Valves play a critical role in heating, air-conditioning, and refrigeration systems, regulating fluid or refrigerant flow to maintain efficiency and performance. In hydronic heating and cooling systems, balancing valves control water distribution across multiple terminals, while expansion valves in refrigeration systems meter refrigerant between compressor, condenser, and evaporator stages. For decades, Danfoss, headquartered in Nordborg, Denmark, has been a prominent manufacturer of such components, with production methods rooted in manual craftsmanship.
Until August 2020, assembling one particular valve type at Danfoss required seven operators performing repetitive overhead screwdriver motions at short intervals. This physically demanding work placed strain on shoulders and arms, raising ergonomic concerns. Seeking to improve working conditions and productivity, Danfoss partnered with Danish systems integrator BILA A/S to design and implement a robotic assembly cell.
The new cell integrates three duAro collaborative robots from Kawasaki Robotics alongside three human operators. The cobots handle repetitive, less complex tasks, while human workers focus on intricate assembly steps requiring precision and judgment. Four former assemblers have transitioned to other roles within the factory. “We have succeeded in eliminating some of the manual processes with monotonous and strenuous tasks that strain employees’ shoulders and arms,” stated Michael Breumsø, vice president of the refrigeration and air-conditioning supply chain at Danfoss. “This is the way forward: Robots can help ensure that industrial workers have a healthier work environment—one in which we can work in until we reach the age of 75.”
Employee reception of the technology has been positive, aided by early exposure to a duAro unit before full deployment. “It made a difference that a duAro cobot was provided to us early in the project, so that we could all see it before implementation. I think this helped to demystify the technology,” Breumsø noted.
Danfoss is among the first European manufacturers to adopt duAro cobots. The duAro platform features a SCARA configuration with two horizontal articulated arms sharing a single axis. Arms can operate independently or in coordinated motion, enabling simultaneous handling of separate components or synchronized tasks. Safety is embedded through low-power motors, soft body construction, and real-time collision detection that halts movement instantly upon contact. The duAro1 offers a 760 mm reach per arm, 150 mm Z-axis travel, ±0.05 mm repeatability, and 2 kg payload capacity per arm. The duAro2 extends reach to 785 mm, Z-axis travel to 550 mm, and payload to 3 kg per arm, with identical repeatability.
Mounted on a wheeled base housing the controller, the cobot can be programmed via direct teach—hand-guiding each arm—or through PC/tablet input of movement parameters. Breumsø emphasized the duAro’s advantages over conventional industrial robots: “The duAro robots are especially good for us, because they are less bulky than [conventional robots, which require shielding], and because they are faster than other cobots, since they have two arms. The cell is easy to monitor because it is not enclosed with a roof, Plexiglas, electronic safety net or soundproofing. This provides an open and flexible workflow and a good cycle time.”
The project’s timeline was notably compressed. Instead of Danfoss’ usual process—producing 70 to 80 pages of technical specifications and running a tender—the company asked BILA to propose a solution from the outset. “It was about making sure that we got the best possible technical solution, and not just the solution that we wanted to have,” Breumsø explained. This collaborative approach cut implementation time by three to six months and reduced administrative overhead.
Before commissioning, engineers from both companies assessed the factory for automation opportunities, identifying 20 potential optimizations. Four projects were selected, including the duAro valve assembly cell. Collectively, these initiatives boosted overall productivity by more than 10 percent within a year, with a projected two-year return on investment. The automation model is slated for replication at other Danfoss sites.
Peter Suhr, global key account manager for BILA, underscored the strategic role of cobots: “When many of the low-hanging fruits have been picked in terms of automation, then the next step is cobots, where some of the task can be automated and other parts are handled manually. This can really improve a manufacturer’s competitiveness in a global market.”