One reason why genuine collaboration and therefore an overlap of workspaces is often not currently implemented in industry is the uncertainty of companies when planning the workstation and the division of work content. When designing HRC applications, there is a lack of appropriate system interfaces for existing simulation and planning software or software used in companies. In addition, there is a need for interdisciplinary expertise in the fields of ergonomics and automation. The empirical knowledge for the implementation of manual and automated production systems is usually available separately. For this reason, the Safemate and KoMPI projects were launched in 2017 together with seven other projects as part of the BMBF's "Assembly expertise" call for proposals. One aspect that all projects have in common is the validation of the basic principles developed using at least one best-practice application. To this end, use cases are identified with the help of the respective project partners and practically integrated into the partners' production processes. The aim is to implement the use cases with measurable added value for the respective companies so that the knowledge gained can be made available to interested companies.

Safemate has set itself the task of creating implementation strategies for safe and accepted collaboration. The guidelines to be developed should be as generic as possible so that they can be used across all industries and, above all, regardless of company size. One use case in the Safemate project deals with the assembly of washing machines at Miele. The scenario implemented is a sub-process in which a so-called air trap is attached to the unit to measure the water level. Employee surveys and workplace evaluations have shown that the existing manual process is ergonomically stressful for employees and therefore needs to be changed. The current planning status envisages manual guidance of the robot, whereby the air trap can be brought into a pre-position on the unit. The final assembly is then carried out automatically by the robot using a force- and torque-guided movement process. The manual guidance to the pre-position is necessary in order to be able to dispense with additional sensors.

An LBR iiwa from Kuka is used in the assembly line at Karl Dungs. (Image: Ruhr University Bochum/Dungs)

One part of the KoMPI joint project deals with the analysis and evaluation of existing manual assembly lines using the HRC Quick Check developed with the project partners. Criteria such as handling weight, order status or the geometry of the components are considered for the selection. One industrial application of the project involves the assembly of pressure control modules at Karl Dungs. The workstation under consideration involves the completion of various small parts and the subsequent packaging process of the assembled pressure monitor. The Quick Check application has shown that, based on the characteristics of the criteria (orderly provision of parts, high quantities) and a separate cycle time analysis, the use of a lightweight robot as part of a coexisting workstation represents a high potential from an economic and balancing point of view. In practical implementation, the LBR iiwa from Kuka has been used in the assembly line in Karl Dungs' real production operations since the beginning of 2018.

The aforementioned reference processes from the Safemate and KoMPI projects will be exhibited at the joint MHI stand at Automatica as part of the public relations work accompanying the project.

The Safemate and Kompi projects are funded by the Federal Ministry of Education and Research (BMBF) as part of the "Innovations for the production, services and work of tomorrow" funding program in the field of "Competence Assembly - Collaborative and Adaptable (KoMo)" and managed by the Project Management Agency Karlsruhe (PTKA).

S. Blankemayer, K. Lemmerz, as

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.

Institute of Production Systems and Logistics (IFA) at Leibniz Universität Hannover

Briefly explained: The IFA
The Institute of Production Systems and Logistics (IFA) at Leibniz Universität Hannover was founded in 1966 and is currently headed by Prof. Dr. Peter Nyhuis. The institute is concerned with the holistic description and design of production systems. Its research focuses on the areas of factory planning, production management and production and work design. www.ifa.uni-hannover.de

Chair of Production Systems (LPS), Ruhr University Bochum

Briefly explained: The LPS
The Chair of Production Systems (LPS) is headed by Prof. Dr. Bernd Kuhlenkötter. The scientific focus of the LPS covers the fields of production management, production automation and industrial robotics. The LPS operates a learning and research factory (LFF) in which the theoretical concepts are implemented and evaluated. Through these demonstrations of the results, the LPS promotes the transfer of technology to industry. www. lps.ruhr-uni-bochum.de

Chair of Assembly Technology (match) at Leibniz Universität Hannover

Briefly explained: The match
The Chair of Assembly Technology (match) at Leibniz Universität Hannover was founded in 2013 by Prof. Dr. Annika Raatz. Since then, ideas for automated and robot-assisted assembly and handling in production have been pursued. The research focuses on collaborative assembly, soft material robotic systems, handling and control technology and precision assembly. www.match.uni-hannover.de