© Fraunhofer

Slide 1

Industrial Technologies 2012

Innovations in robotics towards intelligent, low-cost and universal tools in agile manufacturingFraunhofer-Institute for ManufacturingEngineering and Automation IPAMartin Hägelemmh@ipa.fraunhofer.deAarhus, June 19-21, 2012

© Fraunhofer

Slide 2

0

0,2

0,4

0,6

0,8

1

1,2

1990 1992 1994 1996 1998 2000 2002 2004 2006

USA

Germany

Unit price-Indexindustrial robot 1990=100%

Industrial Robot:

• 40% as of 1990

• Performance increase

- Speed

- Accuracy

- MTBF

- Maintenance

…

1,4 Cost-Index (1990=100%)Labor in Germany

Price Decrease in Industrial Robots

© Fraunhofer

Slide 3

Manual workplace

1

Fixed automation

2

Robot workcell

Units(Parts)/a

„Perfect Automation“

Cost reduction

43

Flexibilityincrease

Industrial Robotics Economies

100 1.000 10.000 100.000 1.000.000

Unit Costs

0,1

100

1.000

10

1

© Fraunhofer

Slide 4

Multi-robotWorkcell

Robot-Robot-Cooperation

Human-Robot-Cooperation

Trends in Robotics Configuration

© Fraunhofer

Slide 5

MManual

Workplace

ARoboticsWorkcell

Basic Prinicple of Human-Robot Cooperation

© Fraunhofer

Slide 6

CCooperative

Workcell

Principles of Human-Robot Cooperation

Cooperating robot

Assisting robot

Intuitive instructionDuring set-up, change-over and

maintenance

© Fraunhofer

Slide 7

ChangeoverProgrammingWorkcell costSensor equippedMaintenance

< once/day “on-line”, shop-floor ~1*robot unit price 100% Worker

< once/year “offline” ~4*robot unit price ~5% of installations Trained staff

Photos: KUKA-Roboter GmbH, SMErobot

Requirements of Future Robotic Designs

Slide 8

Three Major Innovations:1. Robot capable of understanding human-like instructions2. Safe and productive human-aware space-sharing robot3. Three-day-deployable integrated robot system• FP6 Integrated Project• 17 partners, major European robot manufacturers• Project runtime March 2005 - May 2009• www.smerobot.org

SMErobot: A Family of New Robots

Slide 9

Intuitive Instruction

New interaction devices and their use

Tactile guidanceGraphicsSpeech

Slide 10

Safe, Human-aware Space-sharing

Physically harmless and low-cost robot mechanics

Safe robot working without fences

Slide 11

The “3-day deployable” robot workcell

“Plug-and-Produce” Robot program generation bydistributed product-process data

EthernetnetworkEthernetnetwork

© Fraunhofer

Slide 12

A

M

Distance results in:

• Material flow equipment

• Parts presentation

• Lost process time due to serial flowparallelization

=DistanceHuman-Robot Cooperation

Dis

tan

ce

Cost-Benefit of Human-Robot Cooperation I

Parts

Parts

Dis

tan

ceAssemblyProduct

© Fraunhofer

Slide 13

„Reduce to the Max“:

• Focus intelligence on the robot (sensing, control)

• Use of human capabilities(Sensing, decision, …)

• Sharing of manual workplace resources

=Peripherals

Cost-Benefit of Human-Robot Cooperation II

Human-Robot Cooperation

Slide 14

Fronius MAG welding source

KUKA.SafeRobot

KR16 incl. sensor interface (RSI)

Handle/cockpit with F/T sensor, emergency stop, basic operating switches

Touch-screen incl. 3D simulation for interactive modification, optimization

Welding turntablecontrolled by robot

Headset for voicecommands

InTeach-Programming Environment

Safety sensor for detecting intrusive motion robot safety mode.

Slide 16

Test-Implementation: Efficiency Increase

Programming-Method: KCP /6D-Mouse InTeach Efficiency increase

Experienced programmer 16 min 15 min 6%

Non-expert programmer 1 35 min 10 min 71%

Non-expert programmer 2 26 min 12 min 54%

Apprentice 40 min 17 min 58%

Expert welder - 27 min -

Referencework piece

Referenceworkpiece

Slide 17Page 17

27,7%

4,3%

63,4%

1,1% 0,5%

Maintenance& Repair

Disposal

Investment

Initiation

Quality

Operation

Degre

e o

f uti

lizati

on

[%

]

50%

0 80 10060 40 20

100

20

40

60

80

Area: HRC workcellis most cost effective

Area: HRC workcell is cost ineffective

Net present value HRC workcell < 00<Net present value HRC<manual workcellNet present value HRC > manual workcell

Profitability: Manual vs. Human-Robot-Cooperative (HRC) workcells

Profitability: Manual vs. Human-Robot-Cooperative (HRC) workcells:

HRC workcell: Change-over vs operation time [%]

3,0%

Overall equipment efficiency (OEE)in dynamic settings is key:• Utilization ; Transformability “Lean”• Operation time : Efficient Instruction

© Fraunhofer

Slide 18

Human-RobotCooperation?

What about these workplaces?

Robot requirements:

• Symbiotic human-worker cooperation

• Robust bin picking

• Multiple assemblyprocess control

• Machine optimization and learning skills

• Operation of manualprocess equipment

• Low-cost

• Fast change-over

• Displaceable

Typical Kanbanassembly work places

Challeng

e

19

The SMErobotics Work System: Requirements

Ability to manage manufacturingtechnology

Ability to manage manufacturing

costs

Ability to manage manufacturing uncertainties

Automated just-in time programmegeneration technologies

Tools&wizzards fordifferent roles in

human assistance

Symbiotic hum

an-robot interaction

Reduction of required robot expert knowledge

Reduction of installation and operation costs

Learning from worker

Learning from robot

Requirements ofSMEs when usingrobotic systems

SMEroboticssolution paradigm

The SMEroboticswork system

Lean equipment for rapid changeover

Robust production by cognitive competences

Process adaptation and task learning

TCO-effectiveness under uncertainty

SMErobotics work system innovations

20

IT-Chain in SMErobotics: The contract manufacturing scenario

SME-suitable IT chain aligned with production

Symbiotic HRI

Feedback / learning

Formal model knowledge

Page 8 WP Definition

Job

21

IT-Chain in SMErobotics: The contract manufacturing scenario

Job

22

Partners of SMErobotics (FP7); www.smerobotics.org