From assembly in the automotive industry to the production of electronic components: Solutions for human-robot collaboration (HRC) continue to find their way into modern production. Volatile markets and ever shorter product life cycles are the reason for the change in production halls. Those who act and produce flexibly and adaptably can gain a competitive advantage. HRC is one possible solution here. However, this does not apply to all processes. This is because its use must be re-evaluated depending on the application and assessed in terms of cost-effectiveness.

Human-robot collaboration can offer a lot of potential for the right application. What this right process looks like is decided during the planning of the system. This is where the production process is examined more closely and the question of economic efficiency is taken into account. In addition to ergonomic aspects, the time factor is a decisive criterion: How quickly can you switch to HRC? And when will it pay for itself? If everything speaks in favor of its use, the HRC solution can be integrated into the system. Safety plays a decisive role here, as it must be ensured that humans are not put at risk when working with the robot.

The robot must slow down
When working directly with humans, the robot must not only be fast and powerful. In the case of sweeping movements, it must carry out the production step more slowly, but with increased sensitivity, and powerful movements may only be carried out if no one is endangered in the process. This is the only way to eliminate the risk of injury. If an unexpected collision does occur, the robot must immediately switch to stop mode and may only continue working when it receives the "OK" from the human, for example in the form of another touch. Of course, the robot is only HRC-capable if the respective end effectors, such as grippers or other tools that it needs for the process, do not have any sharp or pointed edges.

The worker can touch and guide the mechanical helper. © Kuka

"Know-how, experience and careful planning are crucial in order to realize successful cooperation between humans and robots and to integrate an HRC application," says Kim Reeslev, Kuka Country Manager Denmark & Baltic States. Possible application scenarios can be found in the less automated areas of the automotive industry or other sectors. For example, in the assembly area. Here, the robot can relieve the strain on humans. Another area of application is quality inspection. In all cases, however, it is important to consider each situation individually and ensure the protection of workers: in accordance with the safety standards of ISO 10218, TS15066 Technical Specification and the current machinery directives. After all, production is only permitted by law with a CE marking.

CE marking: you can't do without it!
Validating HRC applications is a crucial process when integrating them into a system. This is because legislation stipulates that certain standards must be met in order to be allowed to produce: From the risk assessment to the safety concept and the validation and testing of all collision scenarios, the final step is CE marking. All risk factors must be assessed before, during and after use of the robot and CE documentation must be created: for the general robot description and for its use.

Ultimately, it is the integrator or the customer who has purchased the robot and installed it in their system who is liable in the absence of CE marking. They must ensure that the application complies with the applicable directives and regulations. Typical risk factors that can occur on the way to CE conformity are, for example, dangerous end effectors with sharp edges, incorrect configuration of the safety software or the stop mechanism. If humans and robots are really to work together, the robot's force and power must be limited. The worker can touch, guide and even collide with the mechanical helper. The robot must therefore have sensitive properties and ensure that biomechanical limit values (force, pressure) are not exceeded in the event of a possible collision. All these aspects must be taken into account in the risk analysis before the application can be put into operation. HRC integration can only be successful if all aspects of safety are taken into account and the solution then also pays for itself in economic terms.

Take the pressure off employees? Make the process more flexible? Be adaptable? These are some of the reasons that could speak in favor of an HRC solution. If the production step is really suitable, then possible fears regarding safety measures should not be a deterrent. At Kuka, customers receive a well-secured HRC solution: robots and necessary safety functions such as subcomponents or sensors are officially certified. "In this way, we want to show our customers that we know what we are doing and that we won't leave them to fend for themselves when it comes to CE marking," says Reeslev. as