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Robotics

Physical robotics integration with Tallyfy

Tallyfy bridges the gap between physical robots and workflow management. Robots can query process documentation, mark tasks complete, and enable real-time visibility into automated operations - creating seamless human-robot collaboration.

Diagram

What to notice:

  • Robots communicate through standard industrial protocols (OPC UA, ROS, MQTT)
  • Tallyfy provides queryable documentation that robots can follow
  • Task completion happens automatically as robots perform work

How robots interact with Tallyfy

Industrial robots and collaborative robots (cobots) connect to Tallyfy through middleware that translates between industrial protocols and REST APIs. Here’s the typical flow:

  1. Robot queries documentation - Before starting work, the robot requests its current task instructions from Tallyfy using GET /api/v1/tasks/{id}
  2. Process execution - The robot performs physical operations following the retrieved instructions
  3. Status reporting - As work progresses, the robot sends updates: PATCH /api/v1/tasks/{id}/complete
  4. Exception handling - If issues arise, robots can pause tasks or request human intervention

The magic happens through protocol translation. Your robot speaks OPC UA or ROS, while Tallyfy speaks REST. A lightweight middleware service (often running on an edge server near the robot) handles this translation.

Supported robot communication protocols

OPC UA (Open Platform Communications Unified Architecture)

Most industrial robots from ABB, KUKA, FANUC, and Siemens support OPC UA. This protocol provides secure, reliable communication with built-in data modeling. Connect through standard OPC UA clients that translate robot states to Tallyfy API calls.

ROS/ROS2 (Robot Operating System)

Open-source robotics middleware used by research institutions and modern collaborative robots. ROS nodes can directly call Tallyfy’s REST API using standard HTTP libraries. The ROS2 DDS layer ensures reliable message delivery even in unstable network conditions.

MQTT (Message Queuing Telemetry Transport)

Lightweight protocol perfect for IoT-enabled robots and cobots. MQTT brokers can forward robot telemetry to Tallyfy webhooks, enabling event-driven task updates. Popular with Universal Robots and smaller collaborative systems.

Custom protocols via edge computing

Legacy robots using proprietary protocols connect through edge computing devices (like industrial PCs or gateways) that translate between the robot’s native language and Tallyfy’s API.

Implementation architecture

Basic integration setup

{
"robot_id": "UR10e_Cell_4",
"tallyfy_config": {
"api_endpoint": "https://api.tallyfy.com/v1",
"auth_token": "Bearer {token}",
"process_id": "warehouse_picking_abc123",
"webhook_url": "https://factory.example.com/robot-events"
},
"protocol_config": {
"type": "opcua",
"server": "opc.tcp://192.168.1.10:4840",
"update_interval_ms": 1000
}
}

Task documentation structure for robots

Tallyfy stores structured instructions that robots can parse and execute. Each task includes:

  • Operation parameters - Speed, force, positions, tolerances
  • Safety boundaries - Keep-out zones, speed limits near humans
  • Quality checks - Measurement points, acceptance criteria
  • Error recovery - What to do when things go wrong
  • Handoff points - When to involve human operators

Real-time progress tracking

As robots work, they continuously update task status:

  1. Task started - Robot begins operation, marks task “in_progress”
  2. Milestone updates - Reports completion percentages (25%, 50%, 75%)
  3. Quality data - Sends measurement results, vision inspection outcomes
  4. Task completion - Marks done with final quality metrics
  5. Exception reporting - Flags issues requiring human intervention

This creates complete visibility into robotic operations. Plant managers see exactly which robots are working on what, current progress, and any bottlenecks - all through Tallyfy’s dashboard.

Human-robot collaboration workflows

Modern manufacturing increasingly relies on humans and robots working together. Tallyfy orchestrates these collaborative workflows by managing handoffs and ensuring safety compliance.

Typical collaborative scenarios

Assembly operations: Robot performs heavy lifting and precise positioning while human handles delicate components. Tallyfy tracks which tasks are robot-assigned versus human-assigned, ensuring smooth transitions.

Quality inspection: Robot performs initial measurements, flags anomalies for human review. Human inspectors receive notifications in Tallyfy when their expertise is needed.

Maintenance workflows: Robots run diagnostic routines and report issues. Maintenance technicians get assigned tasks with detailed robot-generated diagnostic data.

Safety compliance and ISO standards

Integration follows ISO 10218-1:2025 requirements for collaborative applications. Tallyfy maintains audit trails showing:

  • Who (human or robot) performed each task
  • Safety validations completed before robot operations
  • Speed and force limiting compliance during collaboration
  • Emergency stop events and recovery procedures
  • Cybersecurity measures protecting robot control systems

Setting up robot integration

Prerequisites

  • Tallyfy organization with API access enabled
  • Robot controller with network connectivity
  • Edge server or industrial PC for protocol translation
  • IT/OT network bridge configured for secure communication

Step-by-step implementation

  1. Generate API credentials in Tallyfy organization settings
  2. Install middleware on edge server (options include Node-RED, Kepware, or custom service)
  3. Configure robot communication - Set up OPC UA server or ROS nodes on robot controller
  4. Map robot operations to tasks - Define which robot programs correspond to Tallyfy tasks
  5. Test in simulation - Verify API calls work correctly before live deployment
  6. Deploy with safety validation - Ensure all safety systems active during integration testing
  7. Monitor and optimize - Use Tallyfy analytics to identify bottlenecks and optimize cycle times

Advanced automation patterns

Event-driven robot triggering

// Webhook receiver for robot activation
app.post('/webhook/tallyfy', async (req, res) => {
const { task_id, action, metadata } = req.body;
if (action === 'task_ready' && metadata.robot_capable) {
// Trigger robot program
await robotController.startProgram({
program: metadata.robot_program,
parameters: metadata.operation_params,
task_id: task_id
});
}
res.status(200).send('Robot triggered');
});

Multi-robot coordination

When multiple robots work on the same process, Tallyfy manages dependencies and prevents conflicts. Robot A completes welding, triggering Robot B to start painting - all coordinated through task dependencies in Tallyfy.

Predictive maintenance integration

Robots report operational metrics (cycle counts, motor temperatures, vibration levels) as task metadata. Tallyfy’s automation rules trigger maintenance tasks when thresholds are exceeded, preventing unexpected downtime.

Industry applications

Manufacturing and assembly

  • Automotive production lines with mixed human-robot stations
  • Electronics assembly with collaborative pick-and-place operations
  • Furniture manufacturing with CNC machines and robot finishing

Warehouse and logistics

  • Autonomous mobile robots (AMRs) for inventory movement
  • Robotic picking systems with human packing stations
  • Automated guided vehicles (AGVs) coordinated with loading crews

Food and pharmaceutical

  • Robotic packaging lines with human quality control
  • Cleanroom operations with minimal human presence
  • Batch processing with automated sampling and testing

Healthcare and laboratory

  • Surgical robots with procedure documentation
  • Laboratory automation with sample tracking
  • Pharmacy robots dispensing medications

Benefits of robot-Tallyfy integration

Complete process visibility - See exactly what robots and humans are doing in real-time. No more walking the floor to check robot status.

Automatic documentation - Every robot action is logged with timestamps, creating comprehensive audit trails for compliance and continuous improvement.

Flexible work allocation - Dynamically assign tasks to robots or humans based on availability, capabilities, and current workload.

Rapid exception handling - When robots encounter issues, the right human expert gets notified immediately with all diagnostic data.

Performance analytics - Compare cycle times between robots, identify bottlenecks, and optimize workflows using actual production data.

Seamless scaling - Add new robots or production cells without disrupting existing workflows. Just configure the new robot to query Tallyfy for its tasks.

Security considerations

Network segregation

Keep robot control networks (OT) separated from business networks (IT) using DMZ architecture. Tallyfy API calls happen through secured gateways, never direct robot-to-internet connections.

Authentication and authorization

Use separate API credentials for each robot or production cell. Implement role-based access control limiting robots to specific processes and tasks. Rotate tokens regularly and monitor for unusual activity patterns.

Data encryption

All communication between robots and Tallyfy uses TLS encryption. Store sensitive operation parameters and quality data using field-level encryption in Tallyfy.

Fail-safe mechanisms

Robots must maintain local operation capability if Tallyfy connection is lost. Implement store-and-forward patterns to sync data once connectivity restores. Never make safety systems dependent on cloud connectivity.

Vendor-specific integration guides

We’ve conducted deep analysis of major robotics platforms to identify how Tallyfy fills critical gaps in their workflow management capabilities. Each vendor page provides:

  • Current capabilities and limitations analysis
  • Specific workflow gaps and how Tallyfy addresses them
  • Technical integration architecture
  • Real-world use cases and ROI calculations
  • Implementation roadmaps

Robotics vendor ecosystem

We’re analyzing the entire robotics ecosystem to show how Tallyfy addresses critical workflow gaps across all major vendors and applications:

Industrial manufacturing robots

  • Universal Robots - 75,000+ collaborative robots lacking dynamic SOPs
  • KUKA - KRL file-based robots with zero adaptability
  • ABB Robotics (coming soon) - RobotStudio and ABB Ability platform
  • FANUC (coming soon) - FIELD platform and CNC synchronization
  • Yaskawa Motoman (coming soon) - MLX300 controller integration

Mobile inspection robots

  • Boston Dynamics - Extend Spot’s static missions with adaptive procedures
  • Unitree Robotics - Transform $1,600 quadrupeds into knowledge-driven fleets
  • ANYbotics (coming soon) - ANYmal industrial inspection workflows

Warehouse & logistics AMRs

  • Fetch Robotics/Zebra (coming soon) - Symmetry platform workflow orchestration
  • Locus Robotics (coming soon) - LocusONE multi-bot coordination
  • 6 River Systems (coming soon) - Chuck robot fleet management
  • Geek+ (coming soon) - RoboShuttle and sorting robots
  • Mobile Industrial Robots (MiR) (coming soon) - Fleet management integration

Agricultural robots

  • Harvest Automation (coming soon) - Greenhouse material handling
  • FarmWise (coming soon) - Precision weeding workflows
  • Blue River Technology (coming soon) - See & Spray procedures
  • Burro (coming soon) - Autonomous harvest support

Medical & surgical robots

  • Intuitive Surgical (coming soon) - da Vinci surgical procedure management
  • Stryker Mako (coming soon) - Orthopedic surgery workflows
  • CMR Surgical (coming soon) - Versius modular procedures

Humanoid robots (emerging)

  • Figure AI (coming soon) - Figure 02 manufacturing SOPs
  • Agility Robotics (coming soon) - Digit warehouse workflows
  • Tesla Optimus (planned) - General-purpose task management
  • Sanctuary AI (planned) - Phoenix human-like manipulation

What all vendors are missing

After analyzing 20+ major robotics platforms, we’ve identified universal gaps:

No living knowledge base: Robots can’t query “how to” for unfamiliar tasks No cross-robot learning: Improvements stay isolated to individual units No audit trails: Can’t prove which procedures were followed for compliance No version control: SOPs don’t evolve based on operational experience No exception workflows: No structured escalation when robots encounter edge cases

Getting started

Ready to connect your robots to Tallyfy? Start with a pilot project:

  1. Choose a simple process - Pick one robot performing repetitive tasks
  2. Review vendor guide - Check our vendor-specific integration documentation
  3. Document the workflow - Create the process template in Tallyfy
  4. Implement basic integration - Start with just task completion reporting
  5. Validate and expand - Once proven, add more robots and complex workflows

Contact Tallyfy support for robotics integration guidance and example middleware configurations for your specific robot models.

The critical gap: Living SOPs for robotic operations

What robot vendors provide vs. what’s missing

After deep analysis of major robotics platforms, we’ve identified a critical gap across the entire industry. While robot manufacturers excel at hardware control and low-level programming, they universally lack comprehensive workflow management for real-world commercial operations.

What vendors provide:

  • Hardware control: SDKs for movement, sensors, manipulation
  • Programming interfaces: Visual programming, scripting languages, simulation tools
  • Basic task execution: Simple sequential operations, point-to-point navigation
  • Fleet monitoring: Location tracking, battery status, error reporting

What’s consistently missing:

  • Living SOP repository: Dynamic procedures that evolve with operational experience
  • Cross-robot knowledge sharing: Learnings from one robot improving all robots
  • Human-robot workflow integration: Seamless handoffs between automated and manual tasks
  • Compliance documentation: Audit trails showing exactly what procedures robots followed
  • Procedure versioning: Track how SOPs change over time based on real-world feedback
  • Exception handling workflows: Structured escalation when robots encounter edge cases

Three core ways robots use Tallyfy

1. Knowledge lookup: “How do I do this?”

When robots encounter tasks they haven’t been explicitly programmed for, they query Tallyfy’s knowledge base for procedures. Instead of failing or requiring reprogramming, robots dynamically fetch instructions.

Example scenario: A Unitree Go2 robot assigned to inspect solar panels encounters a new panel type. It queries Tallyfy: “How to inspect Tesla Solar Roof tiles?” and receives step-by-step inspection procedures including measurement points, photo angles, and defect criteria.

2. Continuous improvement: “I found a better way”

Robots don’t just consume procedures - they improve them. When robots discover optimizations or encounter edge cases, they update Tallyfy with enhanced procedures, photos, videos, and performance data.

Example scenario: A Boston Dynamics Spot robot performing pipeline inspections discovers that approaching valves from a 45-degree angle reduces inspection time by 30%. It updates the SOP in Tallyfy with video evidence, and all other Spot robots immediately benefit from this optimization.

3. Real-time tracking: “Here’s what I’m doing”

Robots launch processes in Tallyfy and update task status in real-time, creating comprehensive audit trails. Every action is logged with timestamps, sensor data, and outcomes - critical for compliance and continuous improvement.

Example scenario: A Universal Robots cobot assembling medical devices launches a process for each batch. It marks each assembly step complete with torque measurements, vision inspection results, and cycle times. Quality managers see real-time progress and have complete traceability for FDA compliance.

How the three capabilities work together

Diagram

What to notice:

  • Each robot interaction creates valuable data for the organization
  • Managers have complete visibility into robotic operations
  • Knowledge continuously improves across the entire fleet

Vendor-specific integration roadmap (Planned)

After extensive research and strategic planning, here’s our roadmap for integrating with major robotics vendors across B2B industrial and consumer sectors. These integrations are currently in planning phase, with implementation prioritized based on customer demand and technical feasibility.

Industrial robot integrations (B2B)

FANUC Corporation

Market position: 11% global market share, over 750,000 robots installed worldwide Integration approach:

  • Primary protocol: FANUC’s FIELD (FANUC Intelligent Edge Link and Drive) platform
  • Secondary: Direct OPC UA server integration via FANUC Robot Interface
  • Tallyfy connector: Native FIELD app publishing to FANUC app marketplace
  • Key features: CNC synchronization, multi-robot cell coordination, predictive maintenance triggers
  • Timeline: Q2 2026 for pilot customers

ABB Robotics

Market position: $402B market cap, 500,000+ robots deployed globally Integration approach:

  • Primary protocol: ABB Ability platform with OPC UA Robotics Companion
  • Secondary: RobotStudio SDK for simulation-based testing
  • Tallyfy connector: ABB Ability marketplace application
  • Key features: RobotWare integration, SafeMove2 safety validation, OmniCore controller support
  • Special capability: Direct integration with ABB’s IoT Gateway for MQTT/OPC UA bridging
  • Timeline: Q1 2026 for early access

KUKA AG

Market position: Leader in automotive robotics, 500kg payload capacity Integration approach:

  • Primary protocol: KUKA.Connect cloud platform via REST APIs
  • Secondary: KRL (KUKA Robot Language) extensions for direct control
  • Tallyfy connector: iiQoT (KUKA’s IIoT platform) module
  • Key features: KUKA.Sim integration for offline programming, smartPAD teach pendant notifications
  • Timeline: Q3 2026 for select industries

Universal Robots (Teradyne)

Market position: Collaborative robot leader, 75,000+ cobots deployed Integration approach:

  • Primary protocol: UR+ platform with URCap plugin architecture
  • Secondary: Real-time data exchange via RTDE (Real-Time Data Exchange)
  • Tallyfy connector: Published URCap in UR+ ecosystem
  • Key features: Polyscope UI integration, force/torque feedback logging, safety plane configuration
  • Special focus: No-code integration for SMB manufacturers
  • Timeline: Q4 2025 pilot program

Yaskawa Motoman

Market position: 8% market share, leader in arc welding applications Integration approach:

  • Primary protocol: MLX300 controller with Ethernet/IP
  • Secondary: MotoPlus SDK for custom applications
  • Tallyfy connector: i3-Mechatronics digital solution integration
  • Key features: Smart Pendant app, multi-robot synchronization, vision system coordination
  • Timeline: Q2 2026 for pilot customers

Emerging industrial platforms

Unitree Robotics (China)

Market position: Fastest growing quadruped manufacturer, G1 humanoid at $16k Current capabilities:

  • Hardware excellence: Go2 ($1,600), B2 industrial, G1 humanoid ($16k)
  • SDKs: unitree_sdk2 (C++), unitree_sdk2_python, ROS/ROS2 packages
  • Simulation: MuJoCo, Isaac Lab integration
  • Use cases: Power inspection, fire rescue, research

Critical gaps identified:

  • No SOP management: Robots lack access to standardized operational procedures
  • No workflow sequencing: Complex multi-step operations require custom coding
  • No knowledge sharing: Each robot operates in isolation without learning transfer
  • Limited commercial tooling: Focus on research/simulation vs. production deployment
  • No audit trails: No record of what procedures robots followed for compliance

Tallyfy integration approach:

  • Primary protocol: unitree_sdk2 with Python bindings connecting to Tallyfy REST API
  • Secondary: ROS2 integration via unitree_ros2 for distributed deployments
  • Tallyfy connector: Middleware service translating between SDK and Tallyfy’s workflow engine
  • Key features:
    • Go2/B2/H1 robots query Tallyfy for inspection checklists
    • Real-time SOP updates pushed to all deployed units
    • Exception reporting when robots encounter undefined scenarios
    • Automatic documentation of completed procedures for compliance
  • Special capability: Educational institutions can share procedure libraries across research teams
  • Timeline: Q1 2026 beta program

Boston Dynamics

Market position: 1,500+ Spot robots deployed, premium industrial segment Integration approach:

  • Primary protocol: Spot SDK with gRPC-based API
  • Secondary: Network Compute Bridge for ML model integration
  • Tallyfy connector: Spot API client library extension
  • Key features: Manipulation API for arm control, autowalk mission integration, payload coordination
  • Special focus: Inspection and surveillance workflow templates
  • Timeline: Q3 2026 for enterprise customers

Agility Robotics

Market position: Digit humanoid for logistics, Amazon partnership Integration approach:

  • Primary protocol: Agility Cloud API (under development)
  • Secondary: ROS2-based control interface
  • Tallyfy connector: Warehouse management system bridge
  • Key features: Package handling workflows, dynamic path planning, human collaboration zones
  • Timeline: Q4 2026 aligned with commercial deployment

Consumer robot integrations

iRobot (Amazon)

Market position: 50 million Roomba units sold, market leader in home robotics Integration approach:

  • Primary protocol: iRobot Home app API (limited access)
  • Secondary: Matter/Thread smart home integration
  • Tallyfy connector: Smart home hub integration via AWS IoT Core
  • Key features: Cleaning schedule coordination, room-specific task assignment, maintenance reminders
  • Consumer benefit: Integrate cleaning into home routines and checklists
  • Timeline: Q2 2026 pending API access approval

Tesla Optimus

Market position: Planned sub-$20k humanoid, leveraging FSD technology Integration approach:

  • Primary protocol: Tesla API (anticipated, based on vehicle API patterns)
  • Secondary: Local network control via Tesla app framework
  • Tallyfy connector: Tesla Fleet API integration (when available)
  • Key features: Task learning from demonstrations, natural language instructions, safety zones
  • Special capability: Integration with Tesla Energy for optimized charging schedules
  • Timeline: 2027+ aligned with consumer availability

Amazon Astro

Market position: $1,449 home monitoring robot, Ring ecosystem integration Integration approach:

  • Primary protocol: Alexa Skills Kit with Astro-specific APIs
  • Secondary: AWS IoT Events for automation triggers
  • Tallyfy connector: Published Alexa skill with Astro capabilities
  • Key features: Patrol route workflows, visitor check-in processes, medication reminders
  • Timeline: Q3 2025 pilot with select customers

Anki Vector (Digital Dream Labs)

Market position: Consumer companion robot, community-driven development Integration approach:

  • Primary protocol: Vector SDK (Python) with cloud API
  • Secondary: Local REST API via Vector Explorer
  • Tallyfy connector: Community-maintained integration
  • Key features: Reminder notifications, simple task confirmations, presence detection
  • Timeline: Q4 2025 as open-source project

Educational and research platforms

DJI RoboMaster

Market position: Leading educational robotics platform in Asia Integration approach:

  • Primary protocol: RoboMaster SDK with competition framework
  • Secondary: DJI Assistant 2 for programming
  • Tallyfy connector: Educational workflow templates
  • Key features: Competition task management, team collaboration, skill assessment tracking
  • Timeline: Q1 2026 for educational institutions

Figure AI

Market position: Figure 02 humanoid, BMW manufacturing partnership Integration approach:

  • Primary protocol: Proprietary API (under development)
  • Secondary: Industrial Ethernet protocols
  • Tallyfy connector: Manufacturing execution system (MES) bridge
  • Key features: Assembly line integration, quality inspection workflows, training mode capture
  • Timeline: 2027+ aligned with production deployment

Integration architecture patterns

Each vendor integration follows a three-layer approach:

  1. Protocol layer - Native robot communication (OPC UA, ROS, proprietary SDKs)
  2. Translation layer - Tallyfy middleware converting robot data to workflow events
  3. Orchestration layer - Tallyfy managing tasks, dependencies, and human handoffs

Development priorities

Our integration roadmap prioritizes based on:

  • Customer demand - Direct requests from enterprise customers
  • Technical readiness - Vendor API maturity and documentation quality
  • Market impact - Number of deployed robots and growth trajectory
  • Safety compliance - ISO standard adherence and certification requirements
  • ROI potential - Clear value proposition for workflow automation

Partnership opportunities

We’re actively seeking partnerships with:

  • System integrators specializing in robotics deployment
  • Robot manufacturers interested in workflow orchestration
  • Industrial IoT platforms for protocol translation
  • Educational institutions for research collaborations
  • Safety certification bodies for compliance validation

This roadmap represents our current planning based on market research and customer feedback. Actual implementation timelines may vary based on vendor cooperation, technical challenges, and market conditions.

Robotics > Unitree Robotics integration

Unitree has revolutionized robotics with affordable quadrupeds and humanoids but lacks the operational workflow layer needed for commercial deployments where Tallyfy fills critical gaps in knowledge lookup continuous improvement and real-time tracking that current hardcoded programming approaches cannot address.

Robotics > Universal Robots integration

Universal Robots cobots excel at hardware integration through PolyScope X and URCaps but lack dynamic SOP management and knowledge sharing capabilities that Tallyfy provides through seamless URCap integration enabling real-time procedure queries cross-robot learning and comprehensive compliance documentation for enterprise-scale collaborative robotics deployments.

Robotics > Boston Dynamics integration

Boston Dynamics Spot robots excel at mission recording and playback through Orbit software but lack dynamic procedure management and knowledge sharing capabilities that Tallyfy provides through real-time SOP queries cross-robot learning and compliance documentation for truly adaptive autonomous operations.

Open Api > Combining RPA systems and human operators

Tallyfy serves as an orchestration layer that seamlessly connects RPA systems with human workflows to create comprehensive end-to-end process automation while maintaining complete visibility and accountability across both automated and manual tasks.