© Fraunhofer Slide 1 Industrial Technologies 2012 Innovations in robotics towards intelligent, low- cost and universal tools in agile manufacturing Fraunhofer-Institute for Manufacturing Engineering and Automation IPA Martin Hägele Aarhus, June 19-21, 2012

© Fraunhofer Slide 2 0 0,2 0,4 0,6 0,8 1 1, USA Germany Unit price-Index industrial 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 4 3 Flexibility increase Industrial Robotics Economies Unit Costs 0,

© Fraunhofer Slide 4 Multi-robot Workcell Robot-Robot- Cooperation Human-Robot- Cooperation Trends in Robotics Configuration

© Fraunhofer Slide 5 Basic Prinicple of Human-Robot Cooperation

© Fraunhofer Slide 6 Principles of Human-Robot Cooperation Cooperating robot Assisting robot Intuitive instruction During set-up, change-over and maintenance

© Fraunhofer Slide 7 Changeover Programming Workcell cost Sensor equipped Maintenance < 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 instructions 2. Safe and productive human-aware space-sharing robot 3. Three-day-deployable integrated robot system FP6 Integrated Project 17 partners, major European robot manufacturers Project runtime March May SMErobot: A Family of New Robots

Slide 9 Intuitive Instruction New interaction devices and their use Tactile guidance Graphics Speech

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 by distributed product-process data Ethernet network Ethernet network

© Fraunhofer Slide 12 A M Distance results in: Material flow equipment Parts presentation Lost process time due to serial flow parallelization =Distance Human-Robot Cooperation Distance Cost-Benefit of Human-Robot Cooperation I Parts Distance Assembly Product

© 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 turntable controlled by robot Headset for voice commands InTeach-Programming Environment Safety sensor for detecting intrusive motion robot safety mode.

Slide 15 Steps in Interaction Motion data KRL-Program Programming Lead-through motion instructions voice command (motion, process parameters) Actuation of switches on cockpit Lead-through motion instructions voice command (motion, process parameters) Actuation of switches on cockpit Post-Processing Graphics based optimization: process motion parameters Graphics based optimization: process motion parameters Task execution No interaction

Slide 16 Test-Implementation: Efficiency Increase Programming-Method:KCP /6D- Mouse InTeachEfficiency increase Experienced programmer16 min15 min6% Non-expert programmer 135 min10 min71% Non-expert programmer 226 min12 min54% Apprentice40 min17 min58% Expert welder-27 min- Reference work piece

Slide 17Page 17 27,7% 4,3% 63,4% 1,1%0,5% Maintenance & Repair Disposal Investment Initiation Quality Operation Degree of utilization [%] 50% Area: HRC workcell is most cost effective Area: HRC workcell is cost ineffective Net present value HRC workcell < 0 0<Net present value HRC<manual workcell Net 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-Robot Cooperation? What about these workplaces? Robot requirements: Symbiotic human- worker cooperation Robust bin picking Multiple assembly process control Machine optimization and learning skills Operation of manual process equipment Low-cost Fast change-over Displaceable Robot requirements: Symbiotic human- worker cooperation Robust bin picking Multiple assembly process control Machine optimization and learning skills Operation of manual process equipment Low-cost Fast change-over Displaceable Typical Kanban assembly work places Challenge

19 The SMErobotics Work System: Requirements Ability to manage manufacturing technology Ability to manage manufacturing costs Ability to manage manufacturing uncertainties Automated just- in time programme generation technologies Tools&wizzards for different roles in human assistance Symbiotic human-robot interaction Reduction of required robot expert knowledge Reduction of installation and operation costs Learning from worker Learning from robot Requirements of SMEs when using robotic systems SMErobotics solution paradigm The SMErobotics work 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);