Stäubli Electrical Connectors is one of the world's leading manufacturers of electrical connectors for all industrial sectors. In the manufacture of its product range, the Swiss company relies on hybrid assembly systems that combine fully automated and manual workstations. The only drawback of this strategy is that if an operator is absent due to illness, the entire line comes to a standstill. In addition, unmanned night shifts are not possible.

The company now has a solution for precisely such scenarios: the Helmo mobile robot system from Stäubli Robotics. Once trained, Helmo can take over almost any manual task on the assembly lines. The production assistant navigates independently to its workstation, reduces its speed or stops if human colleagues get too close, and then continues its journey in a targeted manner.

The mobile robot system navigates independently to its workstation, reduces its speed or stops if people come too close. © Stäubli

Once Helmo arrives at its workstation, it prepares for its job within a few minutes. The robot positions itself accurately to a tenth of a millimeter by measuring itself using three measuring points permanently installed at the workstation. It then connects itself to the stationary power supply for electricity and pneumatics at the workstation via a multi-coupling and begins its shift. Helmo is equipped with an automatic tool changing system from Stäubli Connectors to enable it to operate flexibly. If today it is the insertion of connector housings and contact pins, tomorrow it could be any other assembly step that Helmo takes over as required. In Allschwil, it is seen less as a robot and more as an assistant that is flexibly on hand wherever it is needed.

The aim there is not to replace human workers with mobile robots - that would not make sense in terms of production technology or economics - but to optimize the availability of hybrid assembly lines or to absorb capacity peaks with a flexible jumper. Sickness-related or other unforeseen absences of human workers have lost their terror in Allschwil. Thanks to Helmo, the company's ability to deliver has been significantly optimized. as

About Helmo:
The mobile robot system can drive and navigate completely autonomously, constantly monitoring its surroundings via three integrated laser scanners. Helmo can either perform tasks fully automatically or collaborate with humans as required. A six-axis TX2-90L standard robot with a payload capacity of 15 kilograms and a reach of 1,200 millimetres is used. The six-axis robot has a complex safety package. All safety functions are certified and meet the strict requirements of safety category SIL3-/PLe.