE

• Risk assessment also for cyber attacks that affect safety-relevant functions.
• Protection against manipulation of control systems.
• Interoperability: Networked machines must interact securely with other systems.
• Documentation requirements: Technical documentation now includes security and cyber aspects.

In summary, it can be said that CRA and the Machinery Ordinance complement each other: CRA regulates product-specific cyber requirements, while the Machinery Ordinance links these with classic safety requirements.

Security and cyber protection as a success factor

Mobile robotics has long been more than just 'moving transport boxes'. The integration of manipulators turns them into flexible, autonomous production assistants. However, the new possibilities also increase responsibility: safety and cyber security must be considered together from the outset. Companies that master this challenge early on will secure regulatory compliance and a clear competitive advantage. The standardization and regulatory landscape (ISO/TC 299, IEC 62443, CRA, new machinery regulation) will play a decisive role in ensuring that physical safety and cyber resilience go hand in hand.