Benchmarking Workshop • Munich • 08 + 09 June 2015

FLA²IR FLexible Automotive Assembly with Industrial Co-WorkeRs

Arne Roennau FZI

Benchmarking Workshop • Munich • 08 + 09 June 2015 2

● Objectives ● Force-based adaptive contour following

● Intuitive user interface for creation of trajectories

● Industrial programming by virtual demonstration

● Impact & Relevance ● Complex 3D contour from 2D visualization

● Easy robot programming for non-experts

● Enables automation of tasks with high part variance

● Desired Setup at Challenger Host (IPA) ● Robot as in benchmarking task, with 3D sensor, force torque sensor

● ROS interfaces as in benchmarking task

● Tablet, example objects, gluing tool (mock-up)

Freestyle

© KUKA Systems

© Univeral Robots

Benchmarking Workshop • Munich • 08 + 09 June 2015 3

Freestyle

● Technological & scientific challenges ● Online model generation for unknown objects

from 3D sensor data

● Mapping of user-specified path to object

● Generation of 12D position / force trajectory

● Contact based adaption during execution

● Approach ● Registration of 3D point clouds, mesh refinement

● Simple tablet-based touch interface for path specification

● Force from surface normals

● Constraint based RRT path planning

● Reactive, sensor based execution

© pointclouds.org

Benchmarking Workshop • Munich • 08 + 09 June 2015 4

Freestyle

● Expected results ● Decreased ramp-up times in production

● “Draw” trajectories instead of programming linear and circular motions (in KRL, RAPID,…)

● More robots for SMEs due to simple / fast / cheap programming of industrial robots

● Application & Dissemination ● Automotive industry, e. g. gluing of windows

● Many applications: pressing of adherend surfaces, deburring, grinding

● Efficient automation of these manufacturing tasks with variable parts will increase flexibility of European SME

© KUKA Systems

© cadmoutsourcing.com

Benchmarking Workshop • Munich • 08 + 09 June 2015 5

Showcase

● Objectives ● Force based assembly of plastic clips

● Handling of flexible polymer sealings

● Robot co-worker: Safe human robot interaction

● Impact & Relevance ● Clip mechanisms and handling of non-rigid objects are

common assembly task solved manually today

● Safe human robot cooperation enables robots to assist in tasks beyond the state of the art

● Planned Setup at Challenger Host (IPA) ● Extended KUKA KR 5 industrial arm

● KR 5 SI developed by MRK-Systeme

● Prototype of tool with integrated sensor

© MRK-Systeme

© Amazon

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Showcase

● Technological & scientific challenges ● Localization and grasping of non-rigid objects

● Strategy based fitting of plastic clips with occlusion

● Development of manipulation tool and safety concepts

● Approach

Benchmarking Workshop • Munich • 08 + 09 June 2015 7

Showcase

● Expected results ● Automation avoids / minimizes ergonomically critical tasks

● Hybrid force / position strategies for manipulation of flexible, elastic objects

● Safe robot co-worker: no fences, more robots on shop floor

● Evaluation of transferability to end-user application

● Application & Dissemination ● Handling of flexible objects can be applied

to wires, ropes, rubber strings

● Clipping objects is a common task for example in the assembly of mobile phones

● Ability to automate tasks that are performed manually today

● Keep production in Europe! © Siemens