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<p>The integration of industrial robots into complex manufacturing environments has accelerated under the paradigm of Industry 4.0, which leverages cyber-physical systems (CPS), the Internet of Things (IoT), and artificial intelligence (AI) to enhance automation, adaptability, and production efficiency. Robots now operate as critical enablers of smart, interconnected systems, but this transformation also introduces persistent challenges related to reliability, accuracy, uncertainty, human-machine collaboration, cybersecurity, and system interoperability. This review provides a comprehensive evaluation of the reliability and safety implications of industrial robotics across both Industry 4.0 and the emerging Industry 5.0 landscapes. Specifically, it (i) traces the technological evolution of robotic systems, (ii) examines their deployment in CPS, digital twins, collaborative robotics, and additive manufacturing, (iii) identifies key reliability concerns including accuracy degradation, thermal and dynamic errors, and AI-driven unpredictability, and (iv) explores future directions toward resilient, ethically aligned, and human-centric robotic systems. With more than 340 references cited, this review bridges the automation-centric goals of Industry 4.0 with the sustainable, inclusive vision of Industry 5.0, offering system-level insights for engineers, researchers, and decision-makers focused on enhancing the safety, dependability, and societal impact of next-generation manufacturing systems.</p>

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Smart industrial robots in the transition from automation to human-centric sustainable systems: a comprehensive review of technologies, challenges, and future directions

  • 期刊论文

  • 发表日期：

    2026年2月4日

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  • Mohamed Slamani,
  • Borhen Louhichi,
  • Mustapha Arslane,
  • Mohamad A. Alawad

摘要

The integration of industrial robots into complex manufacturing environments has accelerated under the paradigm of Industry 4.0, which leverages cyber-physical systems (CPS), the Internet of Things (IoT), and artificial intelligence (AI) to enhance automation, adaptability, and production efficiency. Robots now operate as critical enablers of smart, interconnected systems, but this transformation also introduces persistent challenges related to reliability, accuracy, uncertainty, human-machine collaboration, cybersecurity, and system interoperability. This review provides a comprehensive evaluation of the reliability and safety implications of industrial robotics across both Industry 4.0 and the emerging Industry 5.0 landscapes. Specifically, it (i) traces the technological evolution of robotic systems, (ii) examines their deployment in CPS, digital twins, collaborative robotics, and additive manufacturing, (iii) identifies key reliability concerns including accuracy degradation, thermal and dynamic errors, and AI-driven unpredictability, and (iv) explores future directions toward resilient, ethically aligned, and human-centric robotic systems. With more than 340 references cited, this review bridges the automation-centric goals of Industry 4.0 with the sustainable, inclusive vision of Industry 5.0, offering system-level insights for engineers, researchers, and decision-makers focused on enhancing the safety, dependability, and societal impact of next-generation manufacturing systems.