How Panasonic Components are Shaping the Future of Robotic Arms

The global manufacturing sector is undergoing a major transformation. In many developed nations, declining birth rates and aging populations have led to severe labor shortages, creating pressing challenges for production. As a result, factory automation has emerged as a critical solution. 

Industrial robots are at the forefront of this shift, delivering key benefits such as: 

• Continuous 24/7 operation 

• Elimination of hazardous or repetitive tasks 

• High precision in processes 

• Enhanced overall productivity 

Data from the International Federation of Robotics (IFR) highlights this trend: in 2023, approximately 540,000 industrial robots were installed worldwide. Today, factories across the globe operate a record 4,281,585 units, representing a 10% increase compared to the previous year.

This article explores the key technical hurdles in the fast-paced evolution of robotic systems and highlights Panasonic’s passive component solutions that make these advancements possible. It emphasizes targeted approaches to major challenges, including ensuring durability in extreme conditions and achieving compact designs.

By solving durability and miniaturization challenges, Panasonic’s passive components pave the way for smarter, more efficient robotic systems. As automation continues to evolve, these innovations will play a key role in shaping the factories of tomorrow.

Example: Impact of DC Bias and Temperature on Capacitance 

When a 15V DC voltage is applied, the capacitance of an MLCC can drop by up to 80%, with an additional 10% reduction under extreme temperatures. For instance, if a circuit requires 47µF at 15V DC, the actual usable capacitance is only about 20% of the nominal value. 

In this example, to secure the required capacitance of 47µF for the circuit, more than 220µF of nominal capacitance and over 10 units of 22µF MLCC are necessary. While it is possible to reduce the number of units by selecting MLCCs with larger capacitance, the typical approach is to use multiple low-cost small-capacity MLCCs, as larger-capacitance MLCCs are limited in availability.

Conversely, conductive polymer capacitors do not exhibit significant reductions in capacitance due to DC bias or temperature changes. Therefore, in this example, 10 units of 22µF MLCC can be replaced with a single 47µF conductive polymer capacitor, reducing the number of components and potentially decreasing total costs, including implementation costs, as well as reducing the implementation area.

As robotic arms become smaller and lighter, the demand for compact components with high vibration resistance continues to grow. Panasonic’s conductive polymer hybrid aluminum electrolytic capacitors enable designs that support larger capacitance and higher current while reducing component count—saving valuable space. 

For environments with intense vibration, Panasonic offers specialized vibration-resistant capacitors capable of withstanding acceleration up to 30G, in sizes ranging from 6.3mm to 10mm. 

Traditionally, vibration reinforcement for standard components requires adhesives or bonding processes. By using Panasonic’s vibration-resistant products, these extra steps can be eliminated, simplifying assembly and improving efficiency for manufacturers. 

As industrial robots become more common, the need for components that can maintain stable operation under extreme heat is growing rapidly. Reliability is critical—any failure can directly impact productivity, making the choice of high-performance components essential.

SP-Cap:

Panasonic’s SP-Cap series is engineered for durability in harsh conditions, delivering an impressive lifespan of up to 5,500 hours at 135°C. This makes them ideal for robotic applications that operate under continuous high loads and elevated temperatures. 

POSCAP: 

The POSCAP series offers robust performance in compact designs, with a guaranteed lifespan of 1,000 hours at 125°C. These capacitors are perfect for applications requiring high capacitance in small form factors and can safely replace traditional MnO₂ capacitors. 

OS-CON:  

For exceptional longevity, Panasonic’s OS-CON capacitors stand out, offering up to 20,000 hours at 105°C. The SVT series, for example, boasts an expected lifespan of 12.8 years at 90°C, ensuring long-term reliability for robotic arms operating in high-temperature and demanding environments. 

Additionally, Panasonic’s conductive polymer technology provides significantly lower ESR compared to conventional aluminum electrolytic and tantalum capacitors. This advantage reduces component count and saves space on circuit boards, supporting the miniaturization of robotic systems. 

Anti-sulfur resistors enhance reliability in environments with high sulfur content. Typical areas with elevated sulfur exposure include locations near volcanoes, hot springs, highways with high vehicle emissions, and industrial sites using cutting oils or rubber-based products. Even in general environments, sulfur can emanate from materials such as lubricants or greases used in cooling fan motors, rubber seals for packing or vibration isolation, and certain mold resins. Silicone-based coating materials can accelerate sulfur-induced corrosion (sulfuration). Thus, in such conditions, the use of chip resistors designed with sulfur resistance is essential.

Panasonic's anti-sulfur chip resistors achieve superior reliability by replacing traditional silver electrode materials with highly sulfur-resistant alternatives. Panasonic offers two resistor series tailored to specific requirements: one focused on absolute performance and another optimized for longevity, balancing performance and cost considerations.

1. Gold-based electrode pursuing absolute performance
   The ERJS series utilizes gold-based electrodes, recognized for their exceptional stability and superior sulfur resistance.
2. High palladium electrode enhancing longevity effects
   The ERJU series employs a silver-palladium (AgPd) alloy electrode with high palladium content, significantly improving sulfur resistance by suppressing silver diffusion.

See the immersion test results comparing Panasonic’s anti-sulfur chip resistors against general-purpose resistor electrodes when immersed in sulfur-containing oil.

In typical resistor electrodes, the low palladium content commonly results in failures (disconnections) after approximately 100 hours of sulfur exposure. In contrast, Panasonic’s ERJU series resistors, featuring high-palladium silver electrodes, exhibit no disconnection even after 3,000 hours, substantially enhancing reliability. A direct correlation exists between palladium content and time-to-disconnection; thus, the ERJU series is designed to withstand exposure exceeding 12,000 hours without failure. The ERJS series, with gold-based electrodes, demonstrates even higher reliability, showing no measurable change in resistance values after 3,000 hours.