SP4

SP6-SP8

Figure 1: human-cobot interaction scenario for assembly in the aerospace industry.

1 Objectives

SP5 lies at the heart of the RTD activities in PISA. In SP5, the results of the subprojects SP1-SP4 are integrated and tested, and final demonstration systems will be developed. Specifically, SP5 aims to

• analyze current assembly solutions and identify the requirements for the next generation of assembly technology,
• elaborate concepts for the next generation of assembly systems based on the deep integration and real cooperation between human workers and highly-flexible equipment and devices,
• define testing scenarios for the workplace-sharing, time-sharing and cobotic prototypes, and
• implement and test the final demonstrators.

2 Results and ongoing work

2.1 User requirements on flexible assembly system technology

Based on an analysis of standard hardware and software interfaces and control architectures, critical assembly problems were identified from the viewpoint of end-users and developers of novel assembly technology. This phase of SP5 was achieved through a close cooperation between all partners involved: the industrial partners provided requirements and identified practical needs, while RTD partners presented promising advanced technical concepts and solutions. The specified requirements concern industrial robots, their control systems, and periphery equipment and are aimed at harnessing these to support power-assist applications in assembly processes. The analysis considered three industrial sectors: the automotive, aerospace, and household appliance industries. In addition, preliminary application scenarios were studied.

2.2 Flexible hybrid assembly systems concepts

This phase of SP5 focused on concepts for, and the design of, next generation assembly systems based on the deep integration and real cooperation between human workers and highly flexible equipment and devices. These concepts include workplace-sharing and time-sharing assembly technology, tools for introducing these new technologies, and tools that can monitor these systems. The work began with an overview of the various aspects characterizing the next generation of assembly lines, in particular hybrid assembly lines. These aspects include time-sharing intelligent assembly systems (IAS), power-assist systems and cobotic systems, as well as the reuse and reconfiguration of assembly equipment. The complexity of assembly lines and systems increases steadily. Therefore, special attention must be given to the engineering and planning phase in order to avoid bad designs and architectures. Nowadays, a lot of manufacturing and assembly lines are therefore modelled with 3D tools and are simulated before they are created. An integrated design and planning toolset for the above-proposed next generation of assembly concepts is being developed in PISA. In this phase of SP5, various templates were developed for the integration of assembly lines and IAS. After studying the needs and concepts for hybrid assembly lines, the different target areas were highlighted and the use-cases to be tackled were specified. A comparison was made between traditional assembly line design (without PISA technology) and the new assembly line architectures (with PISA technology). Important concepts here are quality assurance, monitoring, and the impact of the hybrid assembly systems on production, control, and information systems.

Figure 2: advanced assembly concepts for an SME.

2.3 Evaluation of technology prototypes

This phase focuses on the evaluation of technology prototypes for next-generation assembly systems based on deep integration and real cooperation between human workers and intelligent assist devices. The concepts developed in SP1 to SP5 are confronted simultaneously. In order to validate the applicability of these concepts for industrial assembly lines, test benches and evaluation criteria will be prepared. These will enable an assessment of the individual technology prototypes in terms of their technological maturity, application performance, simulation, as well as their planning, optimisation, safety, ergonomy, reusability and reconfigurability and education aspects.

2.4 Demonstration systems and testing scenarios

This phase focuses on the complete definition of the testing scenarios for the workplace-sharing, time-sharing and cobotic prototypes, as required for their assessment in select applications. The environment where individual technology prototypes will evolve is defined and simulated. This includes the prototype and the required peripherals (end tools, part supports and any additional sensorial devices), the parts themselves, the operation sequences, and human interactions. Simulations should allow a realistic visualisation of the application, but also an analysis of the application performance, or reusability and reconfigurability aspects. The demonstration scenarios will especially take into account the needs of the end-users.

2.5 Implementation, testing and assessment of demonstrators

In this phase, the final demonstrators will be implemented and tested, and the results of the tests will be analysed. Comparisons between simulation and real-world results as well as conclusions for the successful introduction of intelligent assist systems will be made in consideration of the expected and obtained performance, compliance to safety regulations and other standards, planning and simulation achievements, improved human interface and reconfigurability. An analysis of the obtained results will be performed including the cost benefits of industrialized prototypes and final applications.

SP4

SP6-SP8