Intelligent and collaborative robotics in the factory of the future

This development offers companies the opportunity to counter the growing shortage of skilled workers by partially automating production processes. Relocating production back to Germany is also becoming more attractive thanks to intelligent robotics, as shorter supply chains become possible.

The question for companies now is: where and how can intelligent and collaborative robotics be best used? The webinar held by Bayern Innovativ's ZD.B Digital Production & Engineering themed platform in October 2023 provided insights into current research activities and results on intelligent and collaborative robotics for industrial applications as part of the webinar series "From research into practice".

Human-Robot Collaboration in Industrial Assembly and Disassembly

In the first presentation, Prof. Dr. Tobias Kaupp, Head of the Center for Robotics (CERI) at the Würzburg-Schweinfurt University of Applied Sciences (THWS), introduced the activities and goals of the center. It is one of the first in Germany to offer a bachelor's degree in robotics and aims to counteract the shortage of skilled workers in regional industry. The institute conducts research and transfer in close cooperation with industry. Robotics research at CERI focuses on two established fields of work: robot-assisted production and assembly, which are the subject of the lecture, and intralogistics in the smart factory with a focus on driverless transport systems.

Comparison between classic and collaborative/intelligent robotics

First, Prof. Dr. Kaupp compares classic industrial robotics and collaborative/intelligent robotics. The main distinguishing criteria include environmental perception/intelligence, safety and programmability. Classic industrial robots have been operating blindly and identically for decades, executing pre-programmed movements with great precision and repeatability. This type of robot is usually programmed once by experts for mass production and there are few changes. Collaborative robots, known as cobots, on the other hand, have the ability to perceive their surroundings and work together with humans. At seven percent, they still account for a relatively small share of the market. The three main reasons for the limited close collaboration are the conflict between safety and productivity, the limited intelligence of the systems and the manual division of assembly steps between humans and robots.

KoPro research project: Collaborative process chains

In order to overcome these challenges, THWS is working on the Collaborative Process Chains (KoPro) project, which is funded by the Bavarian Research Foundation. The aim of this project is to improve the planning and execution phase in assembly. Assembly sequences are to be automatically extracted from product and process data and adapted to the current situation during assembly. An application example shows what this can look like in practice. Here, the collaborative assembly of components is presented, in which a hybrid team of humans, robots and worker assistance systems work together. The aim is to enable collaboration at eye level and thus partially automate assembly processes.

Disassembly using the example of e-waste recycling

Another example deals with disassembly in e-waste recycling. Here, collaborative robots are used to carry out complex disassembly tasks autonomously, such as recognizing components or replacing defective parts. This shows the potential of cobots in various application areas, especially in the waste disposal and recycling industry.

Collaborative robotics for the future of industry

In summary, Prof. Dr. Kaupp emphasizes the importance of further developing collaborative robots to improve cooperation with humans and drive automation in various industrial sectors. While close collaborations in which humans and robots work simultaneously on a workpiece are still the exception rather than the rule, cobots still offer a wide range of possible applications.

The future development of robotics will be an increasing integration of intelligence and adaptability in collaborative systems to enable even more efficient and safe collaboration.

Intuitive configuration and flexible execution on variable robot stations

At the beginning of his presentation, Dr. Korbinian Nottensteiner, a robotics engineer from the University of Würzburg, introduces the topic of "Collaborative robotics".Korbinian Nottensteiner introduces the Institute of Robotics and Mechatronics, which is part of the German Aerospace Center (DLR). The DLR is Germany's aerospace research center with over 30 locations and around 10,000 employees. Although the institute is mainly active in space research, it also conducts research into applications for the production of the future. This requires more flexibility and adaptability in order to meet changing market requirements. To this end, the "Factory of the Future" project was launched by the Institute of Robotics and Mechatronics with the participation of other DLR institutes and external partners. Dr. Nottensteiner shows how variable robot workstations can be used to handle a wide range of production tasks, from assembly to quality assurance. The aim is to create a fully digital process chain that extends from product specification to execution and enables the efficient implementation of new tasks with little effort.

The specially developed collaborative lightweight robot SARA

The collaborative lightweight robot SARA from the DLR Institute of Robotics and Mechatronics plays a central role in this and, together with the Human Factory Interface (HFI), enables intuitive configuration and flexible execution. SARA is characterized by its large workspace, an integrated tool change adapter and special sensors for detecting external forces. This enables safe collaboration with people, the recording of interaction and process forces during demonstrations and the execution of contact-intensive manufacturing processes. In addition to the actual process, the lightweight robot can also independently carry out preparatory steps in a variable workstation using a planning system, thus reducing manual effort.

Practical example: Assembly of a chainsaw

A practical example that is being implemented as part of the project is the assembly of an electric chainsaw. A variable workstation is used here, on which various tools such as grippers and screwdrivers are available. The robot independently places brackets on which workpieces can be positioned. This hardware is transferred to a digital knowledge database using a CAD export. By using reusable, object-centric robot skills and the HFI as a user interface, the tasks can be intuitively parameterized and planned.

Practical example: quality assurance

Another example concerns quality assurance, in which a special measuring device is used to measure bearing rings. Here, too, it is shown how the system can configure tasks independently and perform them sensitively, using human demonstrations to supplement missing knowledge and teach a motion model for the robot skills.

Flexible and adaptable production of the future

Overall, the institute is aiming to integrate more autonomy into the entire process chain in order to relieve the burden on humans. At the same time, it enables interaction with humans at all times in order to realize a flexible and adaptable production of the future. The institute's intelligent collaborative robotics enables intuitive operation and rapid reconfiguration of workstations.

AI for industrial robots: With robobrain® to maximum flexibility in your company

In his presentation, Mr. Roland Singer from robominds emphasized the advantages of intelligent robotics and presented innovative technologies that are driving the industry forward. One of these technologies is the company's proprietary product robobrain® - an intelligent, process-oriented control platform for robots based on artificial intelligence (AI). This advanced technology gives industrial robots intelligence without the need for time-consuming training, thus enabling the rapid implementation of automation processes independently of the robot manufacturer and without expert knowledge.

The control platform functions autonomously and does not require a cloud connection or internet connection. Data is stored on the system and is not transmitted externally unless the operator grants remote access for support or updates.

The combination of the control platform, a robot operating system and specially developed AI capabilities enables the control of various robot components such as robot arms, grippers and vision systems. This leads to individual solutions for warehouse and laboratory automation, depending on the skills and abilities required. Hand-eye coordination, a complex challenge in robotics, is facilitated by the system.

No more time-consuming programming

The conventional, time-consuming and complex programming of robots is revolutionized by intelligent robotics. Instead of hundreds of thousands of manually entered commands, artificial intelligence now provides the required process intelligence. This user-friendly and flexible approach to robot programming is supported by camera systems for object recognition and neural systems for converting this information into movements. This enables the system to identify and handle objects without the need for special training.

Development of skills for various tasks in intralogistics

Different AI skills have been developed for various applications, including recognizing products in boxes, gripping white sausages and pretzels and loading boxes with small load carriers (SLCs). These capabilities allow the system to perform various tasks autonomously. In the SINA (Smart Kitting Solution for Intralogistics Automation) project, an automated warehouse was developed to pick products based on orders.

Mr. Singer's presentation underlined the diverse applications and user-friendliness of intelligent robotics in production. This serves as an example of successful product developments in the industry that enable future-oriented production in which man and machine can complement each other perfectly.

Final panel discussion

Whether it was about the distinction between cobots and lightweight robots, criteria for task assignment between humans and robots or safety features and standards - the final panel discussed the numerous questions from the participants. Among other things, the discussion revealed that although cobots are already capable of performing complex tasks, there are still many challenges and development needs, particularly in the area of sensor technology and interaction with humans. It was also emphasized that safety aspects continue to be of great importance.

The webinar series "From research into practice"

In the event format of the Material & Production division of Bayern Innovativ, research institutions and companies provide insights into current research activities and discuss them with the participants. The aim is to support small and medium-sized companies in particular in making meaningful use of digital technologies in their production processes and engineering.

The Mechatronics & Automation cluster was involved in this webinar - the platform for the cross-sector exchange of expertise in digitalization & Industry 4.0. The strategic innovation topics include production security, additive manufacturing, mechatronic drive technology, artificial intelligence and robotics for the production of the future.

Contact details of the speakers

Prof. Dr. Tobias Kaupp, Professor of Digital Production & Robotics and Head of the Center for Robotics (CERI), Würzburg-Schweinfurt University of Applied Sciences (THWS)
Contact by Mail

Dr.- Ing.Korbinian Nottensteiner, project manager and spokesperson for the Production of the Future domain at the Institute of Robotics and Mechatronics, German Aerospace Center (DLR), Oberpfaffenhofen. (DLR), Oberpfaffenhofen
Contact by Mail

Roland Singer, Partner Manager, robominds GmbH
Contact by Mail