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New Industrial Robotics:
Human and Robot
collaboration for the factory
Dr. Ralf Koeppe, KUKA Laboratories GmbH
KUKA AG - Overview
KUKA Roboter
KUKA Laboratories
KUKA Systems
KUKA AG
Industrial Robotics
Advanced Robotics
Robot based Automation
General Industry
Medical Robotics
General Industry
KUKA
Roboter
Automotive
KUKA
Laboratories
Service Robotics
Technology Platform / Research
KUKA
Systems
Automotive
Factory of the future - Production today
Manual
manufacturing
Level of automation
Full
automation
Key to sensitivity
Joint torque sensor
on each axis
Measuring the Torque
on each axis
Leichtbauroboter – Evolution
DLR LBR1
DLR LBR2
DLR LBR3
1991 – 2005
Project at German
Aerospace Center (DLR)
Robotics and Mechatronics
Centre
Zukunft der Robotik
KUKA LBR3
KUKA LBR4
2005 – 2012
Technology Transfer and
continuing development
and improvement by
KUKA from prototype
LBR 3 to pre-serial
product LBR 4 / 4+
KUKA LBR4+
KUKA LBR iiwa
2013
LBR iiwa
Serial product for
industrial use 24
hours / 7 days
LBR iiwa - Mechatronics
2x Motor
2x GMS
2x Justage
PDS3
PDS2
2x Motor
2x GMS
2x Justage
2x Motor
2x GMS
2x Justage
1x Motor
1x GMS
1x Justage
High level of integration
of electronics and mechanics
Joint Torque Sensor
Motors
Gears
PDS2
PDS1
Factory of the future - Production today
Manual
manufacturing
Level of automation
Full
automation
Factory of the future - Production tomorrow
Manual
manufacturing
HRC1
Level of automation
1) HRC = Human robot collaboration
Full
automation
Source: Daimler
Productivity
Automation based on HRC boosts flexibility and productivity
High flexibility at limited
productivity
High productivity at
limited flexibility
High flexibility and high
productivity by Human-RobotCollaboration
Goal: scalable automation
1
Station no.
1
Expansion
stage
2
Expansion
stage
3
Expansion
stage
4
Capacity
limit
Qualitative representation
3
4
5
6
7
3
1
Product A
8
4
3
Quantity
Expansion
stage
2
2
3
Product B
2
1
Time
Human-Robot Collaboration (HRC) application engineering
Invitation to
tender
Quotation
Detailed
planning
Order
Simulation tool (HRC)
Commissioning
HRC production
concept
Factory
concept
Costeffectiveness
LBR iiwa HRC
technology
Installation
Programming
Process
analysis
HRC expertise
and tools
HRC catalog
Optimization
Acceptance
Work safety
approval
What do manufacturing SMEs say?
“We only have
small series:
No time to
program a robot –
we have to deliver
fast!”
¾ hour stupid work!
Could a robot take over?
We did deburring with a robot, but now we
have different parts!
“We cannot afford
to employ a robot
specialist!”
My best employee shall optimize the
process instead of programming a robot!
Again and again cumbersome teach-in…
When will it eventually work?
Today’s work system – criticism and needs
Criteria
Today
Goal
socioeconomic
 customer orientation
 competition with low-wage countries
 to sustain in the competition with even better
customer orientation
quality
 high quality, precision, delivery reliability
 to further improve the quality
 ambition of employees to deliver good
quality
 to reduce post processing times
 limited by manual processes
 to shorten delivery times (from order)
 sufficient to make profit
 to adapt / customize production
attractiveness
of work
 low: dirty, unhealthy, boring, repetitive
 to improve motivation and health
 difficulties to find experienced welders
 to provide challenging work with “high-tech”
machines (robots, PCs)
safety
 protection for eyes, mouth and ears
required, but not always worn
 to avoid fences, to only use glare shield
 (very) poor, e.g.: lifting and handling of
heavy and bulky work pieces, unhealthy
postures, toxic fumes
 to provide better ergonomics to improve
health conditions
productivity
ergonomics
 to prevent the worker from circumventing
safety measures
Robotics based on mainstream IT technology
[+] Operating
KUKA SUNRISE
Robotics OS
enabling
safe sensor-based
multi-kinematics
application
[+] Programming
Java API /
C++ Core
[+] Hardware
Innovation
New technologies are opening up new applications and markets
4th Robotic Revolution
Intelligent and perceptive
robot systems
2nd Robotic Revolution
Sensitive, safe robot-based
automation (LBR iiwa)
3rd Robotic Revolution
Mobility,
Mobile Manipulation
1st Robotic Revolution
Industrial automation
Industrie 4.0
Driving innovation through collaboration
 non-profit organisation for all stakeholders in
European robotics, founded 2012/09/17
(aisbl = association internationale sans but lucratif)
 >180 members from industry and research
 successful collaboration between industrial and
academic players
 ensuring sustainable development of European
robotics
 private side of a contractual
public-private partnership
(PPP) with the European
Union as the public side
in Horizon 2020
SPARC
The Partnership for
Robotics in Europe
Summary
 New Industrial robots like LBR iiwa enable production systems beyond full
automation
 Human-Robot Collaboration, mobile manipulation and perception are key technologies
 Workers and robots don’t compete! The robot assistant is the device operated
by industrial workers.
 Non-expert robot assistant operation based on SW driven technology is needed for SME
automation, e.g. programming by demonstration and will be available in the future.
Factory assistant
Sensitive assembly /
loading / unloading
Human-Robot
Collaboration
Mobile
Manipulation
Thank you for your attention - [email protected]

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