<p><strong>One key element of the future production landscape is highly flexible Human-Robot Collaboration (HRC). This article describes 3 case studies which illustrate how collaborative robots change the way people will manufacture.<br><br>KUKA, one of the world&#39;s largest suppliers of industrial robots, has written a free, downloadable white paper called &quot;</strong><a href="http://bit.ly/kuka-whitepaper-US" rel="noopener noreferrer" target="_blank"><strong>Shaping future production landscapes</strong></a><strong>.&quot; The white paper describes &#39;megatrends&#39; that impact manufacturing and 3 key factors to designing production infrastructures that can meet the requirements of the future.&nbsp;</strong></p><hr><h1>Intro</h1><h2>Human-robot collaboration&nbsp;</h2><p>In human-robot collaboration, the robot assists the human operator. This means: The machine does not replace the human, but complements his capabilities and relieves him of arduous tasks. These can include overhead work, for example, or the lifting of heavy loads. Autonomous, collaborative robots are also used to supply production workstations.</p><p>In the ideal &#39;factory of the future&#39; there is no separation between automated and manual workstations. Humans and robots collaborate optimally &ndash; without separation and without safety fencing.</p><h2>Human-robot collaboration: the advantages</h2><p>HRC-capable robots (often labeled &#39;Collaborative Robots&#39; or &#39;Cobots&#39;) are rendered mobile and capable of performing different tasks flexibly using mobile platforms. They can thus be individually deployed at whatever location and for whatever purpose corresponds to production requirements &ndash; dependent on the required batch size, for example.<br>Furthermore, these types of robots offer maximum flexibility by means of so-called spontaneous automation: They support a user as an assistant in the case of workload peaks and resource bottlenecks in production operations.</p><p>Human-robot collaboration changes industrial production and manufacturing and can bring a number of advantages over traditional automation or manual labor:</p><ul><li>Increased flexibility in production</li><li>Relief of employees by performing ergonomically unfavorable work steps that could not previously be automated</li><li>Reduced risk of injuries and infections</li><li>High-quality performance of reproducible processes &ndash; without requiring type-specific or component-relevant investment.</li><li>Increased productivity and improved system complexity thanks to integrated sensors</li></ul><p><br></p><h1><strong>HRC Case Studies</strong></h1><p>To give you an idea of the impact of collaborative robots in the workspace we&#39;ve gathered 3 case studies to show you the impact of these robots and the challenges they overcome.</p><p><br></p><h2><strong>Case Study 1: Lightweight robots supporting operators in adhesive bonding processes.</strong></h2><h2><em><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1566292124494-KUKA+LBR+iiwa+Duerr.jpg" class="fr-fic fr-dib" style="width: 766px;"></strong></em></h2><p><em>All images courtesy KUKA</em></p><p>System and machine builder <a href="https://www.durr.com/en/" rel="noopener noreferrer" target="_blank">D&uuml;rr</a> uses two sensitive LBR iiwa robots in final assembly. Without a safety fence, they perform key tasks in the application of adhesive beads. This improves quality, saves time and lowers unit costs.</p><div data-ignore="true">At the company, humans and robots work together in final assembly without the need for physical safeguards. Sensitive lightweight robots are used for the adhesive bonding of GPS antenna covers and tanks in the vehicle body. The solutions improve the quality of the adhesive bonding result, save time and lower unit costs.&nbsp;</div><p><strong>The LBR iiwa detects any fault that arises when the GPS antenna cover is loaded</strong></p><p>For application of adhesive to the GPS antenna cover, the assembly worker places the workpiece into the robot gripper manually. The gripper sucks onto it and moves it to the adhesive nozzle on the application tower. The robot slowly moves the GPS antenna cover upwards to the application nozzle. If it encounters an obstacle, it moves back a little thanks to its collision detection ability and starts the motion over from the beginning. Only after three attempts does it move back into the starting position. Otherwise, the adhesive application process starts and the adhesive bead is applied carefully while the robot executes the path. Finally, back at the starting point, the assembly worker removes the GPS antenna cover and mounts it on the vehicle. &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;&nbsp;</p><p><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe src="https://www.youtube.com/embed/PdAXCNtXabc?&wmode=opaque" allowfullscreen="" class="fr-draggable" style="width: 767px; height: 429px;" frameborder="0"></iframe></span></p><p><strong>Precise adhesive beads thanks to the seventh axis of the LBR iiwa</strong></p><p>For the automated process of gluing the tank into place in final assembly, the skilled worker guides the tank to a turntable with the aid of a manipulator. There he cleans it, moves it into the correct position and transfers it directly to the robot for further processing. When the starting point is reached on the stationary tank, the nozzle opens under pressure so that no air bubbles are created. The robot then applies the adhesive bead onto the tank very evenly. Sensors on the application head monitor the accurate height of the bead. Thanks to its seventh rotating axis, the robot glues in a radius of 360 degrees &ndash; without re-orienting or having to interrupt the bead. As soon as the robot has completed its task, the skilled worker fits the tank into the vehicle body at the specified position.</p><p><a href="http://www.durr.com/" target="_blank">D&uuml;rr</a> has already sold ten systems in the field of adhesive bonding, and is working on HRC solutions for the robot-based adhesive bonding of small washers and other components.</p><p><br></p><h2><strong>Case Study 2: Human-robot collaboration during the adjustment of headlights.</strong></h2><p><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1566292345359-Fahrassistenzsystemprfstnden_Drr.jpg" style="width: 766px;" class="fr-fic fr-dib"></strong></p><p>To reduce the strain on the workers, two KUKA LBR iiwa cobots perform the unergonomic task of adjusting fog lights at Ford. Parallel to this, human colleagues can adjust the main headlights.</p><article data-ignore="true"><p><strong>The initial situation</strong></p>In the automotive industry, vehicle fog lights have previously been adjusted manually by human operators. While stooped over, the human operator searches for the hard-to-reach opening for the adjusting screws in the bumper area. Once he has found the adjusting screw, he positions the tool on it extremely carefully without damaging the adjustment opening on the bumper.</article><article data-ignore="true"><p><strong>The solution</strong></p>To provide relief for the human worker during this ergonomically unfavorable work and simultaneously achieve improved of the adjustment, Ford VOME (Vehicle Operation Manufacturing Engineering), D&uuml;rr Assembly Products and KUKA have jointly developed an innovative alternative concept for the conventional process as part of a feasibility study. The solution called for the use of the KUKA LBR iiwa cobot. The sensitive robot adjusts the fog lights fully automatically. In doing so, humans and robots work on the same vehicle without additional safety equipment.</article><p><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe src="https://www.youtube.com/embed/9HWY-CLR3Co?&wmode=opaque" allowfullscreen="" class="fr-draggable" style="width: 766px; height: 419px;" frameborder="0"></iframe></span></p><p><strong>Teamwork</strong></p><p>While the human operator adjusts the conventional headlights, the cobot adjusts the hard-to-reach fog lights. Two lightweight robots are already in use in four headlight/driver assistance system test stands for the new Ford Focus C519 at the Ford plant in Saarlouis. &nbsp; &nbsp; &nbsp; &nbsp;</p><p><strong>The secret of the HRC concept</strong></p><p>With its size and joint torque sensors, the robot detects contact immediately and reduces its level of force and speed instantly. These characteristics make it possible to work with human operators in confined spaces. Furthermore, with its high-performance servo control, the cobot detects contours quickly under force control. In combination with an end effector specially developed by D&uuml;rr (consisting of a camera system and an adjustment screwdriver), the robot positions the adjustment screwdriver according to the hole coordinates acquired by the camera system. The adjusting screw itself is located approximately 80 mm behind the hole in the bumper. Thanks to sensitive movements, the cobot optimally positions the adjustment tool into the screw head.</p><p><strong>Redundant safety</strong> is provided by the HRC-capable, heavy-duty aluminum gantry from D&uuml;rr Assembly Products &ndash; on which the KUKA LBR iiwa is positioned in a ride-on installation above the light collecting box directly in front of the headlight to be adjusted. The advantage here: additional robot positioning can be dispensed with.</p><p><br></p><h2><strong>Case Study 3: Using a cobot to install pump wells. <br></strong></h2><h2><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1566292578317-KUKAflexFellow_Platzierung_im_Arbeitsbereich_IMG_3628.jpg" style="width: 766px;" class="fr-fic fr-dib"></strong></h2><p>In the future, BSH Hausger&auml;te GmbH will be using a <a href="https://www.kuka.com/en-us/products/mobility/mobile-robot-systems/kuka-flexfellow" rel="noopener noreferrer" target="_blank">KUKA flexFELLOW</a> to carry out the installation of pump wells on the dishwasher production line.&nbsp;</p><article data-ignore="true"><p><strong>The initial situation</strong></p><p>The <a href="https://www.bsh-group.com/us/" rel="noopener noreferrer" target="_blank">BSH Hausger&auml;te</a> GmbH factory in Dillingen, Germany is Europe&rsquo;s largest and most modern factory for dishwashers. Around 10,000 machines leave the production line every day in two-shift operation. There are a total of seven production lines for manufacturing dishwashers.</p><p>Screw fastening of the pump covers in the dishwasher is an ergonomically inconvenient task as the employee has to lean into the dishwasher housing to perform the task. The mechanical assistant now takes on this monotonous step in the process.&nbsp;</p><p><strong>The task &nbsp; &nbsp;&nbsp;</strong>&nbsp; &nbsp;</p><p>Its contribution has already been tested successfully over several months as part of a pilot system. In addition to relieving the human operator of a cumbersome task, the robot also contributes by documenting its work and indicating whether the screws have been tightened correctly or not.</p><p><strong>The solution &nbsp; &nbsp; &nbsp; &nbsp;</strong></p><p>The key challenge when designing the system was to ensure that the manual workstation remained unchanged and that the automation solution could be integrated into the existing assembly line. Its sensitive and responsive capabilities enable it to recognize if, for example, a pump well component is not positioned correctly and then presses it into place.&nbsp;</p><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe src="https://www.youtube.com/embed/jtkJQJXO7AQ?&wmode=opaque" allowfullscreen="" class="fr-draggable" style="width: 767px; height: 413px;" frameborder="0"></iframe></span><p>The advantages of using a cobot:</p><ul><li>Reduction of the manual workload in an ergonomically inconvenient task</li><li>Automated documentation of work steps</li><li>Indication of correct screw fastening operation</li></ul><p>Using its responsive capabilities, the cobot can then calibrate itself independently at its workstation, use a search run mode to find the screw positions, re-apply pressure to the component if it is not correctly positioned and finally tighten the four screws.</p><p><br></p><hr><h1><br></h1><h1>Further Reading</h1><ul><li>Specifications of the <a href="https://www.wevolver.com/wevolver.staff/kuka.lbr.iiwa/" rel="noopener noreferrer" target="_blank">KUKA LBR iiwa</a></li><li>&quot;<a href="http://bit.ly/kuka-future" rel="noopener noreferrer" target="_blank"></a><a href="http://bit.ly/kuka-whitepaper-US" rel="noopener noreferrer" target="_blank">Shaping future production landscapes,</a>&quot; KUKA&#39;s white paper describing the &#39;megatrends&#39; that impact manufacturing and 3 key factors (<strong>people, technology and adaptation</strong>) to designing production infrastructures that can meet the requirements of the future.</li></ul><p><br></p><p><br></p></article>

In human-robot collaboration, human and machine work hand in hand. The human operator controls and monitors production, the robots perform the physically strenuous work. Both contribute their specific capabilities.

Human-robot collaboration: 3 Case Studies

<p><em>This article is part of a series about the usage of robots in harsh environments, written by post-doctoral robotics researcher Matthew Nancekievill. Find the second article, on subsea environments,&nbsp;</em><em>here.</em></p><hr><p><strong>Lets face it, there are some jobs that we just don’t want to do, or CAN’T do that we will have to get robotic platforms to complete.</strong> This is especially true of harsh environments such as subsea, mining, space, arctic, often forgotten surgical robotics and nuclear decommissioning. In this article we are going to take a brief look at robotic platforms currently deployed within the nuclear industry, why they’re required and solutions that are still required for all you innovators out there. &nbsp;With decommissioning costing the UK £3billion/yr and estimated costs of £121 billion over the next 120 years, there is a requirement for increased efficiencies and decommissioning rates that robotics can provide.&nbsp;</p><p>Hopefully this article acts as a summary of robotic solutions in nuclear decommissioning without being too much of an exhaustive list.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNTU5NjY4MDk3MDA3LUltYWdlIDIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib"></p><h1><strong>A look at the Nuclear Decommissioning Environment</strong></h1><p>Decommissioning happens around us all the time, old buildings get torn down, coal power plants shutdown and vehicles get scrapped. The nuclear industry is no different with the reactors, storage facilities and processing elements all requiring decommissioning when they reach the end of their useful life.</p><p>Hazardous substances can be found in all the above environments with asbestos, chemicals used during refinement, rare earth metals and oils that can’t be put into our main waste stream all examples of hazardous substances. The Nuclear industry faces all the same problems but adds one to the list, “nuclear waste”.</p><p>I’ve always felt that nuclear gets a bad rap in the press, with all the pollutants and oil spills throughout the years created from coal power plants seemingly ignored when nuclear waste is mentioned. However, the effects of nuclear radiation on the body can be very unforgiving.</p><p>To give you a flavour, researchers working with weak radioactive sources, such as myself, are allowed a total yearly dose of &lt;1 mSv attributed to radiation work, registered radiation workers in the UK &lt;20 mSv. This is a large safety factor to account for medically proven effects of radiation at radiation levels &gt;250 mSv with 1,000 mSv likely to kill you within a few days to a couple of weeks. (Average background radiation dose in the UK is approximately 2.7 mSv)</p><p>Compare this to radiation doses in some of the most radioactive places on earth, such as the UK’s Sellafield Site or the Fukushima accident, where in the most extreme cases (<strong><u>no really</u></strong>, the most <strong><em>extreme</em></strong> cases, the majority is not like this) dose-rates of around 10,000 mSv.h<sup>-1</sup> are possible (check-out <a href="http://irid.or.jp/en/research/20150420-2/" rel="noopener noreferrer" target="_blank">these survey results</a> from the IRID and the shape-changing robot mentioned later.</p><p>This is before you add in the difficulties of the physically constrained and tight working spaces, high temperatures, contaminated water used for cooling and, in the case of nuclear accidents such as Fukushima, an unknown physical layout “behind the door” due to explosions within the reactor buildings.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNTU5NjcyODIxNzYyLUZ1a3UuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib"></p><h1><strong>Current Practices</strong></h1><p>In less radiologically extreme environments, much of the work is carried out by human workers in air-fed suits with multiple layers of gloves, some of which could be lead-lined (<strong><em>lead-lined gloves</em></strong>) worn to avoid contamination and puncturing of the suit on sharp edges. This often means that with all the getting ready, decontamination at the end of the shift and the physical exertion required to operate in these suits, an 8-hour work shift could result in anywhere between 15 minutes to 2 hours of actual decommissioning with power tools cumbersome to use and movement awkward. Workers have been known to empty their boots at the end of their shift of all their sweat that has built up… Workers are, at the root of it, tasked with dismantling the facility. This means cleaning, chopping and moving all sorts of materials into the correct waste stream and then moving on to the next object or structure.</p><h2><strong>Robotics in Nuclear</strong></h2><p>It is clear that some of these repetitive tasks or highly radioactive areas lend themselves to the use of robotic platforms. There has been a large body of work conducted on developing solutions for just that. Aquatic robotic platforms for use within submerged nuclear waste storage tanks, robotic manipulators for laser cutting of structures, drone-based devices for site surveys and ground-based robots for automated warehouse characterisation and unknown environments.</p><p>Examples of these are:</p><p>The Forth AVEXIS, developed jointly by Forth Engineering and the University of Manchester. A submersible ROV designed to be deployed within the Magnox Swarf Storage Silo and fit through a 6” access port. More information within the video.</p><p><span class="fr-video fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe src="https://www.youtube.com/embed/OLvAQFz5wh8?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" allowfullscreen="" class="fr-draggable" style="width: 766px; height: 443px;" frameborder="0" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-gtm-yt-inspected-7="true" id="626921597" title="Avexis ROV" data-gtm-yt-inspected-29="true" data-gtm-yt-inspected-37="true"></iframe></span></p><p>The LaserSnake2, which combines a multi-jointed “snake-arm” manipulator with a powerful laser-cutter. Developed by OCRobotics, The Welding Institute, National Nuclear Laboratory, Laser Optical Engineering Ltd. And ULO Optics. It is designed to cut and reduce the size of objects and structures to fit in dedicated waste containers.</p><p><span class="fr-video fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe src="https://www.youtube.com/embed/hqOfRhJsaEQ?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" allowfullscreen="" class="fr-draggable" style="width: 766px; height: 436px;" frameborder="0" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-gtm-yt-inspected-7="true" id="439090068" title="LaserSnake2 - Laser cutting for nuclear decommissioning at Sellafield - a world first." data-gtm-yt-inspected-29="true" data-gtm-yt-inspected-37="true"></iframe></span></p><p>Researchers from Bristol University have just recently flown a drone over the Chernobyl Red Forest highlighting the site survey capabilities of drones applicable to all nuclear sites.</p><p><span class="fr-video fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe src="https://www.youtube.com/embed/_Eto98XTm-4?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" allowfullscreen="" class="fr-draggable" style="width: 766px; height: 394px;" frameborder="0" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-gtm-yt-inspected-7="true" id="334628213" title="YouTube video player" data-gtm-yt-inspected-29="true" data-gtm-yt-inspected-37="true"></iframe></span></p><p>Hitachi-GE have also developed a “shape-changing robot” to characterise the internals of Fukushima. Designed to be passed through small gaps in a long cylindrical shape, it is then capable of morphing into a “U” shape for stability. Equipped with a radiation tolerant camera and dosimeter, multiple robots were deployed with valuable data returned.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNTU5NjY4MzQ5NTkyLVNoYXBlLWNoYW5naW5nIElSSUQtSGl0YWNoaSByb2JvdCAtIDQ1MC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib"></p><p>However, one of them got stuck, which leads me to my next point.</p><h1><strong>The problem with Robots</strong></h1><p>I love robots, and I believe that robotic systems HAVE to and WILL have a huge part to play in harsh environments, but there are still things that have so far left deployment of robotic systems on the fringes of use. These include, but are not limited to:</p><ul><li><strong>Robots are dumb</strong>: When compared to a human assessing a situation. The Hitachi shape-changing robot fell foul of a common problem with robotic systems, it got caught in a hole in the grating it was driving on it wasn’t expecting and that could not be seen by the human operator with the robot not “smart” enough to avoid or raise a flag. Robots are only as smart as we make them!</li><li><strong>Radiation effects:</strong> Robots readily survive longer than humans but there are still failures of the electronics in high dose areas.</li><li><strong>Tether entanglement:&nbsp;</strong>Most robots (not including drones) are often required to be connected via tether. This is for safety, in-case the robot breaks, meaning it can be unceremoniously dragged out but causes issues with entanglement.</li><li><strong>Robots require a skilled pilot:</strong> That skill-set is not common.</li><li><strong>The industry isn’t ready:</strong> When things have been done a certain way for a long time, it is difficult to change that. Not to mention all the legal licensing issues and who takes responsibility when something goes wrong?! Media storms surrounding the ethics of robots taking jobs and becoming our future overlords do not help (thanks a lot Terminator).</li></ul><h1><strong>In Conclusion</strong></h1><p>There is a great body of work being completed within industry and research institutions developing bespoke solutions for specific problems and there have been many successful deployments and also many unsuccessful deployments, which is all part of innovation! Not included above but deserve a mention with regards to innovation and deployments to Brokk and Seabotix robotic systems that are often used daily.</p><p>To really get consistent robotic platform deployments in nuclear decommissioning, further innovation improving the capabilities of robotic platforms is required as well as upskilling of the workforce and events showcasing the technology to industry. Communication is key and the continued development of systems by all the engineers out there.</p><hr><p><em>This article is part of a series about the usage of robots in harsh environments, written by post-doctoral robotics researcher Matthew Nancekievill. Find the second article, on subsea environments,&nbsp;</em><em>here.</em></p>

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Human-robot collaboration: 3 Case Studies

Robotics for Harsh Environments - Nuclear Decommissioning