D1: Intuitive Instruction of Fettling Castings for the Foundry

D2: Fast Installation and Small Batch Size Production Change
D3: Robot Assistants as Multi-Purpose Tools

D4: Robot Assistant for a Woodworking Facility
D1: Intuitive Instruction of Fettling Castings for the Foundry

Automatic task execution
Fettling and finishing of castings where the worker intuitively instructs a robot to machine surface geometries.

The worker attaches a simple measuring tool onto the robot and fixes the work piece for registering the robot‘s geometry. Work cell, tool, product and CAD data are matched automatically and the robot program is generated either from CAD or by interactive lead-through by the craftsman. Modifications can be entered intuitively using direct interaction with the robot and speech communication.

Results of D1: see exhibits and program of Final Workshop

Presentation at AUTOMATICA 2008:

D1 at Automatica
New parallel kinematic robot for industrial applications
  • Unique concept for demanding handling- and process-applications
  • Modular PKM-structure with high mechanical stiffness and bandwidth
  • Lightweight wrist-concept performing high precision and rigidity
  • Rack and pinion drives on linear axes for high dynamics at TCP
  • Lightweight and low-inertia arm system – quick to assemble, easy to configure

New parallel kinematic robot
SME end-user involved
Norton Cast Products Ltd.
D2: Fast Installation and Small Batch Size Production Change

Intuitive instructions
The three-day-deployable integrated robot system is made by:
  1. Physical installation of various components and connection to services must be done the first day.
  2. Configuration for data, I/O communication on day 2.
  3. Programming of robot trajectories, Process setup on day 3.
In case of change of production (small batch size), steps 2 and 3 must be repeated (in a loop), but in this case the production change must be done in one day instead of two.

  • On day 1 the cell is loaded from the truck and installed. Every part is mechanically referenced. Then the cell is powered, possibly by means of only electrical energy, in such a way the SMEs does not need to built circuits for compressed air or cooling water.
  • Day 2 is dedicated to installing all device communications for data exchange and I/O mapping.
  • On day 3 the programming (downloading from CAD or pbd) and the process setup is performed. Production starts.
Results of D2: see exhibits and program of Final Workshop

Presentation at AUTOMATICA 2008:

D2 at Automatica
A SMART robot in any shop floor
  • Flexible 3D localization of workpieces with autonomous grasp planning
  • Processing without programming
  • Collision avoidance by automatic reduction of speed and change of movement

A SMART robot
SME end-user involved
Hirschvogel Umformtechnik GmbH
D3: Robot Assistants as Multi-Purpose Tools

Application example: Assembly
The scenario deals with using robot assistants as a versatile tool at a manual workplace. Such an assistant would allow flexible degrees of automation, from manual to fully automatic. Many applications and processes could be imagined, e.g., assembly, arc welding, machining, etc. In the sequel an assembly and a welding scenario are exemplarily described.

Operation of the worker′s third hand:
A portable robot arm is carried to its new workplace. Minimal effort is required to set-up the robot by using plug-and-play peripheral devices and intuitive calibration methods. Thereafter, the robot is instructed to perform an assembly operation, i.e., it is not programmed in the classical (text-based) sense. Defining a more complex assembly task means to interactively define a sequence of simple or more complex operations.

Results of D3: see exhibits and program of Final Workshop

Presentation at AUTOMATICA 2008:

The worker′s third hand
The SME worker′s third hand
  • Easy set-up of the robot at the normal workplace
  • Point-, path- and area-related processing tasks are programmed by demonstration
  • The robot intelligently assists the worker during production
  • Optionally, a 3D scanner checks the quality of the workpieces and may be used to prepare additional automated processing steps

Five Minute Robot Programming
Five Minute Robot Programming
  • Intuitive robot programming within minutes using the “InTeach” environment: software tools to record, adopt and replay trajectories
  • Multimodal commanding using haptics, speech and 3D user interfaces
  • Programming can be done by the process expert, specialist is not required
SME end-user involved
Paul Treffler Stahl- und Maschinenbau

D4: Robot Assistant for a Woodworking Facility

Application example: drilling
The robot is used as an extended tool at the manual workplace of a woodworker. Main tasks are trimming, dressing, milling, gluing, and shaping of free forming surfaces.

Teach motion, geometry, and processes efficiently with pointing devices, gestures, and vision assistance for small production runs (lot size 1-10). Tactile guidance to link geometry and process information together. Reuse of programs facilitated by program libraries or primitives, editing functions to revise the process and fast recalibration. Assuming lack of detailed 3-D CAD models: vision based or tactile generation of model data for complex surfaces will support on-line path generation for complex 3-D surfaces. The robot environment must operate in normal wood working conditions including dust and noise. The demonstrator with human-robot cooperation should be as fast as or faster than a worker working on small series productions. The demonstrator should adhere to safety standards and cover at least five different woodworking processes.

Results of D4: see exhibits and program of Final Workshop

Presentation at AUTOMATICA 2008:

D4 at Automatica
Woodworking assistant
  • Robot used as a versatile tool of a joiner in a crafts joinery
  • Coupling to various conventional manual tools of a joiner using just a tool adaptor
  • The robot intelligently assists the worker during production
  • Operation and programming by intuitive man-machine interfaces, which include graphics- and speech-based input possibilities

D4 at Som
SME end-user involved
Schreinerei Som

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