With the aim of testing human-robot collaboration in advance, a virtual environment for the simulation and training of collaborative assembly scenarios was implemented at the Bremen Institute of Structural Mechanics and Production Systems (bime). Here, a real workplace is virtually simulated and the assembly operations of humans and robots are transferred to an interactive simulation in virtual reality (VR). Virtual testing can thus reveal potential problem areas at an early stage and relevant aspects such as ergonomics and occupational safety can be examined in advance. The result is an interactive VR simulation in which explicit requirements for workplace and system design can be derived and validated.

Virtual testing can reveal potential problem areas at an early stage.

The technological basis for the development of the training, testing and programming environment for human-robot interaction lies in physics-based, real-time capable system simulation. Using the Industrial Physics simulation solution, complex mechatronic systems can be simulated and test runs of robot programming can be checked. To implement the simulation, the CAD model of the assembly system and assembly object is transferred to the simulation environment and the work plan is implemented step by step.

The interactive live presentation of simulation models on head-mounted displays and augmented reality (AR) glasses creates the technical prerequisites for creating a VR or AR-supported, collaborative development environment on these hardware platforms.

The robot paths generated in the simulation can be transferred to the robot controller of the assembly system and incorporated into the assembly process.

To integrate human behavior into the simulation process, haptic feedback is implemented using a force feedback system. This enables the highest possible level of immersion in the virtual world. Collision geometries with the human body as well as human activities such as handling and assembly activities are included accordingly and possible errors in the collaborative system are revealed. The robot paths generated in the simulation can be transferred to the robot controller of the assembly system and incorporated into the assembly process. This means that new configurations can be tested and implemented in the system without interfering with the operation of the assembly system, particularly in the assembly of products with many variants.

The methodology developed for virtual testing can also be used to derive training scenarios in which an employee learns how to use collaborative robots at a virtually mapped workplace and is gradually introduced to topics such as division of labor, human-robot interaction and process safety. The application-oriented design of the scenarios is made possible by findings from an evaluation with a real system. A validation of the scenarios will also assess the extent to which they optimize the start-up phase of collaborative systems in terms of employee acceptance, training time and perception of safety. Accordingly, individual training requirements can be designed for companies in order to enable and sensitize their employees for the start-up and operation of collaborative assembly systems.

The knowledge gained from the previous virtual testing will be used to identify, evaluate and validate success factors in relation to the introduction and benefits of collaborative systems. In the Kokomo research project ("Consolidation of life cycle information for the collaborative assembly of multi-variant products"), three industrial application scenarios are being simulated and physically tested. The result is an implementation catalog that provides recommendations for the implementation and use of collaborative systems and also enables SMEs to remain permanently adaptable through the use of collaborative assembly systems and to adapt to new product variants within a very short time. P. Rückert/as

© MHI

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: http://www.wgmhi.de.

© bime/Patrick Rückert

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. Around 70 employees currently work at the bime. The Assembly Systems and Production Design departments, headed by Prof. Dr.-Ing. 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 layout of handling devices and the modularization of production systems and equipment are the subject of the research work. The working group also focuses on planning tools for efficient planning processes and high-quality planning results that can be achieved at an early stage. The bime, represented by Prof. Dr.-Ing. Kirsten Tracht, is a member of MHI e.V.(http://www.bime.de)