an evaluation methodology for the conversion of manual assembly systems into human robot collaborative workcells

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A Method to Distinguish Potential Workplaces for Human-Robot Collaboration

The high dynamics of globalized markets and their increase in competition, as well as the demographic changes in western countries causing an increasing shortage of skilled personnel are resulting in major challenges for production companies today. These challenges relate in particular to the processes of assembly forming the last process step in the value chain due to its high share of manual labor. Collaborative assembly, which is characterized by immediate interaction of humans and robots, utilizes the strengths of both partners and is seen as an opportunity to achieve a higher level of flexibility in assembly just as well to support and relieve people of for instance non-ergonomic tasks through automation at work. Although almost every robot manufacturer already has collaborative systems in its product portfolio, these are not yet widely used in industrial production. This might have a variety of reasons, such as the fear of a risky investment or the lack of expertise within the company related to collaborative systems. This article shows a conceptual method that helps companies implementing human-robot-collaboration in their production more quickly and with less implied risk, thus addressing the forthcoming challenges. As a first step, companies must be qualified to make a suitable selection for a possible collaboration scenario. To achieve this, they need a tool to analyze and to evaluate their production processes according to their suitability for human-robot-collaboration. An important feature for an easy and effective use is that the process is formalized so that employees of companies can quickly and easily analyze different processes. The necessary criteria and procedures are developed accordingly and are integrated into the selection method. The main goal is to give the company a recommendation which of their processes are most suitable for human-robot-collaboration, so that they can be used effectively in their production

A Concept for User-Centered Delegation of Abstract High-Level Tasks to Cobots for Flexible Lot Sizes

Technical advances in collaborative robots (cobots) are making them increasingly attractive to companies. However, many human operators are not trained to program complex machines. Instead, humans are used to communicating with each other on a task-based level rather than through specific instructions, as is common with machines. The gap between low-level instruction-based and high-level task-based communication leads to low values for usability scores of teach pendant programming. As a solution, we propose a task-based interaction concept that allows human operators to delegate a complex task to a machine without programming by specifying a task via triplets. The concept is based on task decomposition and a reasoning system using a cognitive architecture. The approach is evaluated in an industrial use case where mineral cast basins have to be sanded by a cobot in a crafts enterprise

Methodology for the definition of the optimal assembly cycle and calculation of the optimized assembly cycle time in human-robot collaborative assembly

AbstractIndustrial collaborative robotics is an enabling technology and one of the main drivers of Industry 4.0 in industrial assembly. It allows a safe physical and human-machine interaction with the aim of improving flexibility, operator's work conditions, and process performance at the same time. In this regard, collaborative assembly is one of the most interesting and useful applications of human-robot collaboration. Most of these systems arise from the re-design of existing manual assembly workstations. As a consequence, manufacturing companies need support for an efficient implementation of these systems. This work presents a systematical methodology for the design of human-centered and collaborative assembly systems starting from manual assembly workstations. In particular, it proposes a method for task scheduling identifying the optimal assembly cycle by considering the product and process main features as well as a given task allocation between the human and the robot. The use of the proposed methodology has been tested and validated in an industrial case study related to the assembly of a touch-screen cash register. Results show how the new assembly cycle allows a remarkable time reduction with respect to the manual cycle and a promising value in terms of payback period

Emerging research fields in safety and ergonomics in industrial collaborative robotics: A systematic literature review

Abstract Human–robot collaboration is a main technology of Industry 4.0 and is currently changing the shop floor of manufacturing companies. Collaborative robots are innovative industrial technologies introduced to help operators to perform manual activities in so called cyber-physical production systems and combine human inimitable abilities with smart machines strengths. Occupational health and safety criteria are of crucial importance in the implementation of collaborative robotics. Therefore, it is necessary to assess the state of the art for the design of safe and ergonomic collaborative robotic workcells. Emerging research fields beyond the state of the art are also of special interest. To achieve this goal this paper uses a systematic literature review methodology to review recent technical scientific bibliography and to identify current and future research fields. Main research themes addressed in the recent scientific literature regarding safety and ergonomics (or human factors) for industrial collaborative robotics were identified and categorized. The emerging research challenges and research fields were identified and analyzed based on the development of publications over time (annual growth)

Human centric collaborative workplace: the human robot interaction system perspective

The implementation of smart technologies and physical collaboration with robots in manufacturing can provide competitive advantages in production, performance and quality, as well as improve working conditions for operators. Due to the rapid advancement of smart technologies and robot capabilities, operators face complex task processes, decline in competences due to robots overtaking tasks, and reduced learning opportunities, as the range of tasks that they are asked to perform is narrower. The Industry 5.0 framework introduced, among others, the human-centric workplace, promoting operators wellbeing and use of smart technologies and robots to support them. This new human centric framework enables operators to learn new skills and improve their competencies. However, the need to understand the effects of the workplace changes remain, especially in the case of human robot collaboration, due to the dynamic nature of human robot interaction. A literature review was performed, initially, to map the effects of workplace changes on operators and their capabilities. Operators need to perform tasks in a complex environment in collaboration with robots, receive information from sensors or other means (e.g. through augmented reality glasses) and decide whether to act upon them. Meanwhile, operators need to maintain their productivity and performance. This affects cognitive load and fatigue, which increases safety risks and probability of human-system error. A model for error probability was formulated and tested in collaborative scenarios, which regards the operators as natural systems in the workplace environment, taking into account their condition based on four macro states; behavioural, mental, physical and psychosocial. A scoping review was then performed to investigate the robot design features effects on operators in the human robot interaction system. Here, the outcomes of robot design features effects on operators were mapped and potential guidelines for design purposes were identified. The results of the scoping review showed that, apart from cognitive load, operators perception on robots reliability and their safety, along with comfort can influence team cohesion and quality in the human robot interaction system. From the findings of the reviews, an experimental study was designed with the support of the industrial partner. The main hypothesis was that cognitive load, due to collaboration, is correlated with quality of product, process and human work. In this experimental study, participants had to perform two tasks; a collaborative assembly and a secondary manual assembly. Perceived task complexity and cognitive load were measured through questionnaires, and quality was measured through errors participants made during the experiment. Evaluation results showed that while collaboration had positive influence in performing the tasks, cognitive load increased and the temporal factor was the main reason behind the issues participants faced, as it slowed task management and decision making of participants. Potential solutions were identified that can be applied to industrial settings, such as involving participants/operators in the task and workplace design phase, sufficient training with their robot co-worker to learn the task procedures and implement direct communication methods between operator and robot for efficient collaboration

Smart working technologies in industry 4.0 : contributions to different manufacturing activities and workers’ skills

A Indústria 4.0 é considerada a quarta revolução industrial porque utiliza uma ampla integração de tecnologias de informação e de operação na fabricação industrial. Apesar dessa perspectiva tecnológica, diversos estudos vêm evidenciando a importância de considerar o fator humano para o desenvolvimento de um sistema de manufatura inteligente. Nesse sentido, a dimensão denominada como Smart Working precisa ser melhor investigada, uma vez que entender como as tecnologias afetam os trabalhadores e as habilidades desses são cruciais para o bom desempenho das fábricas. Em razão disso, o objetivo desta dissertação foi entender como as Smart Working Technologies (SWT) podem contribuir para as atividades e as habilidades dos trabalhadores da manufatura. Para tanto, primeiramente foi realizada uma análise abrangente da literatura para identificar as SWT e seus impactos nas capacidades dos trabalhadores em suas atividades de manufatura. Deste modo, foram analisados 80 artigos que relacionam as SWT em oito atividades de manufatura. Posteriormente, foi selecionada uma das SWT mais relevantes conforme a literatura, os robôs colaborativos, para identificar os efeitos das tecnologias nas habilidades dos trabalhadores. Deste modo, foram analisados 138 casos de aplicação reportados por uma das empresas fornecedoras líderes mundiais, bem como três entrevistas com empresas adotantes da tecnologia. Os resultados apontam que existem 15 SWT que podem ser implementadas nas atividades de manufatura e relacionadas às capacidades dos trabalhadores. Além disso, os resultados também apontam que podem existir quatro efeitos das SWT nas habilidades dos trabalhadores. Estes achados demonstram que de acordo com a estratégia da empresa uma SWT pode impactar de diferentes formas os trabalhadores.Industry 4.0 is considered the fourth industrial revolution because it uses a broad integration of information and operating technologies in industrial manufacturing. Despite this technological perspective, several studies have highlighted the importance of considering the human factor to develop a smart manufacturing system. In this sense, the Smart Working dimension needs to be further investigated since understanding how technologies affect workers and their skills are crucial for factories' good performance. Therefore, the objective of this dissertation was to understand how Smart Working Technologies (SWT) can contribute to the activities and skills of manufacturing workers. To this end, firstly a systematic literature review was carried out to identify SWTs and their impacts on workers' capabilities in their manufacturing activities. Thus, 80 articles relating to SWT in eight manufacturing activities were analyzed. Subsequently, one of the most relevant SWTs according to the literature, collaborative robots, was selected to identify the effects of technologies on workers' skills. In this way, 138 application cases reported by one of the world's leading supplier companies were analyzed, as well as three interviews with companies that adopted the technology. The results show that there are 15 SWT that can be implemented in manufacturing activities and related to workers' capabilities. In addition, the results also point out that there may be four effects of SWT on workers' skills. According to the company's strategy, these findings demonstrate that an SWT can impact workers in different ways

Smart Technologies for Precision Assembly

This open access book constitutes the refereed post-conference proceedings of the 9th IFIP WG 5.5 International Precision Assembly Seminar, IPAS 2020, held virtually in December 2020. The 16 revised full papers and 10 revised short papers presented together with 1 keynote paper were carefully reviewed and selected from numerous submissions. The papers address topics such as assembly design and planning; assembly operations; assembly cells and systems; human centred assembly; and assistance methods in assembly