Mechanisms for ensuring the security of collaborative robot systems in industrial settings

Prakhar Goyal; Kothakonda Sairam; Nihar Ranjan Nayak; Sasanka Choudhury; A. Aranganathan; K. Suneetha; Gagan Tiwari

doi:10.31893/multirev.2025ss0106

Keywords:

industrial internet of things (IIoT)

cyber-physical vulnerabilities

role-based access control (RBAC)

intrusion

Abstract

Manufacturing is being revolutionized by Industrial Collaborative Robots (Cobots), which facilitate safe and effective human‒machine cooperation. Cobots are flexible, function without physical barriers, and integrate seamlessly into production lines, in contrast to traditional robots. The Industrial Internet of Things (IIoT) and cloud connection are driving their wider use. However, there are serious safety risks associated with this evolution, such as illegal access, data breaches, and operational interruptions. Because cybersecurity principles are not fully integrated into system architecture, cobots are still vulnerable despite progress. Poor IT and OT network segmentation, outdated firmware, a lack of real-time monitoring, and uneven safety standards are some of the main drawbacks. The majority of cobots are ill-equipped to handle complex threats like data poisoning and AI model modification. The purpose of this review is to analyse the security issues that collaborative robot systems are now facing and investigate workable solutions that guarantee operational integrity and safety in networked industrial settings. Cyber-physical vulnerabilities, current attack vectors (such as network spoofing and illegal firmware access), and security best practices are the main topics of the paper's thorough literature assessment. It combines results from industry case studies and scholarly research to pinpoint gaps and suggest solutions. Cobot-related dangers are considerably decreased by important strategies including network segmentation, role-based access control (RBAC), frequent patch management, intrusion detection systems (IDS), and physical security enforcement. Every method has its own benefits, ranging from limiting user permissions and separating risks to stopping malware from spreading and instantly identifying unusual activity. A multilayered protection approach integrating operational, technical, and physical precautions is necessary to secure collaborative robot systems. A proactive, coordinated strategy combining robotics engineers, cybersecurity specialists, and industry stakeholders is crucial to guaranteeing robust and reliable deployments as cobots become increasingly autonomous and integrated with external data sources.
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This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

How to cite

Goyal, P., Sairam, K., Nayak, N. R., Choudhury, S., Aranganathan , A., Suneetha, K., & Tiwari, G. (2025). Mechanisms for ensuring the security of collaborative robot systems in industrial settings. Multidisciplinary Reviews, 8, 2025ss0106. https://doi.org/10.31893/multirev.2025ss0106

[1] Ananias, E., & Gaspar, P. D. (2022). A low-cost collaborative robot for science and education purposes to foster the Industry 4.0 implementation. Applied System Innovation, 5(4), 72.

[2] Bi, Z. M., Luo, C., Miao, Z., Zhang, B., Zhang, W. J., & Wang, L. (2021). Safety assurance mechanisms of collaborative robotic systems in manufacturing. Robotics and Computer-Integrated Manufacturing, 67, 102022. https://doi.org/10.1016/j.rcim.2020.102022

[3] Bonci, A., Cen Cheng, P. D., Indri, M., Nabissi, G., & Sibona, F. (2021). Human-robot perception in industrial environments: A survey. Sensors, 21(5), 1571. https://doi.org/10.3390/s21051571

[4] Brandstötter, M., Berns, K., & Görges, D. (2020). Versatile collaborative robot applications through safety-rated modification limits. In K. Berns & D. Görges (Eds.), Advances in service and industrial robotics. RAAD 2019. Advances in Intelligent Systems and Computing (Vol. 980, pp. 485–493). Springer. https://doi.org/10.1007/978-3-030-19648-6_50

[5] Byner, C., Matthias, B., & Ding, H. (2019). Dynamic speed and separation monitoring for collaborative robot applications–concepts and performance. Robotics and Computer-Integrated Manufacturing, 58, 239–252. https://doi.org/10.1016/j.rcim.2018.11.002

[6] Diana, L., Dini, P., & Paolini, D. (2025). Overview of intrusion detection systems for computer networking security. Computers, 14(3), 87. https://doi.org/10.3390/computers14030087

[7] Fausto, A., Gaggero, G. B., Patrone, F., Girdinio, P., & Marchese, M. (2021). Toward the integration of cyber and physical security monitoring systems for critical infrastructures. Sensors, 21(21), 6970. https://doi.org/10.3390/s21216970

[8] Gualtieri, L., Rauch, E., & Vidoni, R. (2022). Development and validation of guidelines for safety in human-robot collaborative assembly systems. Computers & Industrial Engineering, 163, 107801. https://doi.org/10.1016/j.cie.2021.107801

[9] Khalid, A., Kirisci, P., Khan, Z. H., Ghrairi, Z., Thoben, K. D., & Pannek, J. (2018). Security framework for industrial collaborative robotic cyber-physical systems. Computers in Industry, 97, 132–145. https://doi.org/10.1016/j.compind.2018.02.009

[10] Kildal, J., Martín, M., Ipiña, I., & Maurtua, I. (2019). Empowering assembly workers with cognitive disabilities by working with collaborative robots: A study to capture design requirements. Procedia CIRP, 81, 797–802. https://doi.org/10.1016/j.procir.2019.03.202

[11] Levratti, A., Riggio, G., Fantuzzi, C., De Vuono, A., & Secchi, C. (2019). TIREBOT: A collaborative robot for the tire workshop. Robotics and Computer-Integrated Manufacturing, 57, 129–137. https://doi.org/10.1016/j.rcim.2018.11.001

[12] Liu, Z., Wang, X., Cai, Y., Xu, W., Liu, Q., Zhou, Z., & Pham, D. T. (2020). Dynamic risk assessment and active response strategy for industrial human-robot collaboration. Computers & Industrial Engineering, 141, 106302. https://doi.org/10.1016/j.cie.2020.106302

[13] Ma, X., Mao, C., & Liu, G. (2022). Can robots replace human beings?—Assessment of the developmental potential of construction robots. Journal of Building Engineering, 56, 104727. https://doi.org/10.1016/j.jobe.2022.104727

[14] Magalhaes, P., & Ferreira, N. (2022). Inspection application in an industrial environment with collaborative robots. Automation, 3(2), 258–268. https://doi.org/10.3390/automation3020013

[15] Manikandan, B., Ganesh Kumar, G., Kanakaprabha, S., Vijaya Kumar Reddy, R., & Janani, R. (2025). Blockchain technology for the cobot's cybersecurity issues. In Intelligent robots and cobots: Industry 5.0 applications (pp. 377–399). Wiley. https://doi.org/10.1002/9781394198252.ch18

[16] Matheson, E., Minto, R., Zampieri, E. G., Faccio, M., & Rosati, G. (2019). Human–robot collaboration in manufacturing applications: A review. Robotics, 8(4), 100. https://doi.org/10.3390/robotics8040100

[17] Mhaskar, N., Alabbad, M., & Khedri, R. (2021). A formal approach to network segmentation. Computers & Security, 103, 102162. https://doi.org/10.1016/j.cose.2020.102162

[18] Mugarza, I., Flores, J. L., & Montero, J. L. (2020). Security issues and software update management in the industrial Internet of Things (IoT) era. Sensors, 20(24), 7160. https://doi.org/10.3390/s20247160

[19] Muppalaneni, R., Inaganti, A. C., Ravichandran, N., & Nersu, S. R. K. (2025). AI-powered role-based access control (RBAC): Automating policy enforcement in enterprise environments. Journal of Advanced Computing Systems, 5(2), 1–12.

[20] Pal, A., Restrepo, V., Goswami, D., & Martinez, R. V. (2021). Exploiting mechanical instabilities in soft robotics: Control, sensing, and actuation. Advanced Materials, 33(19), 2006939. https://doi.org/10.1002/adma.202006939

[21] Pizoń, J., Cioch, M., Kański, Ł., & Sánchez-García, E. (2022). Cobots implementation in the era of Industry 5.0 using modern business and management solutions. Advances in Science and Technology Research Journal, 16(6), 166–178. https://doi.org/10.12913/22998624/156222

[22] Taesi, C., Aggogeri, F., & Pellegrini, N. (2023). COBOT applications—recent advances and challenges. Robotics, 12(3), 79. https://doi.org/10.3390/robotics12030079

[23] Tasooji, T. K., & Marquez, H. J. (2022). A secure decentralized event-triggered cooperative localization in multi-robot systems under cyber attack. IEEE Access, 10, 128101–128121. https://doi.org/10.1109/ACCESS.2022.3227076

Abstract

References

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