The use of collaborative assembly systems makes it possible to increasingly eliminate the strict separation between rigid automation and manual assembly. While in the past the question of the extent to which human work can be replaced by robots was often discussed, collaborative systems offer the possibility of providing individual support to skilled workers in ergonomically unfavorable or monotonous work steps. There is currently a great deal of uncertainty about the resulting economic efficiency of innovative, collaborative workplace systems. The direct savings potential is offset by high, one-off investment costs. The introduction of collaborative assembly systems places specific demands on the selection of suitable robots, workplace design and employee skills, which companies must analyze in advance. In order to simplify the introduction and operation of collaborative assembly workstations, the KoKoMo research project ("Consolidation of life cycle information for the collaborative assembly of multi-variant products") uses information consolidation to feed back and integrate the operating data of corresponding assembly systems and product data of the products to be manufactured into planning systems. The possibility of flexibly adapting these processes to new product variants by transferring process knowledge about similarities and optimally integrating human and robot capabilities is the central starting point. The aim of the project is to distribute the tasks to the highest possible degree in an automated and skill-based manner to the human and robot resources depending on the respective batch size.

The eleven-partner consortium of the KoKoMo project includes three application partners, each of which has different requirements for collaborative assembly. What the products to be assembled have in common is that a large number of variants exist due to configurations, which means that batch sizes of one to several hundred are produced. The assembly of all three products is currently carried out entirely manually. Euchner, a company involved in the project as a user, is planning to make the production of door locking systems collaborative in the future. At Lenze, a special work step for adjusting the gear backlash of bevel gearboxes is being tested for collaborative capability. The third use case comes from KSB and relates to the assembly of running parts for sewage lifting units. The use cases contain typical assembly tasks, including in particular joining, screwing, pressing, applying media, testing and crimping. The process steps represent a wide range of requirements in terms of skill, precision and strength.

Augmented reality teach-in of a collaborative robot without gripper. (Image: bime, Patrick Rückert)

To validate the methods developed in the research project, a demonstrator adapted to the requirements of the application partners is being created at the WZL machine tool laboratory at RWTH Aachen University. The basis is a manual workstation with touchscreens for human-machine interaction. A Kuka LBR iiwa, all derivatives of Universal Robots, the Franka Emika robot and an APAS from Bosch are available as collaborative robots, which are enabled to perform various tasks such as joining, screwing, dosing/application or testing by means of a tool changing system. The physical demonstrator is complemented by various IT systems that interact with each other when integrated into a PLM concept with a standardized database. This enables continuous planning from product design to assembly by humans and robots.

With the aim of being able to test the real requirements of collaborative assembly processes in a virtual environment in advance, a virtual demonstrator is being developed at the Bremen Institute of Structural Mechanics and Production Systems (bime). Virtual and augmented reality systems are being used to test collaborative application scenarios and coupled with a physical simulation. By linking the robot controller to a real-time simulation, processes can be virtually validated and concepts can be examined at an early stage with regard to their feasibility and cost-effectiveness. In this way, demand-oriented training of employees can be carried out in a virtual and risk-free environment in order to create acceptance for collaborative robotics and to reveal and reduce fears of new technologies. This approach serves to sustainably ensure efficient and high-quality service provision by employees in the company. pb

Bremen Institute of Structural Mechanics and Production Systems (bime)

Briefly explained: The bime
The Bremen Institute of Structural Mechanics and Production Systems (bime) is an institute of the University of Bremen in the Faculty of Production Engineering - Mechanical and Process Engineering. Kirsten Tracht, develop solution concepts for the production of complex products in increasingly networked and agile environments. In addition to the development and operation of production systems, the design of assembly processes, the design of handling devices and the modularization of production systems and equipment are the subject of the research work.(www.bime.de)

Machine Tool Laboratory WZL of RWTH Aachen University

Briefly explained: The Machine Tool Laboratory
For decades, the Laboratory for Machine Tools and Production Engineering (WZL) at RWTH Aachen University has been synonymous worldwide with successful and forward-looking research and innovation in the field of production technology. In six research areas, both basic research projects and research projects geared to the requirements of industry are carried out. In addition, practical solutions for the rationalization of production are developed. The Machine Tool Laboratory is headed by the four professors Christian Brecher, Fritz Klocke, Robert Schmitt and Günther Schuh.(www.wzl.rwth-aachen.de)

Scientific Society for Assembly, Handling and Industrial Robotics (MHI e.V.)

Briefly explained: The MHI e.V.
The Wissenschaftliche Gesellschaft für Montage, Handhabung und Industrierobotik e.V. (MHI e.V.) is a network of renowned university professors - institute directors and chair holders - from German-speaking countries. The members conduct both fundamental and application-oriented research on a wide range of current topics in the fields of assembly, handling and industrial robotics. Further information on the society, its members and activities: www.wgmhi.de.