Smart Factory is a complex system that integrates the main elements of the Industry 4.0 concept (e.g., autonomous robots, Internet of Things, and Big data). In Smart Factories intelligent robots, tools, and smart workpieces communicate and collaborate with each other continuously, which results in self-organizing and self-optimizing production. The significance of Smart Factories is to make production more competitive, efficient, flexible and sustainable. The purpose of the study is not only the introduction of the concept and operation of the Smart Factories, but at the same time to show the application of Simulation and Artificial Intelligence (AI) methods in practice. The significance of the study is that the economic and social operational requirements and impacts of Smart Factories are summarized and the characteristics of the traditional factory and the Smart Factory are compared. The most significant added value of the research is that a real case study is introduced for Simulation of the operation of two collaborating robots applying AI. Quantitative research methods are used, such as numerical and graphical modeling and Simulation, 3D design, furthermore executing Tabu Search in the space of trajectories, but in some aspects the work included fundamental methods, like suggesting an original whip-lashing analog for designing robot trajectories. The conclusion of the case study is that—due to using Simulation and AI methods—the motion path of the robot arm is improved, resulting in more than five percent time-savings, which leads to a significant improvement in productivity. It can be concluded that the establishment of Smart Factories will be essential in the future and the application of Simulation and AI methods for collaborating robots are needed for efficient and optimal operation of production processes.

The application of the Industry 4.0′s elements—e.g., industrial robots—has a key role in the efficiency improvement of manufacturing companies. In order to reduce cycle times and increase productivity, the trajectory optimization of robot arms is essential. The purpose of the study is the elaboration of a new “whip-lashing” method, which, based on the motion of a robot arm, is similar to the motion of a whip. It results in achieving the optimized trajectory of the robot arms in order to increase velocity of the robot arm’s parts, thereby minimizing motion cycle times and to utilize the torque of the joints more effectively. The efficiency of the method was confirmed by a case study, which is relating to the trajectory planning of a five-degree-of-freedom RV-2AJ manipulator arm using SolidWorks and MATLAB software applications. The robot was modelled and two trajectories were created: the original path and path investigate the effects of using the whip-lashing induced robot motion. The application of the method’s algorithm resulted in a cycle time saving of 33% compared to the original path of RV-2AJ robot arm. The main added value of the study is the elaboration and implementation of the newly elaborated “whip-lashing” method which results in minimization of torque consumed; furthermore, there was a reduction of cycle times of manipulator arms’ motion, thus increasing the productivity significantly. The efficiency of the new “whip-lashing” method was confirmed by a simulation case study.

Nowadays, resources for production (raw materials, human, energy, etc.) are limited, while population, consumption and environmental damage are continuously increasing. Consequently, the current practices of resource usage are not sustainable. Therefore, manufacturing companies have to change to environmentally friendly and innovative technologies and tools, e.g., industrial robots. Robots are necessary in the production sector and also in terms of sustainability: (1) the application of robots is needed to compensate for the lack of human resources; (2) robots can increase productivity significantly; and (3) there are several hazardous (e.g., chemical, physical) industrial tasks for which robots are more adequate than human workforce. This article introduces a newly elaborated Hybrid Algorithm for optimization of a robot arm’s trajectory by the selection of that trajectory that has the smallest cycle time. This Hybrid Algorithm is based on the Tabu Search Algorithm and also uses two added methods—Point Insertion and Grid Refinement—simultaneously to find more precisely the optimal motion path of the robot arm in order to further reduce the cycle time and utilize the joints’ torque more efficiently. This Hybrid Algorithm is even more effective than applying the Tabu Search method alone and results in even higher efficiency improvement. The Hybrid Algorithm is executed using MATLAB software by creating a dynamic model of a 5 degree-of-freedom robot arm. The main contribution of the research is the elaboration of the new Hybrid Algorithm, which results in the minimization of robot arms’ motion cycle times, causing a significant increase in productivity and thus a reduction in specific production cost; furthermore, obstacles in the workspace can be avoided. The efficiency of the Hybrid Algorithm is validated by a case study showing that application of the new algorithm resulted in 32% shorter motion cycle time.

The advantage of the globoid worm gearing, that all teeth of the worm are in mesh in every moment, is well-known. The main advantage of the helical worm gearing, the easy production is also known. The paper presents a new gearing construction that tries to combine these two characteristics in one novel worm gearing. This solution, similarly to the manufacturing of helical worm, applies turning machine instead of the special teething machine of globoid worm, but the path of the cutting edge is not parallel to the axis of the worm but has an angle in the vertical plane. The resulted in form is a hyperbolic surface of revolution that is very close to the hourglass-form of a globoid worm. The worm wheel then generated by this quasi-globoid worm. The paper introduces the geometric arrangements of this new worm generating method then investigates the meshing characteristics of such gearings for different worm profiles. The considered profiles are circular and elliptic. The meshing curves are generated and compared. For the modelling of the new gearing and performing the meshing analysis the Surface Constructor 3D surface generator and motion simulator software application was used.