Automate 2017 Show and Conference Participation Hits New Heights
Includes Visitors from Over 70 Countries Including China
The IFR Committees recently gathered in a series of virtual meetings. These conversations replaced our regularly scheduled meetings during the automatica tradeshow, which would have been last week.
The IFR Committees recently gathered in a series of virtual meetings. These conversations replaced our regularly scheduled meetings during the automatica tradeshow, which would have been last week. Even though they lacked our usual opportunity for face-to-face, one-to-one networking, our virtual assembly worked astonishingly well, creating a feeling of solidarity in these difficult times. In total, 75 people gathered in five web discussions to review preliminary results of the IFR statistics, exchange views and ideas, and push our industry further after COVID-19.
The coronavirus has impacted our economy and our personal lives for more than four months now. While it is hard to imagine what the future will look like, there are hopes that the market will slowly recover, and that business will return to normal in fall. The situation differs across the globe. Some countries are leading the way toward recovery, while infection rates are increasing in others. One would imagine that economic recovery will also come at varying times.
The past months proved to be a showcase of the benefits of robotics, demonstrating how automation can help companies become more flexible and adapt to volatility in the marketplace. Robots were used to quickly adapt manufacturing lines for production of personal protective equipment, respirators, and other goods desperately needed by frontline personnel. New solutions have been developed and deployed for robots in service. For example, disinfectant robots and robots for home delivery and telepresence robots saw unprecedented attention.
Over the course of time, automation is expected to become even more important to a company’s success by safeguarding competitiveness, maintaining supply chains, and reducing human contact in manufacturing to avoid infections. The media have quickly acknowledged these success stories, and robotics has received tremendous attention in the news and from the broader public. It is clearly integral to the future of manufacturing.
We should move forward with confidence, patience and persistence to get through this crisis, to learn from the opportunities it presents, and to come out stronger.
Stay safe, and best wishes to you, your families, and your teams.
The IFR General Assembly elected Marina Bill (ABB), Kenji Yamaguchi (FANUC) and Masahiro Ogawa (Yaskawa) as new members for the IFR Executive Board. The delegates are following Steven Wyatt (ABB), Junji Tsuda (Yaskawa) and Shinsuke Sakakibara (FANUC).
Marina Bill currently serves as Global Head of Marketing & Sales for ABB’s Robotics and Discrete Automation business, Kenji Yamaguchi is President and Chief Executive Officer of FANUC Corporation and Masahiro Ogawa holds the position of Managing Executive Officer of Yaskawa Electric Corporation and General Manager Robotics Division.
Association delegates Hiroshi Fujiwara (JARA), Xiaogang Song (CRIA), Jiegao Wang (Estun) and Patrick Schwarzkopf as well as the representatives of the Research Committee, Prof. Alexander Verl (University Stuttgart) and Prof. Jong-Oh Park (Chonnam University) were confirmed as Executive Board members.
For the first time ever, the annual IFR General Assembly meeting was held as web meeting due to the corona pandemic. Delegates from around the globe were joining the meeting at different local time. This was a new challenge for both the attendees and the organizers.
The IFR Robot Suppliers Committees also met in the same week and elected Marina Bill as its new Chair, supported by Marcus Mead (Yaskawa) as Vice-Chair, following Andreas Bauer (KUKA) and Bruno Schnekenburger (Yaskawa).
After her election, Marina stated: “I am honored to bring my experience, education and skills to IFR, and look forward to putting them toward a good cause. I would like to use the knowledge and international experience gained in my career to help raise the voice of the global robotics industry.”
Melonee Wise (Fetch Robotics) replaces Martin Haegele (Fraunhofer IPA) as Chair for the IFR Service Robot Group and Armin Schlenk (Yaskawa) took over the IFR Marcom Committee from Steven Wyatt (ABB) already end of last year.
After a week of meetings and elections, all important positions have now been filled again. The General Secretariat is looking forward to a fruitful collaboration with all delegates in these challenging times.
The Autonomous Mobile Robot Phollower is used in a hospital in Slovakia (Kosice - Saca) for autonomous transportation of drugs and medical material between hospital central medications storage and hospital departments located on 11 different storeys empowering hospital pharmacy management.
This is enabling safe distribution of drugs and hospital material without personal contact also into zones where special restrictions have been applied or quarantine is applied.
Robot can move along its global path, and reach the goal without colliding with static and moving objects. Version of AMR for hospital purposes was designed with respect to dimensions of hospital elevators and its sufficient space for all of the hardware components, drives, the lifting platform and two battery packs. The footprint of the current AMR version is 600 mm, the height of the base is 270 mm and the platform length is 1250 mm.
AMR Phollower weights 75 kg and nominal load is limited to 60 kg of cargo. Using the latest B&R hardware components and the most recent software stacks for autonomous localization, navigation and mapping we have developed a logistics solution which is suitable for use in the more demanding tasks even in hospital environments. The AMR hospital version project was co-developed with Technical University of Kosice, Slovakia.
The main features of the current model Phollower 100:
no magnetic tape required
360° Laser scanner area
Adaptive safety zones
The AMR is able to navigate itself on the basis of lidar, 3D camera and a virtual map. The laser scanner area covers 360° whereby the body of the robot has an interchangeable front and rear with zero turning radius which allows reversible movement. The AMR uses odometry and allows trajectory creation with custom curves and instant map redrawing. The variability of Phollower 100 offers many use cases - it can be used with collaborative robots, carry boxes, pallets or pull payload of any kind.
What started with a vision – eyeglasses as an accessory – back in 1964 has since grown into the world’s leading brand of lightweight glasses with sales in excess of € 100 million: “Silhouette”.
Silhouette is the brand name of the lightest glasses in the world, manufactured with painstaking detail and an individual design language. They are made in Austria using the best materials and latest technologies by a workforce numbering more than 800 people, and exported all over the world (export quota 95 percent). Since 2013, a KUKA KR 5 arc robot has been a firm feature of the production process at Silhouette.
A clear vision of what matters
Silhouette has stood for technical perfection and innovative design for 50 years. These are eyeglasses without frames, screws and hinges, combining functional and esthetic appeal with vision. Right from the beginning, the product range has been characterized by a consistent approach to paring things down to the essentials. Silhouette glasses have been launched into space more than 35 times on board NASA missions, and they are also worn by the Vienna Philharmonic Orchestra on its world tours as well as by a host of prominent celebrities, businesspeople and politicians.
The effects of wear over time combined with increasing maintenance costs of the facility prompted Silhouette to rethink its own production process in 2011. According to the Linz-based glasses producer, there are no fully automatic production systems available on the market able to handle the complete manufacturing process end-to-end; as a result, the existing equipment would have to undergo a complete overhaul. The project was taken on by Siemens and KUKA. It was possible to start operation after a conversion period lasting only four months. Since then, the system has been running smoothly in three-shift working.
The solution in detail
High-quality Silhouette sunglasses are made in a manufacturing process that is first-class throughout. The polycarbonate glasses are cut precisely to shape using the modernized multiple-spindle production system in which a KR 5 arc ensures that the blanks are fed in with the necessary precision. The KUKA robot uses its vacuum grippers to take the allocated eyeglass blanks out of the stacking magazines, places them in a centering station where they are exactly positioned and transfers them to the milling machine. This mills and drills the contours of the polycarbonate glasses in several steps. In this process, the multiplespindle center is capable of achieving tolerances of ± 0.015 mm and surface qualities with an average surface roughness of Ra = 0.1 μm. At the end of the machining process, vacuum grippers come into play again, placing the completed glasses into transport boxes. The KR 5 arc makes it possible to run a fully automated night shift thanks to its great flexibility, reliability and extreme degrees of freedom.
The robot and the machine tool are controlled using a centralized, high-end CNC, a Sinumerik 840D sl. This was extremely important for Silhouette, because although the machining technicians know precisely how to operate the machine tools, they are not familiar with handling a multiple-axis jointed-arm robot. The Siemens RunMyRobot software interface meant that these inhibitions could be dispensed with.
From today’s perspective, it is apparent that the investment has proven to be extremely sensible because of significant advantages in terms of productivity, reliability and user-friendliness. As a result, Silhouette, with KUKA and the mxAutomation software interface, always succeeds in producing optically correct lenses – 20 percent faster than before the system was renewed. “mxAutomation allows the KUKA robot to be programmed in the familiar environment of the machine tool – that saves long familiarization periods and helps overcome any initial reservations associated with robots,” says Joachim Strobel of KUKA Roboter GmbH.
Great Plains Manufacturing, an agriculture equipment manufacturer, needed a unique robotic welding solution to reduce their time to market as well as their overall production costs.
The company began as a small shop in Salina, Kansas, and has grown into one of the largest privately-held manufacturers in their industry. They understood that as their company continues to grow, automation is essential to remain competitive and strengthen their growth potential.
Great Plains Manufacturing had complex production schedules that were not easily automated. Their production runs were between 5 and 1,000 pieces, with cycle times from 10 seconds to 60 minutes. It wasn’t unusual for them to produce 30 product lines in one month. The amount of tooling this required posed significant obstacles to the efficiency and cost benefits of robotic automation.
Genesis leveraged virtual solutions for proof of concept, design and process prior to building or implementing the system. Virtual solutions simulate successful automation to ensure that mistakes and inefficiencies aren’t built into the system.
Virtual solutions for robotic welding included 3D simulation of welding processes, 3D immersive virtual environment simulations and reach studies to demonstrate the capabilities and limitations of the proposed automation system.
Leveraging their in-house Virtual Solutions Center, Genesis was able to provide Great Plains with a clear understanding of the proposed robotic welding system. Together they were able to make the necessary tweaks to fine tune the system. Using the virtual system design, Great Plains was able to develop the custom tooling they needed in-house, and prepare offline programming, all while Genesis was building the system.
The result was a streamlined integration project that saw the system fully operational on the very same day it was implemented.
Great Plains Manufacturing received a custom robotic welding solution that helped improve their time to market and speed of production, ultimately increasing their competitiveness in the agriculture equipment manufacturing space.
With KUKA Toledo Production Operations (KTPO) KUKA set a new milestone in terms of the digital supply chain and Industry 4.0. The manufacturing solution consisting of networked systems and architectures was set up as long ago as 2006 and was ahead of its time. The plant enabled a quantum leap in productivity.
Up until 2006, the efficient production of high volumes and a wide range of models and variants on the same production line had always been considered impossible. KTPO proved the opposite: the body-in-white plant for Jeep® Wrangler bodyshells is pioneering in terms of networking and process control – as well as offering unprecedented flexibility. KUKA was already implementing Industry 4.0 in reality back then.
The “Internet of Things in a Box”
A vehicle body – of whatever model and whatever version – comes off the production line every 77 seconds. Reliably, day in, day out, for the last ten years. To achieve this, KUKA linked the plant’s 259 robots and 60,000 other devices with powerful back-end monitoring systems and a master data management system. This was essentially the development of “IoT in a Box” which has evolved dynamically and continuously ever since.
For years, the plant has been one of the most efficient body-in-white lines in the US automotive industry and one of the pioneers of Industrie 4.0. So far, at a rate of nearly one a minute, around one and a half million bodies-in-white for the Jeep® Wrangler have rolled off the same line, irrespective of whether they are for the classic two-door model or for the four-door “Unlimited” series.
Pioneering operator model
The Jeep® Wrangler is a success story – in terms of both production and demand. In order to keep up effortlessly with the increasing production figures, KTPO made use of an intelligent control system to enable non-stop output of bodyshells in two-shift operation. “KTPO reliably produces top-quality vehicle bodies,” emphasizes KTPO Managing Director Jake Ladouceur.
The operator model at KTPO is also pioneering. In the four production facilities at the “Toledo Supplier Park”, several suppliers take on responsibility for the manufacture of entire preliminary stages in their own production shops. Chrysler itself is responsible for painting and final assembly.
KTPO as an intelligent lifecycle management platform
What began with the networking of production processes via back-end monitoring systems, has meanwhile developed into an intelligent lifecycle management platform as part of Industrie 4.0. The fully digitized solution, linked to production, controls and monitors the entire value chain in real time, from receipt of materials to the actual production processes and goods dispatch. It also identifies weak points and optimizes capacity utilization.
Day in, day out, KTPO impressively demonstrates that KUKA is operating a body-in-white production facility that can meet the most exacting standards of the global automotive industry in terms of quality and efficiency as well as the requirements of Industrie 4.0.
LT Automation and Intelligent Systems have developed a robotic system with transport boxes for automatically checking and sorting blood samples at Aalborg University Hospital.
Aalborg University Hospital is the largest hospital in the North Jutland region of Denmark. Up to 3,000 blood samples arrive here in the lab every day. They must be tested and sorted – a time-consuming and monotonous process which was done manually until now. The university hospital has now automated the procedure: a robot-based system and intelligent transport boxes ensure the quality of the samples – and show how workflows in hospitals can be simplified by automation.
New process reduces the workload on employees and optimizes workflows
Up to 3,000 blood samples are delivered to the lab in Aalborg University Hospital every day and need to be presorted in accordance with the requested test. This task is monotonous on the one hand, and requires particular care on the other. In order to free up lab technicians from this work, the hospital set itself the goal of automating the sorting process for blood samples. Two local companies were involved in achieving this: LT Automation A/S designed and implemented the robotic solution. The software developer Intelligent Systems A/S developed the software that monitors the temperature of the blood samples during transportation.
The previous manual process was as follows: the lab staff opened the transport boxes on arrival, removed the blood samples and sorted them for further clinical analysis. Because of the large number of boxes, the hospital employees often suffered from tendon and muscle injuries as a result of the repetitive work. “We wanted to automate this process to ease the burden on our employees,” explains Annebirthe Bo Hansen, Department Head at Aalborg University Hospital. “Furthermore, we were looking for a solution to improve monitoring of the quality and temperature of the blood samples.”
KUKA robots and RFID logger facilitate quality assurance
In order to optimize the workflow, LT Automation and Intelligent Systems developed a robotic solution as well as an innovative transport box. Two KUKA KR AGILUS series robots, a KR 3 and a KR 10, were installed in the sorting system. “There were several reasons for choosing a robot from KUKA,” states LT Automation CEO Lasse Thomsen. “One of them was that the robots meet the technical requirements. And another reason was that the white external appearance fits with the image expected in a sterile environment.” The robots are controlled via the mxAutomation control system. A conveyor belt feeds the transport boxes to the robots shielded by Plexiglas screens.
The special feature of the “intelligent transport box” is the integrated RFID data logger, which not only tracks the transport route of every single box. The logger also saves what temperature was present inside the box at what time. A key factor, as explained by Annebirthe Bo Hansen: “In order to ensure the quality of the blood samples, the temperature must consistently be 21° C +/- 1° C.” By introducing the “intelligent transport box”, the hospital realized that this was not always guaranteed in the past. “The new technology has helped us to discover and rectify sources of error,” states Annebirthe Bo Hansen, expressing her satisfaction. “That is an important improvement.”
The blood samples travel long distances before reaching the hospital: they are taken in general medical practices in the region surrounding the hospital. Doctors place the glass tubes filled with the samples vertically into the transparent transport boxes, which are stored in an appropriate cabinet ensuring the optimal temperature. At time of collection the courier scans the boxes, enabling their transport route to be tracked. The courier brings the blood samples to the hospital where they are scanned and registered on arrival.
In the lab, a technician places the transport boxes on the input conveyor of the robotic system. At that moment, an RFID scanner installed in the room reads the data logger. “If the scanner detects that the temperature inside a box has deviated from the specified temperature at any time during its journey, it automatically sends a notification to the robot,” explains Lasse Thomsen. “The robot offloads the affected box from the system to the lab technician’s workplace.” The employee takes a close look at the data saved on the logger in order to decide whether the blood samples in the box can still be used.
If the data logger does not indicate any improper temperatures, the first robot opens the box, takes the blood samples out and sets them down for sorting. Then the robot places the cover back onto the box and offloads it so that it can be reused for transportation. At the same time, the second robot sorts the unpacked glass tubes by the color of their stopper, which it identifies with the aid of a scanner. The presorted samples are output from the system such that the lab technician can carry out the blood test. On average, the system needs 1.5 minutes per box, which is equivalent to a capacity of forty boxes per hour.
Optimizing the process and improving the workplace
The new system was initially tested in March 2019 and went into full operation in August. “We are highly satisfied with this solution,” concludes Annebirthe Bo Hansen. “The working environment and workflows have improved considerably with this change.” The lab technicians now have more time not only to analyze the blood samples but also to spend with patients. In addition, the automated sorting and continuous temperature control in the transport box have reduced potential sources of error.
“The new system makes Aalborg University Hospital a forerunner on the path to ‘Hospital 4.0’,” says Lasse Thomsen. “Automation can help simplify workflows and assure high quality especially in times when there is a shortage of skilled personnel.” For this reason, he sees great potential in the robotic solution: it would be of interest to all hospitals with their own clinical biochemical lab, in this form or similar.
Every five minutes, KUKA robots in northern Italy print head brackets for face shields. More than 1,000 are thus produced every day. The Italian company Caracol-AM is donating parts of the production to local hospitals and institutions.
Since the beginning of the coronavirus pandemic, the demand for face shields has risen rapidly. Caracol-AM has used its experience in the field of additive manufacturing to develop an automated 3D printing solution with KUKA robots. Head mounts for face shields are printed. Additionally, industrial 3D-printers print reusable protective masks.
“During the COVID-19 emergency, we want to make a contribution with our 3D printing processes. Thanks to our experience in this field, we were able to react quickly and convert our production,” says Francesco De Stefano, CEO of Caracol-AM. “Our robotic systems and industrial printers are running at full speed to produce protective equipment. The headgear printed by the KUKA robots is complemented by a plexiglas, which Caracol-AM purchases from a partner company, to protect against droplet infection.”
Caracol-AM has been active in the field of additive manufacturing for three years and employs 15 people. “Our KUKA robots help us to produce quickly and meet the high demand for protective equipment. The robot systems are in operation around the clock,” explains De Stefano.
World Robotics 2020 will be published in September 2020. Orders will already be accepted. With your pre-order you will get immediate access to World Robotics 2019 and in September for the 2020 edition.
Robotics is a hot topic these days!
Many cutting edge technologies are connected with the field of robotics, like machine learning and AI, IIOT, man-machinecollaboration or autonomous mobile systems. Intelligent robots are the crucial part of digitalization of the manufacturing industry.
The global manufacturing industry is facing big challenges however, like rapidly changing consumer trends, shortage of resources, shortage of skilled workers, aging society, and demand for local productions.
Flexible industrial robot-based automation delivers the solution to all these challenges. World Robotics observes the robotics industry and offers profound statistical data. It is your key to the world of industrial robots and service robots.
In the post-pandemic era, in response to the concerns on workforce and productivity, the global manufacturers will need to actively set out a forward-looking strategy to expands the scope for the use of safe collaborative robots.
Due to limited resources and land, how factories can quickly set up, relocate or increase production capacity with their existing plant and workforce is a highly concerned issue. Therefore, Touché Solutions launched the safe, efficient and easy to install T-Skin, the world’s first tactile sensor safety technology to obtain CE ISO 13856-3 certification. Once installed, T-Skin immediately enables industrial robots to collaborate with human workers. Moreover, it also enhances workplace safety, makes quick production line reconfiguration possible without being constrained by the fixed workspace, and increases productivity to stay competitive.
During the post-COVID era, solutions for safe, efficient, and quickly implementable production line modification are required
Touché Solutions C.E.O., Andrew Lu “In the post-pandemic era, it’s a must for workers to keep a safe distance on the production line. To meet the post-pandemic demand, in manufacturing industries such as automobile and electronic assembly or metal stamping, factory managers need the solutions to quickly increase level of automation or modify production line to increase the productivity and efficiency. Among all, safe human-robot collaboration is the best solution.”
“This is why fast and easy installation is an important design concept of T-Skin. It quickly gives any robot arm safety protection for use in any industrial environment. After completion of a risk assessment, a robot installed with T-Skin ensures the workplace safety of human staff during collaboration and protect collaborative robot arms from being damaged during operation. In response to the post-pandemic workforce planning, the safe human-robot collaboration to deploy robots installed with T-skin for the repetitive tasks is the biggest boon to the production line.” Moreover, after being upgraded as collaborative industrial robots, it’s possible to remove robots from fences to optimize the use of workplace that increases production efficiency per unit space.
T-Skin (formerly called Contact Skin), Touché Solutions’ pioneering technology for use on a robot arm, is an actual touch-and-stop system. In April, 2020 the system obtained the European Union’s CE ISO 13856-3 and ISO 13849-1 certification: its product safety and functional safety were both certified.
To provide more comprehensive protection for users, besides T-skin, Touché Solutions has also developed the T-Skin Pad Module. With its modular design, it can be quickly assembled to fit the end effectors of different sizes. When installed, the safety protection mechanism is more comprehensive.
New impetus- CE certification and rebranding Touché Solutions
Touché Solutions (formerly Mechavision) will soon mark its third anniversary. Company chairman Camus Su: “The feedback on our products from the market over the last three years has given us even greater confidence in tactile technology and its applications for future robots. We have chosen the time of obtaining CE certification to rebrand as Touché Solutions, reflecting our commitment to make headway in the international market and become the leading brand for tactile sensor technology. We will continue providing solutions for human-robot collaboration, and help clients achieve their production capacity and quality optimization goals.”
The Corona crisis highlights the important contribution that robots make to industry and to society. Research funding programs (R&D) are vital to enable and further support these developments. IFR summarized national funding programs in the new "World Robotics R&D Programs".
New technologies, such as Artificial Intelligence, Big Data and 5G, drive government funding in Asia, Europe and America. What are the targets of the officially driven government research funding programs and what can we learn from these findings? This has been researched by the International Federations of Robotics and published in the new paper “World Robotics R&D Programs”.
“Each country has its own characteristics of robot programs based on its specific background and history,” says Prof. Dr. Jong-Oh Park, Vice-Chair IFR Research Committee and member of the Executive Board. “Therefore, we see that robotics programs set up by the most advanced robotics countries have a very different strategic focus.”
Robotics R&D programs - officially driven by governments
The strategic plan Made in China 2025 comes as a blueprint to upgrade the manufacturing capabilities of Chinese industries. This includes advanced robots among the top 10 core industries. The Robot Industry Development Plan sets out the goals for China in 2020, including: (1) developing three to five globally competitive robot manufacturers, (2) creating eight to ten industrial clusters, (3) achieving 45% of domestic market share for China’s high-end robots, and (4) increasing China’s robot density to 100 robots per 10,000 workers. The statistical yearbook “World Robotics” by IFR shows that China reached a robot density of 140 units per 10,000 workers in the manufacturing industry in 2018. In 2019, the Chinese government invested 577 million USD in the development of intelligent robots.
The New Robot Strategy in Japan is a key policy of the Abenomics Growth Strategy. The robot-related budget for 2019 has been increased to 351 million USD, with the aim to to make Japan the robot innovation hub in the world. The action plan includes manufacturing as well as important service sectors like healthcare, agriculture and infrastructure. According to the statistical yearbook “World Robotics” by IFR, Japan is the world´s number one industrial robot manufacturer and delivered 52% of the global supply in 2018.
The Intelligent Robot Development and Supply Promotion Act of Korea is pushing to develop the robot industry in Korea as a core industry in the fourth industrial revolution. The 3rd basic plan for Intelligent Robots published in 2019 promotes systematic selection and concentration of promising public and private sectors. Focus areas are: manufacturing businesses, selected service robot areas (including healthcare and logistics), next-generation key components and key robot software. The robot-related budget for 2020 is 126 million USD (151 billion won). The statistical yearbook “World Robotics” showed a new record stock of about 300,000 operational industrial robots in the Republic of Korea in 2018 (+10%). Within five years, the country has doubled its number of industrial robots in operation. Following Japan and China, the country ranked third in 2018.
Robotics projects funded by Horizon 2020, the European Union´s 8th Framework Program, represent a wide variety of research and innovation topics – ranging from manufacturing, commercial and healthcare use to consumer, transportation, and agri-food robotics. Through this program, EC provides an estimated 780 million USD funding for robotics research and innovation over its seven-year runtime. The main topics of the Work Program 2018-2020 are related to digitization of industry through robotics, robotics applications in promising new areas, and robotics core technologies such as AI and cognition, cognitive mechatronics, socially cooperative human-robot interaction, and model-based design and configuration tools with the total budget of 173 million USD.
As part of its High-Tech Strategy, Germany support the use of new digital technologies within industry and administration. The “PAiCE” program with a funding budget of 55 million USD (50 million euros) over five years emphasizes the development of digital industry platforms as well as collaboration between companies using these platforms. In particular, the robotics-oriented projects are focusing on the creation of platforms for service robotics solutions in the various relevant application areas including service, logistics, and manufacturing fields. Germany is the fifth largest robot market in the world and number one in Europe, followed by Italy and France. In 2018, the number of robots sold increased by 26% to almost 27,000 units – a new all-time record.
The National Robotics Initiative (NRI) in the USA was launched for fundamental robotics R&D supported by the US Government. The main goals focus on fundamental science, technologies, and integrated systems needed to achieve a vision of ubiquitous collaborative robots assisting humans in every aspect of life. Moreover, in NRI-2.0, collaboration between academia, industry, non-profit, and other organizations is encouraged. The budget of NRI for 2019 is 35 million dollars. Additional robotics funding for application in defense and space is provided through the Department of Defense (DoD) and the Mars Exploration Program. According to the statistical yearbook “World Robotics”, robot installations in the United States increased for the eighth year in a row to a new peak in 2018. Regarding annual installations, the country has taken third position from the Republic of Korea.
Files for Download
Please find the information paper “World Robotics R&D Programs” by IFR for download here.
International Federation of Robotics
phone +49 (0) 40 822 44 284
E-Mail: [email protected]
Gui-Deog Kang, Chief Operating Officer of Robostar, has been elected as the new President of Korea Association of Robot industry(KAR) recently.
He has more than three-decade experience in robot and automation business. He established Robostar in 1999 with several collegues at LG Electric. Before joining Robostar, he had worked at the robot business division in LG Electric since 1987.
“I will dedicate myself to the growth of the robot industry by making use of my 30 years’ experience in this field.” says the new President.
At the inaugural speech, the president also pointed out the importance of collaboration with other industries, strengthening the buildup of the robot industry ecosystem and exchange with overseas partners and customers.”
He received the “Industrial Service Medal of 2019”, from the South Korean government, the most prestigious award in robot business field.
Companies around the world are increasing their use of industrial robots: Within five years, the global operational stock rose by about 65% to 2.4 million units (2013-2018). For the same period of time, the U.S. Bureau of Labor Statistics reported a positive impact on the job market: Employment in the automotive industry – the largest adopter of robots – increased by 22% from 824,400 to 1,005,000 jobs (2013-2018).
These facts contradict the conclusions recently published by MIT´s news office on economist Daron Acemoglu´s research. Based on data between 1990 to 2007 he deduces an overall negative effect of robots on employment in blue-collar working communities in the US. Yet, recent experience in the US, Europe and Asia proves the opposite: robot adoption will likely be a critical determinant of productivity growth for the post-COVID-19 economy. These are results of the International Federation of Robotics.
“The impact of automation on employment is not in any respect different from previous waves of technology-driven change,” says Milton Guerry, President of the International Federation of Robotics. “Productivity increases and competitive advantages of automation don´t replace jobs – they will automate tasks, augment jobs and create new ones.”
OECD Research: “Ten times more productive”
Research by the OECD shows that companies that employ technology effectively are ten times more productive than those that do not. To equip the workforce with the soft skills and technical knowledge required in the post-COVID-19 economy, a tight collaboration between industry, government and educational institutions is needed. Governmental policy incentives should encourage corporate investment in training and support funding of education.
Renaissance of industrial production
Companies around the globe are reassessing their global supply chain business models in reaction to the lessons learned from coronavirus. This will likely accelerate the introduction of robots, leading to a renaissance of industrial production in some regions – and bringing back jobs. After the crisis, IFR expects a considerable boost for robotics and automation, even if the industry cannot currently decouple itself from the economic downturn.
The world is currently facing an unprecedented situation: the novel coronavirus pandemic is spreading around the globe and is heavily affecting the global economy and our societies. No one can predict how long this situation will last nor the consequences that follow.
The world is currently facing an unprecedented situation: the novel coronavirus pandemic is spreading around the globe and is heavily affecting the global economy and our societies. No one can predict how long this situation will last nor the consequences that follow.
As representatives of the robotics and automation industry, we are best suited to find the solutions that support society and aid in its recovery. As IFR, our focus should be to use our skills and knowledge, leveraging what we know best, to tackle the issue at hand and become stronger in a world without borders.
IFR has already started collecting ideas, case studies, and best practices on how our technology provides beneficial solutions. This includes the use of robotics to safeguard local production and reduce dependency on global supply chains. Mobile collaborative robotics solutions are alleviating resource shortages caused by sudden illness and quarantine measures. Flexible production technologies have proven successful at increasing the production of goods in scarce supply, while mobile robotics is being used to relieve strain within hospitals and the logistics sector.
We welcome your input as we begin sharing this information with our broader communities through our blogs, press activities, and social media. Help us tell the story that will shape the direction of our industry for years to come.
Travel restrictions have limited our opportunities to meet in person and hold official IFR meetings at international trade fairs. Last week, the Automatica fair was postponed to December 8-11, 2020. As a result, we have decided to switch to webmeetings. Although different from our usual way to exchange ideas and make decisions, I am confident these virtual environments will enrich our opportunities for collaboration and relationship building and provide us with options for continued networking during the crisis and after.
While it is obvious that this pandemic will have an impact on our industry, it is too early to quantify it, as the global situation changes daily. However, IFR is uniquely positioned not only to weather this storm but also provide assistance to others along the way.
I am convinced that together we will get through this.
Stay safe, and best wishes to you and your family.
Robots play an important role in fighting the coronavirus SARS-CoV-2 around the globe. Disinfection robot UVD for example has been in high demand since the outbreak of COVID-19 pandemic. Chinese hospitals have ordered more than 2,000 UVD robots by Danish manufacturer Blue Ocean Robotics. They started to destroy viruses in Wuhan, where the global pandemic began.
The units operate in more than 40 countries – in Asia, Europe and the United States. UVD uses ultraviolet light (UV-C) to kill harmful microorganisms. The robot is the current holder of the IERA innovation award by IEEE and the International Federation of Robotics (IFR).
“We are now helping solve one of the biggest problems of our time, preventing the spread of viruses and bacteria with a robot that saves lives,” says Claus Risager, CEO of Blue Ocean Robotics. “The immediate demand has increased a lot with the outbreak of COVID-19. Existing customers buy many more units than before, and many new customers are ordering the UVD robots to fight coronavirus and other harmful microorganisms.” This is an ongoing success story for the IERA award winning robot. Blue Ocean Robotics has seen a growth in sales of more than 400 percent annually over the last two years.
Robot moves autonomously
The Danish robot moves autonomously around patient rooms and operating theatres - covering all critical surfaces with the right amount of UV-C light in order to kill specific viruses and bacteria. The more light the robot exposes to a surface, the more harmful microorganisms are destroyed. In a typical patient room, 99.99 % of all viruses and bacteria are killed within 10 minutes.
Robot helps at airports, schools or office spaces
“UVD is a supplementary device which assists the cleaning staff,” said Claus Risager. For safety reasons, it works on its own and automatically disengages the UV-C light if someone enters the room. The collaborative robot can be used in various enclosed spaces – not only in hospitals. The technology also works in environments such as office spaces, shopping malls, schools, airports and production facilities.
“Robots have a great potential of supporting us in the current severe corona pandemic,” said Dr Susanne Bieller, General Secretary of the International Federation of Robotics.
“They can support us in healthcare environments, but also in the development, testing and production of medicine, vaccines and other medical devices and auxiliaries. Disinfection tasks performed e.g. by UVD units or safe distribution of hospital material in quarantine zones - without personal contact - provided e.g. by Photoneo´s mobile robot Phollower, are just two of many examples.”
By now, medical robots represent a well-established service robot market with a considerable growth potential. Sales of medical robots increased by 50% to 5,100 units in 2018. This is according to the statistics published in World Robotics by IFR.
Phollower (developed under the working title Pathfinder ) is a new-generation autonomous mobile robot for an ultra-modern material transport and handling in warehouses, hospitals, hotels and factories. It helps the staff in hospitals and other health care centers with distribution of medicines, laundry and other material to respective workplaces. It saves a lot of time and energy, and no adjustments of premises are needed to allow the robot to move in a given space, including via elevators, without any difficulties. Carrying (max 100 kg/ 220.5 lbs) and pulling (max 350 kg/ 771.62 lbs).
The IFR Executive Round Table, the IERA Award presentation and the International Symposium on Robotics ISR are postponed to December 2020. All events are co-located at the automatica trade fair in Munich. The organizers of the event just announced a postponement related to the coronavirus.
Due to the increasing global spread of coronavirus (SARS-CoV-2) and based on the recommendations of the German Federal Government and the Bavarian State Government, Messe Munich felt compelled to postpone automatica 2020. This measure has been taken in consultation with the VDMA Robotics + Automation Association as conceptual sponsor and in responsibility for the health of exhibitors and visitors. automatica 2020 will instead take place from December 8 to 11, 2020.
The IFR Executive Round Table as press event will now take place on December 9, 2020.
The World Robotics report shows that Europe is the region with the highest robot density globally, with an average value of 114 units per 10,000 employees in the manufacturing industry. For more facts about robots watch IFR´s video news about Europe in one minute.
The Executive Board of the International Federation of Robotics (IFR) elected Milton Guerry of SCHUNK USA as new President. Klaus Koenig of KUKA Robotics has been appointed as IFR´s new Vice President.
“I feel very honored to serve as new IFR President and look forward to a successful collaboration with Klaus Koenig and our IFR members,” says Milton Guerry. He held the position of IFR Vice President since December 2019. Milton succeeds Steven Wyatt (ABB, Switzerland), who is leaving ABB. Steven held the rotating post of President since December 2019 and prior to that served on a two-year term as IFR´s Vice President.
Milton Guerry thanked Steven Wyatt for his many years of successful work for the International Federation of Robotics: “Steven did a wonderful job to support the world of robotics. He inspired the robotics industry and their stakeholders, such as the representatives of national robotics associations from all over the globe, delegates of robot manufacturers and research institutes as well as the media. We will continue his mission to further improve the understanding of the rapidly changing world of robotics and automation.”
Milton Guerry heads the SCHUNK USA team as its President based in Morrisville, North Carolina. He joined SCHUNK in 2000 and has held various leadership roles, assuming his current role as President in 2007. Milton is a member of the Robotic Industries Association’s (RIA) Board of Directors. He began his career in the automotive industry in a number of engineering and technical functions.
Klaus Koenig serves as Chief Executive Officer (CEO) of KUKA´s Robotics division based in Augsburg, Germany. He joined KUKA AG in July 2017 as Chief Operating Officer (COO). Before, he had held various leadership positions in the German automotive industry. During his career he also took on international jobs, with multi-year assignments operating out of Canada and Italy. Klaus holds a degree in mechanical engineering from the University RWTH in Aachen, Germany.
Exporting to over 90 countries in five continents, Istanbul-based Erkul Cosmetics is a leading producer of beauty products such as foundation cream, compact powder blush, eye shadow, mascara, lipstick, lip-gloss and nail varnish.
To fill eyeliner, nail polish and face powder containers and bottles, Erkul had traditionally used conventional human-operated filling machines. But consistency issues were impacting quality and output. To resolve these problems, FANUC modelled and evaluated three new automated solutions using its offline FANUC ROBOGUIDE simulation software. By looking at robot access, type of arm and cycle time values, FANUC was able to finetune and live test the solutions.
Automating the eyeliner line
Comprising eight FANUC robots, the new automated solution for eyeliners eliminates the quality issues the company was facing and increases output to 90 eyeliners per minute – a 30 percent improvement. The system includes a conveyor tracking application that transfers the finished products straight onto the belt.
A lot of care was taken in selecting the right grippers. These needed to be capable of running at high speeds but also be sensitive enough not to crush the delicate eyeliner containers. Using the gripper, the robot retrieves an empty eyeliner container from a magazine and places it precisely into the filling machine. To ensure the containers are filled completely without gaps, the robot completes a precise downward movement during the filling process.
FANUC achieved this precise synchronous motion by supplementing its standard line tracking software with a special Karel program. Thanks to high-speed skip input, the volumetric filling signal from the system filling machine is accurate to a millisecond and results in products being transferred quickly from the filling machine into the eyeliner magazine. At the end of the conveyor, a robot uses line tracking software to transfer the eyeliners onto the packaging line.
Picking the right colour with iRVision
For the next task – to place nail polish bottles in the filling mould – a very different approach was taken. Since they come in different shapes and colours, nail polish bottles would normally pose a problem for most vision systems. However, when used with RGB type backlight lighting technology, FANUC iRVision recognises the bottles as they arrive for separation on a vibrating circular table. Used in combination with three M-2iA/3S delta type robots located in different cells, the system recognises and handles 70 parts per minute.
Two of iRVision’s command tool features play a key role in detecting the location and angles of the parts in around 80 msec. These are the CSM Locator Tool [Curved Surface Locator Tool] for detecting cylindrical and curved surface parts and the GPM Locator Tool [Geometrical Pattern Model] for detecting bottle types with sharp lines.
Silicone type vacuum pads are used to hold the bottles firmly and prevent the risk of scratching. The robot also uses these pads to wrap and pack the bottles.
To ensure the line runs as smoothly as possible, alarm messages received from the robot are conveyed to the supervisor system and recorded. Data such as the product, cycle time, productivity, total stance, etc. are actively incorporated into production planning.
Thanks to its maintenance reminder feature, the robot also exports the mechanical and electrical servicing information required by the maintenance schedule.
Picking and placing
Finally, a FANUC LR-Mate 200iD/7L robot was installed to load the face powder container lids into the filling station and transfer the filled containers to the output conveyor. Previously this had been done be human operators, with both production loss and quality problems occurring. Installing the robot eliminated these issues and resulted in products being transferred at a rate of 75 units per minute.
The smart solution
Key to the Erkul Cosmetics solution are FANUC iRVision (integrated imaging systems) and FANUC ROBOGUIDE Simulation Software. But compared to the alternatives, the solution also offers the benefits of:
Advanced image processing thanks to in-built-iRVision control software (no need for 3rd party software and hardware).
Simple and easy to understand programming structure and customizable UIF menus
Precise positioning capability (0.01 mm repeatability)
Fast and precise line tracking software
Stable and fast robot cycle times.
Low maintenance costs, versatile and advanced training and technical support, lifetime spare parts supply warranty.
One platform, many solutions
FANUC’s One FANUC approach also meant that Erkul Cosmetics was able to benefit from other automation solutions such as FANUC ROBOSHOT plastic injection machine, ROBODRILL machining centre, PM-iA control unit. Thanks to FANUC’s common control system, using these is just like using any other FANUC product and requires a minimum of training for staff already familiar with FANUC controls.
The technical support provided to install and adapt these machines resulted in a production ecosystem that operates smoothly and efficiently with a bare minimum of downtime. Providing a full set of performance data, the system also offers Erkul Cosmetics high traceability and sustainable production volume on both robots and other machines. In addition, the lines have been designed to adapt to a wide range of different products with a minimum of setup time required.
To implement the solution FANUC Turkey, worked with Erkul Cosmetics’ technical and manufacturing team. FANUC training and support enabled Erkul to dispense with the services of a system integrator and train their own staff in the robot automation process. This reduced the cost of installing and implementing the solution considerably.
Erkul Cosmetics currently produces cosmetics around the clock using 25 FANUC 6-axis robots, 4 FANUC 3-axis delta robots, 36 FANUC ROBOSHOTS (full servo injection moulding machines), 1 FANUC ROBODRILL (machining centre) and 4 FANUC control units (PM-iA). The key benefit automation provides Erkul Cosmetics is the ability to minimise the problems and issues that were arising from the manufacturing process. This has enabled the company to spend more time on product development and R&D activities. By doing so, Erkul Cosmetics have reduced their manufacturing costs and become more competitive.
A high degree of automation – supported by elements of Industrie 4.0: component machining processes at KUKA provide insight into future-oriented production processes.
At first glance, production hall 10 at KUKA’s site in Augsburg looks just like any other production environment at a German or international machine manufacturer: a slight smell of oil is in the air, machine tools from various manufacturers are hard at work machining metal parts – and diligent employees are running the show. One of these employees is Rainer Eder-Spendier, Administrator for Automation and Robotics in Hall 10. “I am passionate about this hall,” says the 51-year-old. “The high and sensible degree of automation in production is what sets us apart. We embrace intelligent automation and digitization here.”
What you don’t notice at first sight: all of the machines in the hall are connected to the cloud and feature various Industrie 4.0 functions. Standing with a tablet in hand, in front of a Burkhardt + Weber safety fence that surrounds a machine tool, Rainer Eder-Spendier explains: “For instance, we have a digital overview of the entire hall. This is similar to the map apps for smartphones. It allows me to monitor all of the machines and retrieve their data.” With a quick tap of his index finger, he checks the status of two Heller machining centers which are loaded and unloaded by a KUKA robot on a regular basis. Similar to a smart watch or a fitness tracker, the robots and machines collect a wide array of data and transmit these data to the cloud. The data are then displayed in various visualizations on the user interface of the tablet. “But that’s not all,” says the Munich native, who has been working for KUKA for more than a quarter of a century. “If error messages appear, we can make use of a wiki-type service that has been compiled by our service technicians over a number of years. The database comprises almost half a million proposals for solutions. We can also retrace every process step in retrospect using the built-in technology – this works in a similar way to a black box on an airplane. What’s more, we can have the software notify us of any irregularities in the production process – this is similar to an ECG.”
Communication as the basis for smart production
There is a total of seven cells and eleven robots in Hall 10. The robots, which are from a number of different model series, were all manufactured by KUKA. The machines that they work on are commercially available machine tools from various manufacturers. The robots machine components such as base frames, rotating columns, arms and link arms. The components are assembled right next door in the robot assembly shop. “In this hall, the robots work on the various components that we need to manufacture our robots,” says Rainer Eder-Spendier, in summary. He then goes on to emphasize: “Not only was it important to test the new technical possibilities exhaustively, but also to deploy them in a truly sensible manner. It is also important that the machines have interfaces that accommodate what is referred to as the handshake.”
The handshake refers to the communication between the robot and the machine tool. This is essential if the components of the system are to coordinate with one another. In the cell, the robot can act either as a master or a slave. As a master, the robot specifies the procedures and notifies the machine that, for instance, a workpiece has been loaded and the door can now be closed. If the robot is deployed as a slave, it responds to commands from an external controller.
Shorter throughput times, greater efficiency
Machine tools are usually loaded manually by workers. The worker often stands around waiting for the machines to finish machining the workpiece. Once the machining proce-dure has been completed, the worker removes the workpiece and sets it down on a pallet before loading a new workpiece into the machine. Not only is this procedure monotonous, it is also relatively inefficient. As we can see from Hall 10, the process can be optimized using automation. “In our hall, the robots take on the tasks of loading and unloading the machines,” explains Rainer Eder-Spendier. “Consequently, very few human workers are involved in the production process. In fact, it is possible to run the production process without human involvement for a certain period of time, even on weekends and during night shifts.” To make this possible, the cells are equipped with feed units such as turntables and feed conveyors. The workers load these manually with the components that are to be machined. The robot therefore has access to a stockpile that will last up to eight hours depending on the number of prepared workpieces and tasks to be performed by the machine.
The level of productivity is also improved by the fact that the robots also carry out secondary tasks. “In some of our cells, the robot cuts helicoil threads into pre-drilled holes while the machine tool machines the next workpiece,” says Rainer Eder-Spendier, citing an example. In most of the cells, workpiece deburring is another task that the robots perform. In this way, waiting periods are used efficiently, and the throughput times of individual parts are shortened because the machines are relieved of machining tasks such as drilling holes and milling operations falling within a tolerance range of +/- 0.2 mm. Thus, better use can be made of valuable machining time on the machine tools and more parts can be produced.
Robots work hand in hand with machine tools from various manufacturers
In practice, one of the robot cells in Hall 10 could look like this: three machine tools from the manufacturer Grob have more than 30 of the system’s pallets at their disposal and can therefore respond quickly and flexibly to various requirements. The worker clamps the workpiece to be machined in a clamping fixture at a changeover station. Next, the component is loaded into the cell together with the pallet and the fixture. A KR 600 R2830 FORTEC robot performs the chain of individual steps and the material transport from the machine tool to the reworking cell where the machined metal parts are finished – for example, deburred, drilled or furnished with helicoils. The robot approaches the three machines via a linear unit and then brings the finished part back to the relevant operator position. The worker releases the clamping fixture, removes the part and sets it down on a pallet.
In another cell featuring two machining centers from the manufacturer Heller, the procedure is similar. With the aid of a pneumatic gripper, a KR 500 L480-3 MT FORTEC robot picks up a workpiece that has been placed onto a turntable and loads it into one of the two machines. To enable it to load both machines alternately, the robot is installed on a linear unit. Four feeding stations provide sufficient raw material. As soon as the machining process has been completed in the machine, the robot deburrs the part at the changeover station. Finally, the robot sets the part down on a turntable.
A machine tool from the company Burkhardt + Weber is also loaded and unloaded by a KR 500 FORTEC robot. The machine tool, which machines link arms and rotating columns, is equipped with a double pallet changer: one pallet holds the clamping fixtures for the link arms, the other pallet holds the fixtures for the rotating columns. While the robot loads a workpiece onto one pallet, the machine works on the workpiece that is clamped on the other pallet.
The advantages of automation and networking
“Automation makes the worker’s tasks significantly easier because, in most cases, the worker is no longer required to manually load the machine tools with heavy workpieces,” says Rainer Eder-Spendier. The worker is merely required to supply the material. This, however, takes a lot less time and physical effort, meaning that the system can achieve a greater level of productivity. Another advantage: it is not necessary to have profound robot-specific expertise to carry out the deburring tasks.
As soon as the cells have been switched to this mode, they can be operated in G-Code using the KUKA.CNC software like a conventional machine tool. The data that are recorded – even those that pertain to components manufactured by companies other than KUKA – are made available in the cloud. That way it is possible to have full visibility and exercise full control over the current production process, achieve a greater level of transparency and optimize task scheduling at all times.
Roboteco SpA recently developed a robotic welding cell for its customer Steel-Tech aimed at improving production and inserting into the production process a new machine that is totally interconnected with all stages of the manufacturing process.
With the installation of the new robotic cell, Steel-Tech aims to unify its processes, interconnecting the machines to increase speed and enable tracking and quality control the production flows in a systematic and reliable way.
Through its production management software, Steel-Tech is able to monitor and manage all the main machines in the factory; transferring production orders, controlling production flow and cycle times and, finally, observing the results.
Panasonic Desk Top Programming & Simulation DTPS allows off-line robot weld program development in a virtual 3D space followed by direct machine upload and interfacing with production management programs.
System interconnection allows parameter and quantity control enabling cycle control and optimisation.
The production management software automatically downloads analyses and saves the data from the welding robot in its own archive. One of the main benefits is having total interconnection of the production process starting from the offline programming, through the control of the production process and the parameters, to the tele-monitoring services in case of fault.
The Arc Welding Robot Solution
The cell developed by Roboteco-Italargon after a preliminary study phase together with the customer is composed of a Panasonic TAWERS TIG arc welding robot model TM-1400 with filler metal and two working stations with turn-tilt positioners.
TAWERS (The Arc Welding Robot Solution) robot is a unique architecture in which a single CPU controls and monitors the robot movement synchronized with the filler metal feeding and welding parameter control – “All in One” welding solution from one manufacturer. Integrated into the weld system is the Human Machine Interface Teach Pendant to facilitate program creation.
A single source software and a user-friendly HMI allow the operator to create and optimise welding programs using the wide range of functions available through the Teach Pendant and utilizing specific subprograms.
For example, the Welding Navigator subprogram assists the operator by calculating the welding parameters through selection of workpiece variables (material, thickness etc.) using data derived from extensive research.
The specific design of Panasonic TAWERS TIG torch simplifies the welding process. The wire is inclined towards the welding pool with an angle of precisely 30° and is pre-heated by passing close to the arc. By means of this special torch configuration the robot programmer can focus on TCP (the tungsten electrode) without having to worry about wire positioning, gaining high flexibility and better torch positioning.
This Panasonic torch design can easily support all robot functions including AVC (Arc Voltage Control), the adaptive software that allows to keep stick-out (distance between electrode and workpiece) constant.
Data Management and Industry 4.0
Roboteco-Italargon and Steel-Tech have agreed to make intensive use of arc welding data management software.
Through adaptive control, the CPU of the robot supplies and controls all process parameters (current, voltage, welding speed, wire speed, wire feeder servo motor’s electrical consumption etc.) and arc welding data management software allows the user to set alarm ranges, to view them remotely via an external PC and to record them in logs filed by welding section.
The robot system is also equipped with the Roboteco Industry 4.0 kit that allows interconnection with Steel-Tech general management software.
Roboteco Industry 4.0 kit is the result of a study with the goal of making interconnection of the robotic cell with external environment easy and flexible and enabling data and information exchange. For example transfer of production orders, quantity of pieces to produce compared with the pieces already produced, real welding parameters compared with set parameters, cycle time, robot alarms and status and many other available information.
All information is extrapolated from the robot in an external PLC with dedicated HMI and with a simple library open to be connected with all the main software languages (HTML, VB, C#, Java, etc.).
This kit could also enable remote access from a mobile device by implementing web pages, accessible via mobile devices (tablet, smartphone, etc.) external to the company network or PC connected to the same line.; the same kit could enable the connection through FTP Server.
The industry 4.0 kit allows also for remote control of the machine; Roboteco-Italargon’s technician can access from the service offices the robot status and alarms. In this way the technicians could analyse possible faults and cooperate with customer to solve them remotely.
Desk Top Programming & Simulation System (DTPS)
In order to make the programming more efficient, Steel-Tech utilizes the offline programming software Panasonic DTPS.
DTPS is a simulation software developed exclusively for Panasonic robots. With this software, users can create and edit robot programs and verify robot motion offline. DTPS enables a smooth transfer of robot programs from office PC to the robot controller.
DTPS makes it possible to run the robot program on the PC in simulation and optimise the robot movement with the corresponding welding parameters offline.
By importing the 3D CAD files of the pieces to be welded, the company can utilize DTPS to verify the accessibility of the robot in each position of the pieces to be welded, evaluate the cycle time, avoid collision, program the robot movement and all process parameters and edit or modify it by PC and various other functions which make it an indispensable tool for optimising welding processes.
The benefits are the reduction of welding cell machine downtime, time saving of programming welding lines by using special macros in DTPS software and analysis of product costs through process simulation.
Today Steel-Tech is utilizing the new welding robot for welding stainless steel parts for one of tis distinguished customer; the welding programs were designed totally in the 3D environmental of DTPS and transferred to the robot with the production orders.
Integrating the sophisticated TAWERS welding system with the Roboteco Industry 4.0 kit and DTPS under a general production management software enables complete process interconnectivity and smart data feedback. Understanding in real time the performance of the production processes allows for early identification of errors or uncharacteristic machine performance, which could help to avoid major faults and thus reduce downtime. Combining DTPS with weld data feedback allows for optimisation of cycle time leading to maximised output rates. With Industry 4.0 kit the robot is interconnected with Steel-Tech production management software that oversees also other machines and phases of the production exchanging with them data in term of IoT.
About the companies
Roboteco SpA was founded in 1988, having sensed a growing need in the market for automated arc welding and, thanks to the almost thirty-year partnership with Panasonic Welding System, Roboteco has specialized in the promotion and integration of Panasonic TAWERS technology, a revolutionary fully integrated welding robot solution, focusing on the Automotive and General Industry sectors. In 2017 Roboteco S.p.a. acquired Italargon, another historical brand manufacturer of robotic and automatic welding solutions. Since becoming Roboteco-Italargon, the company has continued to grow and has diversified from MIG and TIG to Laser Beam Welding (LBW).
Steel-Tech Srl is a company originally established as manufacturer of components for cereal mills and since has diversified towards a wider range mechanical metal processing. With the generational changeover, the company has evolved to introduce welding processes, mainly using TIG, in different sectors like medical, pharmaceutical, food & packaging and metal furniture.
The company development continued with the introduction of robotic TIG welding with a first Roboteco-Italargon cell some years ago and further today with a new robotic cell also equipped with TIG welding process and Panasonic TAWERS (The Arc Welding Robot Solution) system, but intended for integration into the new industry 4.0 company development.
As a global leader in gear systems whose customers demand just-in-time delivery, KOKI depends on reliability and uptime from its fleet of 60 robots. The German company, founded in 2003, makes precision gear shifters and boxes for some of the world’s leading automakers.
KOKI has a strong commitment to continuous improvement and innovation, as well as lean production. As part of this commitment, the company challenged ABB to find new ways of improving robot availability and productivity. It decided on the production site of Glauchau, Germany, which had experienced issues in the past. ABB was already supporting KOKI with service for its welding robots, which included annual maintenance as well as rapid response time for on-site issues. ABB proposed connecting one of KOKI’s welding robots in Glauchau to ABB’s Condition Monitoring and Diagnostics, part of ABB Ability Connected Services.
Digital services increase competitiveness
ABB began connecting its robots to advanced services in 2007, and today some 7,000 ABB robots are connected to the ABB AbilityTM Connected Services platform, at more than 750 customer sites, in 40 countries, with more than 40,000 robots delivered with embedded connectivity. Every new ABB robot can be connected to the Internet of Things to unlock leading digital technologies for greater performance and reliability. Condition Monitoring and Diagnostics is a secure service that monitors the condition of robots around the clock and alerts users to situations which could lead to unplanned downtime. It can send alarms by e-mail or SMS in case of critical issues or provide actionable data to operators through an intuitive web-based application. This data can also be used to better prepare service experts for more efficient on-site visits, for example giving them a snapshot of the system at the point of the failure.
During the course of the year, ABB’s Condition Monitoring and Diagnostics detected conditions which could have caused the robot to shut down and were able to proactively alert KOKI, so the problem could be addressed before a problem occurred. For many manufactures, the cost of downtime has dramatically increased the past several years. Experts estimate that it costs over $1 million an hour to have an unplanned stoppage at a large automotive factory. Given the just-in-time delivery expected by many of KOKI’s customers, a welding robot failure can have severe consequences to its commitments. In the past KOKI often had to convert another cell with the same robot model to duplicate the lost production, a time intensive process with risks.
Data evaluation increases availability and lifetime
Based on this positive experience, KOKI has connected all their 60 robots to ABB Ability Connected Services. KOKI’s entire manufacturing process benefits from the new options that are available through the networked ecosystem. Via ABB Ability Connected Services and the data derived from it, ABB can carry out condition-based maintenance and inspection more effectively. Ad hoc repair tasks can also be planned quickly and precisely together with KOKI using live data. This allows activities to be prioritized, supporting the efficiency and smooth running of the most important customer processes. The connected robots can also provide intelligence to benchmark the performance of their entire fleet and identify and correct underperforming robots. “During audits, automotive manufacturers ask us how we can guarantee the safety of the systems. Robot maintenance, monitoring, service and support all play an important and decisive role here,” underlines Sven Sparmann, Site Manager for Maintenance, Repair and Overhaul at KOKI in Niederwürschnitz, Germany.
“The approach is very practical, and we are informed in advance. Error detection allows us to carry out adjustments when production has stopped, without interrupting the production process,” enthuses Sparmann. “We’ll be linking all new robots – both at our domestic and international sites – to ABB Ability Connected Services, that’s quite clear,” Sparmann concludes.
KUKA / Case Studies Industrial / Case Studies Collaborative Robots
In measuring technology, maximum precision is the only thing that counts. This provides ideal conditions for the use of robots. For efficient use, however, they must be able to grip various large objects without damaging them. At measuring technology specialist Perschmann Calibration GmbH, the sensitive KUKA LBR iiwa robot performs the loading of a coordinate measuring machine and thus automates the calibration process.
Identification of the task
“A human hair is roughly 50 µm thick and the silk threads of a spider are approx. 5 µm. The precision with which we at Perschmann Calibration calibrate measuring instruments is approx. 0.5 µm,” explains Dr. Detlef Rübesame, Head of Technology at Perschmann Calibration GmbH. The calibration service provider from Braunschweig specializes in the calibration of manual measuring instruments. Among other things, it performs the high-precision inspection of gauges such as measuring pins and setting rings. The company’s customer base consists primarily of customers from conventional mechanical engineering, the automotive industry or the aerospace sector. The customers use the measuring instruments for quality assurance in their production processes. There measuring instruments must be regularly calibrated in accordance with Standard ISO 9001 to fulfill international quality standards. Exact values are thus measured during the calibration process so that not even small dust particles can influence the measurement. Besides dust particles, the temperature also has an impact on the measurement result. For this reason, the temperature is continuously maintained and the measuring instruments themselves are also subject to a controlled climate for a defined period of time so that no measurement variation can occur.
Medium-sized enterprises such as Perschmann Calibration GmbH are constantly searching for future-oriented solutions to remain competitive in their business segment. “In collaboration with KUKA, the company Hexagon – which also produces the coordinate measuring machine – introduced us to a concept for the automation of our calibration process and, as a result, to an even more customer-friendly option for the quick calibration of many different measuring instruments. We adopted the idea right away,” recalls Detlef Rübesame.
Since December 2017, the KUKA flexFELLOW solution upon which the sensitive KUKA LBR iiwa (intelligent industrial work assistant) robot is installed has been used at Perschmann Calibration. The KUKA flexFELLOW is a complete solution, consisting of a robot platform on which the HRC-capable LBR iiwa robot is installed.
Two transport units with fork slots are provided for this. In the first work step, the LBR iiwa moves to the first transport unit and checks whether there are measuring instruments in the individual slides. It then removes these instruments and moves them into the correct position for the scanner. Besides scanning, the measuring instrument has air blown on it to eliminate any dust and prevent incorrect measurement. Once the system has identified the type of measuring instrument, the LBR iiwa clamps it in the clamping device. The coordinate measuring machine then starts the calibration procedure. Once the process is completed, the robot grips the measuring instrument again and places it in the second transport unit. Meanwhile, the information about the calibration procedure is transferred to a computer where the certificate is issued for each part. The robot works in three-shift operation.
An important question while planning the production changeover was how the coordinate measuring machine and the LBR iiwa could detect and assign the various different geometries of the measuring instruments. The measuring instrument itself meets this challenge by controlling the measuring process. Equipped with a data matrix code, it forwards all important information (such as the type of measuring equipment or the diameter) on to the coordinate measuring machine. Using this special data matrix code (DMC), the coordinate measuring machine can independently initiate the measurement. Intervention by an employee is no longer necessary.
Evaluation of the solution of the challenge
Perschmann enjoys numerous advantages from the robot-based application and the fully automated calibration procedure thanks to Industry 4.0 elements. The procedure is shortened and the calibration process can become more customer-oriented since the collective processing of various measuring instruments is no longer a problem with the KUKA lightweight robot. “Automation makes sense since we deal with very large quantities. At the same time, the system is coordinated in a way that allows it to work autonomously for a long period of time,” explains Detlef Rübesame. The second advantage of the system is that the robot detects if the compartment is empty and reacts by independently moving to the next full one. This is real added value since the robot can therefore continue working autonomously during the night shift. The next morning, the employee finds a fully-calibrated unloading system.
With the KUKA LBR iiwa, Perschmann Calibration can now calibrate around the clock – and do so in two different modes. Whereas production during the day runs in the safer, slower HRC mode, a switch into full automation mode can be made at night when no people are in the robot’s working range. The KUKA LBR iiwa then works ten times as fast. This is possible because other safety regulations apply to operation without humans. Thanks to the additional, fully-automated calibration during the night shift, Perschmann Calibration GmbH gains additional inspection capacity. Detlef Rübesame is very pleased with the new process and believes that the investment in the system will soon have paid for itself. “The task of management is to ensure that we continue to be proactive and are not forced to react by the actions of others. With the full automation of the calibration process, we have taken a further step in this direction.”
MIR / Case Studies Service / Case Studies Industrial
The increasing networking of industrial production requires more and more intelligent solutions in the field of intralogistics. Mobile robots help to successfully meet the demand for a highly flexible and transparent material flow. A Danish manufacturer shows how it works.
The factory of the future has been taking shape for a long time; digital platforms are being used, people and machines are collaborating in everyday work, manufacturing technologies are becoming continuously more efficient. At the same time, the increasingly automated processes require innovative concepts for intralogistics. Industry 4.0 can only function optimally if production and logistics processes are efficiently linked.
However, such networking is often not taking place yet. Highly qualified employees often take care of in-house transports manually, at the expense of efficiency. Logistics 4.0 calls for solutions that act as a flexible link between individual production stages. One obvious answer is mobile robots, which enable simple, dynamic and cost-effective automation of internal flows of goods. In this way, processes can be linked, resources used purposefully and employees relieved.
Danish robotics expertise
One of the pioneers in this field is Mobile Industrial Robots (MiR). The company from Odense specializes in the development of autonomous, mobile robots for material handling. Autonomous because MiR robots can independently navigate in a dynamic environment thanks to their sensor systems and security algorithms without interfering with the infrastructure of production facilities. This enables them to operate safely side by side with humans. Top modules such as shelf units or cart-pulling hooks eventually make the robot colleague a flexible tool that can automate almost any transport task.
Doubling of production capacity at Kamstrup
The example of Kamstrup A / S shows how a seamless flow of goods between static production lines and production cells can be realized by mobile robots. At the manufacturer of intelligent meter solutions, four MiR100 robots equipped with conveyor top modules, transport semi-finished products and finished products without human intervention. The intralogistics solution meets the Industry 4.0 paradigm of digital networking by integrating it into the company’s ERP system. When a sales representative issues a new order, the mobile robots will receive a list of routes that they will gradually follow.
Kamstrup has almost completely automated its production through the transport robots, which are in continuous operation. The manufacturer uses maximum production capacity and keeps its delivery expectation of only 72 hours. “The MiR robots play a crucial role in maximizing our throughput. They even allowed us to double our production, “explains Flemming Møller Hanser, production manager at Kamstrup.
Intralogistics 4.0 made very user-friendly
A look at practical examples not only shows how mobile robotics makes factories fit for the future. It also emphasizes that innovative technology is for everyone because even users without prior programming skills can set up the MiR robots and make them work. The robots can be easily operated via an intuitive user interface with any mobile device or computer. The mobile robots are collaborative and designed to work safely side by side with its human colleagues. When the robot takes over the internal transportation tasks, it leaves time for its human colleagues to do more valuable tasks, ensuring smooth and efficient workflows.
After all, the focus of Industry 4.0 is always the well-rehearsed coexistence of man and machine. At Kamstrup, this means relieving the employees from monotone transportation tasks and letting them use their expertise for prototype development. This ultimately makes the manufacturer both future-oriented and competitive.
Universal Robots / Case Studies Industrial / Case Studies Collaborative Robots
The Miami startup Creating Revolutions was experiencing double-digit product reject rates in the assembly of their hospitality service pager. The UR3 cobot now handles soldering, drilling, silicone dispensing and light assembly while being controlled and monitored in a cloud-connected system, reducing rejects to near zero while increasing production efficiency almost five-fold.
Creating Revolutions makes a customer service paging system for the hospitality industry. The hockey puck sized Communication Disc connects guests with their waiter through their smart phone. Assembling the disc is a complex tasks requiring great accuracy and repeatability. “The problem is you can’t efficiently repeat a specific process the exact same way over and over again as a human being,” says Einar Rosenberg CEO of Creating Revolutions, who was on the lookout for an automation solution that could meet both quality and quantity requirements.
“We looked at about 40 different robot companies, and most of them didn’t have a very good way to program them; they required too many things for the environment; or they were too big or too jerky,” says Rosenberg who concluded his research by choosing a collaborative UR3 robot from Universal Robots.
“The UR3 was elegant, it was fast and smooth. We knew it had the exact precision that we really wanted. Our project reject rate has gone from double digits to below 1%, our overhead is significantly reduced while the increase in our production is a high multiple,” says Rosenberg.
The UR3 handles two different cycles: first, the robot checks that the aluminum housing parts are lined correctly on a tray. The robot then picks up the part, places it into a clamp, picks up a silicone injector and aligns the silicone, then places an acrylic disc on top, before placing the assembled part back on the tray. Next step is drilling and soldering: The robot picks a disc with a copper base out of a dispenser, and places it into an optical laser sensor that aligns the disc, the robot then places the disk into a holder, affixing it by closing two clamps.
“The UR3 grabs a drill from the utility belt and performs a peck drilling process, because the acrylic shatters if you just force it. The robot is sensitive enough to basically pop it in until it makes a perfect hole,” says the Creating Revolutions CEO. With drilling complete, the UR3 grabs the soldering iron, adding three points of pre-soldering.
“Having the UR3 perform the pre-soldering has increased the efficiency of the process almost five-fold,” says Rosenberg. “The manual soldering process really required the operator to have three hands.”
“The UR3 was elegant, it was fast and smooth. We knew it had the exact precision that we really wanted. Our project reject rate has gone from double digits to below 1%, our overhead is significantly reduced while the increase in our production is a high multiple.” Einar Rosenberg, CEO.
The benefits of the UR3 integration
The UR3 was integrated in Creating Revolutions’ assembly line by Hirebotics, a Universal Robots Certified System Integrator that works like a staffing agency for cobots, letting manufacturers rent cobots by the hour without any upfront costs. Hirebotics handles all programming, deployment and maintenance of the robot, while Creating Revolutions pays for only the hours it’s operable.
It took just a few weeks from when Creating Revolutions first got in contact with Hirebotics until the UR3 was ordered, installed and programmed. Matt Bush, co-founder of Hirebotics, explains that in order to run a “robot staffing agency” quick deployment is imperative. “What has enabled us to do that is the ease of programming the UR robots. The UR interface makes it simple to get it up and running in production much faster than a lot of the other solutions we have worked with in the past,” says Bush, who also built a cloud-connected mobile app, enabling Creating Revolutions to receive real-time production data and notifications when the robot requires attention. “By gathering details on the number of units that the UR3 produces in a given period of time, we can combine all data and create realistic, very accurate forecasts of our production needs, such as how many humans are needed and what we need to focus on to produce at optimal levels,” says Rosenberg, who also has the UR3 work unassisted after hours.
Having a robot perform several assembly steps has become a huge selling point for Creating Revolutions.
“When our customers come here and see the UR3, they realize the quality and precision guaranteed because of the robot. Because we’re not an established company, they want to feel like the product that they’re going to be using is not going to fail on them,” he says. “The robot demonstrates to them a strength, which then reinforces the sale for us. “
From 2020 to 2022 almost 2 million new units of industrial robots are expected to be installed in factories around the world. New technology trends and market developments enable companies to react to changing requirements. The International Federation of Robotics shows top trends to innovate.
“Smart robotics and automation are vital to deal with new consumer trends, demand for product variety or challenges from trade barriers”, says Dr. Susanne Bieller, General Secretary of the IFR. “New technological solutions pave the way for more flexibility in production.”
Simplification, Collaboration and Digitalization are key drivers that will benefit robot implementation.
Robots get smarter
Programming and installation of robots become much easier. How this looks in practice: Digital sensors combined with smart software allow direct teaching methods, so-called “Programming by Demonstration”. The task that the robot arm is to perform is first executed by a human: He literally takes the robot arm and hand-guides it through the movements. This data is then transformed by the software into the digital program of the robot arm. In future, machine learning tools will further enable robots to learn by trial-and-error or by video demonstration and self-optimize their movements.
Robots collaborate with workers
Human-robot collaboration is another important trend in robotics. With the ability to work in tandem with humans, modern robotic systems are able to adapt to a rapidly changing environment. The range of collaborative applications offered by robot manufacturers continues to expand. Currently, shared workspace applications are most common. Robot and worker operate alongside each other, completing tasks sequentially. Applications in which the human and the robot work at the same time on the same part are even more challenging. Research and Development (R&D) focuses on methods to enable robots to respond in real-time. Just like two human workers would collaborate, the R&D teams want them to adjust its motion to its environment, allowing for a true responsive collaboration. These solutions include voice, gesture and recognition of intent from human motion. With the technology of today, human-robot collaboration has already a huge potential for companies of all sizes and sectors. Collaborative operations will complement investments in traditional industrial robots.
Robots Go Digital
Industrial robots are the central components of digital and networked production as used in industry 4.0. This makes it all the more important for them to be able to communicate with each other - regardless of the manufacturer. The so called “OPC Robotics Companion Specification”, which has been developed by a joint working group of the VDMA and the Open Platform Communications Foundation (OPC), defines a standardized generic interface for industrial robots and enables industrial robots to connect into the Industrial Internet of Things (IIoT). The digital connectivity of robots with e.g. cloud technology is also an enabler for new business models: Robot leasing for example - called Robots-as-a-Service - has advantages that might be especially attractive for small and medium-sized enterprises (SMEs): no committed capital, fixed costs, automatic upgrades and no need for high-qualified robot operators.
For more trends on the global robotics market please see our website.
The new World Robotics report shows that more than 2.4 million industrial robots are operating in factories around the world. Global sales value hit a new record of 16.5 billion USD. For more facts about robots watch IFR´s video news in one minute.
Steven Wyatt (ABB, Switzerland) has been elected as the new President of the International Federation of Robotics by its Executive Board. Wyatt succeeds Junji Tsuda (Yaskawa Electric Corporation), who has served in the rotating post since December 2017. Milton Guerry (SCHUNK, USA) has been appointed as IFR´s new Vice President.
The new IFR President, Steven Wyatt, has a decade of international experience gained in the flexible automation industry. He is currently global Head of Portfolio and Digital for ABB’s Robotics & Discrete Automation business. Prior to joining ABB in 2010, the native Scot worked in a series of executive marketing & sales roles within the plastics industry globally. Mr. Wyatt holds a degree in Chemical Engineering from the University of Edinburgh. Before being elected President of IFR, Wyatt assisted his predecessor, Junji Tsuda, as Vice President, a role he held for two years.
Steven Wyatt thanked the outgoing IFR President, Junji Tsuda, for sharing his esteemed and valuable industry expertise with key international stakeholders and the world’s press. “As the voice of the robotics industry, Junji Tsuda did an exemplary job in setting forth our members’ viewpoint on the key topics impacting our industry. As its new President, it is my pleasure to carry on his successful work. Together with the new Vice President, Milton Guerry, I will continue Junji Tsuda´s mission to deliver improved awareness and a better understanding of the rapidly changing world of flexible automation.
The new IFR Vice President Milton Guerry began his career in the automotive industry in various engineering and technical functions. Today, he heads the SCHUNK USA team as its President. Guerry is a member of the Robotic Industries Association’s (RIA) Board of Directors. He joined SCHUNK in 2000 and has held various leadership roles assuming his current role as President in 2007.
The Spanish Association of Robotics and Automation (AER) incorporates Alex Salvador as Managing Director, whose appointment was approved on October 22 by the AER Board of Directors. Alex Salvador replaces Marc Ollé, who leaves office after 7 years in the entity to undertake new professional challenges.
Alex Salvador is Bachelor in Economics and MBA from the University of Barcelona, and has developed his entire professional career in the industrial business environment, occupying management positions in both multinational and SMEs, in the areas of commercial-marketing and general direction. He has teaching experience and in recent times he has specialized in talent management and organizational transformation.
As the new Managing Director of the AER, he assumes the challenge of consolidating the organizational structure of the Association in addition to generating projects that allow the Spanish Robotics & Automation sector to be at the forefront of innovation and Industry 4.0.
It must be highlighted that AER – represented by Luis Basañez, current General Secretary of AER – was one of the founding partners of IFR in 1987 at the meeting held in connection with the 17th International Symposium on Industrial Robotics ISIR. Since then, AER & Barcelona have hosted two ISIR Symposiums, both in 1992 (23rd) and in 2009 (40th), thus demonstrating its total commitment with IFR.
The World Robotics report shows a new record stock of about 300,000 operational industrial robots in the Republic of Korea in 2018 (+10%). Within five years, the country has doubled its number of industrial robots. Following Japan and China, the country ranked third in 2018. But the dynamics of robot installations has decreased in recent years and for 2019 a continued decrease is expected.
“Robot installations declined by 5% to 37,807 units in 2018,” says Junji Tsuda, President of the International Federation of Robotics. “Both, the electrical/electronics industry and the automotive industry reduced installations – together they account for 82% of total demand.”
South Korea is affected by the US-China trade dispute, but there could be positive as well as negative effects: China is an important export destination for Korea´s intermediate products. The conflict could result in decreasing demand from China. In contrast, Korean products might substitute Chinese products. But currently, the South Korean economy is in troubled waters. Declining demand for electronic products and announcements of investment reductions by major electronics companies point towards another year of decreasing robot installations.
Robots needed to remain competitive
In the long run, the extensive use of robots is vital in order to maintain competitiveness. Korea’s population is ageing rapidly. By the middle of this century, it will have one of the oldest populations out of all OECD countries, just behind Japan, Italy and Greece. In 2050, more than one third of the population will be over the age of 65 and around half of all workers will be aged 50 and over. This helps to explain why South Korea has already embraced robots, particularly in its manufacturing sector, where “robot density” ranks second place in the world - following Singapore. With 774 industrial robots per 10,000 employees, the Republic of Korea has more than twice the number of Germany (3rd with 338 units) and Japan (4th with 327 units).
Korea´s Workforce Development
The Workforce Development and Training Act, updated in 2019, is one important initiative in a series of government- driven programs. People get support to develop skills of how to handle robots and automated machines. The “Smart Manufacturing Innovation Strategy” announced the build-up of 50,000 smart factory workers by 2022. And the Third Robot Basic Plan with a runtime of 5 years will support training of 2,200 workers for small and medium-sized enterprises by 2023.
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These days, the global robotics community will meet at the 23rd iREX, hosted from December 18 to 21 at the Tokyo Big Sight. Robot manufacturers and robot-related companies from around the globe are going to display and demonstrate the latest advancements in robot technology.
These days, the global robotics community will meet at the 23rd iREX, hosted from December 18 to 21 at the Tokyo Big Sight. Robot manufacturers and robot-related companies from around the globe are going to display and demonstrate the latest advancements in robot technology. The IFR booth is located at W2-15. We are looking forward to meeting you there!
Prior to the iREX, on December 17, IFR members will already meet at the venue to review recent IFR activities and to exchange and discuss opinions on the market development and future IFR activities.
For me, this IFR meeting will be a special one. It will be my last meeting as IFR’s President, given that my term of office ends this day. I had the pleasure to take over this presidency in late 2017, a year known for the global robotics boom. The following years turned out to be exciting and challenging: We have seen new record figures in many countries and passed the mark of 400,000 new industrial robots globally installed per year. We have seen the global market for service robots expanding to almost USD 13bn. The IFR supports the robotics industry on its growth path by promoting the benefits of robotic automation for human workers, industry and society. Our positioning papers, key messages, and blog posts address the general public. Our press releases have been cited more than 10,000 times every year in newspapers and journals all over the world. IFR representatives participated in numerous politically relevant meetings, conferences and events and communicated our joint positions to policy makers.
I am looking forward to passing on the IFR president’s chair to my successor, whom I wish the best luck and success in guiding us into the future of robotic automation.
Zimber Verpackungen has expanded its production by introducing a fully automatic, flexible robot system for component assembly. At the heart of the system are three efficient Yaskawa Motoman MH5 industrial robots. The latter can grip complex components of diverse shapes and perform the most demanding automation tasks.
The company – based in Gutach im Breisgau in Baden-Wuerttemberg – specialises in the production of high-quality packaging. Over the last few decades its customers have found everything they need for packaging and shipping their merchandise. Based on the trust placed in it by its customers, Zimber Verpackungen has extended its business model. In a fully automated process, state-of-the-art machines package complete sets as well as small and large series to customer specifications.
Complex assembly operations broaden the product portfolio
The decision was already made eight years ago by Ralf Zimber, Managing Director of Zimber Verpackungen. As an additional service, the lucrative contract packaging sector was to be expanded by the assembly of a wide range of complex components. But how could they take on this ambitious challenge in view of the constantly increasing requirements in terms of quality and flexibility?
Following deliberations and enquiries with a number of mechanical engineers, it quickly became clear: the task was only economically feasible with a supervised in-house development. Together with a free-lance designer a detailed requirement profile was prepared and the options were weighed up in a cost-benefit ratio.
Flexibility and speed as a key criterion
“Our most important aim in the development of the system was to achieve maximum flexibility while ensuring minimum loss of time for setup procedures and assembly,” reports Ralf Zimber.
Wishes became reality in a 15-month development and construction phase. Today, Zimber Verpackungen is ideally equipped for jobs involving complex components. A state-of-the-art system with three Yaskawa Motoman MH5 industrial robots was installed. Now a wide range of parts for the electronics industry, e.g. plug connectors and cable glands, as well as components for the heating industry and for many other applications, can be accurately assembled in the shortest of times.
Speed counts at Zimber Verpackungen. For this reason, the company did not want to miss out on the advantages of 3D printing. The pickup heads, robot grippers and even the O-ring assembly fixtures are almost wholly fabricated by the 3D printing process.
Ralf Zimber: “Due to the extremely short replenishment time of about one week and the low manufacturing costs – only a fraction of those for conventional manufacturing – 3D printing has become indispensable in the production of components.”
Robots control all assembly fixtures
Depending on requirements, at Zimber Verpackungen either the high-speed robot or a round table can be used for parts transport. The round table with built-in screw-driving station is used for components that need to be screw-mounted. The latter can easily handle the right- and left-hand threads of the different components.
If the components do not need to be screwed, the high-speed Yaskawa robots take care of the complete parts transport. Individual parts are fed via universal conveyor belts. Pick-ups specially made in the 3D printing process and custom-made for the respective component are used.
The robot controller also controls all assembly fixtures. In addition to complex components consisting of up to eight individual components, at Zimber Verpackungen this enables the simultaneous assembly of two simple, but completely different components.
The 6-axis Motoman MH5 robots are optimally suited for the diverse and complex tasks of the Breisgau-based packaging specialist. The model is specifically designed for use in the areas of handling, machine loading, processing and distribution applications. With a payload of 5 kg, a dead weight of only 29 kg and an extended range of up to 895 mm the MH5 is extremely efficient. It was designed for use in a confined working environment. Due to its flexible mounting possibilities on the wall, ceiling or floor, the robot saves valuable production space. The slim design facilitates setup procedures. The maximum workspace is generously dimensioned with 160 degrees in both directions.
In order to meet the challenge of maximum flexibility, each of the three “Motomen” at Zimber Verpackungen is equipped with several electrically powered grippers. These are geared to differing dimensions and thus flexibly adjusted to the respective components. A further advantage is the gentle handling of the components. Robust metal parts of different dimensions, or sensitive O-rings and thin-walled plastic parts, are securely held and transported by one and the same system. The repeatability of the MH5 is accurate to 0.02 mm.
Quality assurance by high-resolution camera
Individual parts are correctly positioned or assembled as required by a high-resolution camera integrated into the robot controls. If necessary, the latter can even accurately measure specific features of the components, e.g. the diameter or angle of grooves. Simple and fast integration and high quality were key considerations in the decision in favour of Yaskawa.
First practical applications
The newly designed system has meanwhile proven itself in industrial practice: the Motoman handling robots at Zimber are currently manufacturing 12-pole cable connectors for HUMMEL AG, a company with headquarters in Denzlingen, southern Baden. The latter comprise a total of six individual components that must be joined together with utmost accuracy, notwithstanding high cycle times.
HUMMEL, a medium-sized, family-owned enterprise, is a well-known manufacturer of joining technology, electrotechnical components and heating accessories, has for many years stood for quality, precision and reliability. A high level of vertical integration with development, construction, toolmaking, manufacture, electroplating and assembly under one roof offers the best prerequisites for implementing individual customer solutions.
A new fully automatic module assembly system enables packaging and assembly specialist Zimber Verpackungen to assume the most technically demanding packaging tasks and the assembly of single parts. Three Yaskawa Motoman MH5 handling robots execute customer orders flexibly and reliably. In an environment marked by a shortage of skilled labour, this enables the company to continue growing.
Ralf Zimber, Zimber Verpackungen, Waldkirch
Alexander Luna Garcia, Sales GI Robots & Products, Yaskawa Europe GmbH, Robotics Division, Allershausen
Sales of industrial robots in India reached a new record of 4,771 new units installed in 2018. That is an increase of 39 percent compared to the previous year (2017: 3,412 units). India now ranks eleventh worldwide in terms of annual installations.
“India is one of the strongest growing economies among the emerging markets in Asia,” says Junji Tsuda, President of the International Federation of Robotics. “Whilst the recent global results were quite moderate, India saw an impressive growth rate of 39% in 2018. The number of robot installations has been growing rapidly for several years now. Between 2013 and 2018, India saw a compound annual growth rate of 20%.”
Prospects for further increasing robot installations are promising. The Indian GDP is expected to grow by more than 7% in 2019 and companies across many industries intend to expand capacities. India has a young population, hence a strong workforce in need of jobs. The country needs to expand its manufacturing industry to create more job opportunities. Higher wages and the rising share of affluent citizens in India are the main drivers of a growing and promising consumer market.
The automotive industry remains the largest customer industry by far, with a share of 44% of total installations. But the strongest growth driver in 2018 was the general industry, increasing by 28%, consisting of the rubber and plastics industry, the metal industry and the electrical/electronics industry. Robot use in non-automotive manufacturing is catching up with the automotive sector.
Robot stock and India´s potential
Regarding annual installations, India now ranks eleventh in the global annual supply – three places higher compared to the previous year and ahead of Singapore, Canada and Thailand. The operational stock of robots rose to about 23,000 units: +21% compared to 2017. The country’s automation potential is illustrated by a low robot density figure in the automotive industry: 99 industrial robots per 10,000 employees is less than a fourth of Indonesia’s density (440 units) and far away from China (732 units) and the frontrunner Korea (2,589). India’s robot density in the manufacturing industry only reaches a value of 4 industrial robots per 10,000 employees.
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The new World Robotics report shows an annual global sales value of 16.5 billion USD in 2018 – a new record. 422,000 units were shipped globally in 2018 - an increase of 6 percent compared to the previous year. IFR forecasts shipments in 2019 will recede from the record level in 2018, but expects an average growth of 12 percent per year from 2020 to 2022.
Chinese manufacturers gain domestic market share
US robot installations rose by 22 percent
Europe´s robot installations rose by 14 percent
“We saw a dynamic performance in 2018 with a new sales record, even as the main customers for robots – the automotive and electrical-electronics industry – had a difficult year,” says Junji Tsuda, President of the International Federation of Robotics. “The US-China trade conflict imposes uncertainty to the global economy – customers tend to postpone investments. But it is exciting, that the mark of 400,000 robot installations per year has been passed for the first time. The IFR´s longer term outlook shows that the ongoing automation trend and continued technical improvements will result in double digit growth - with an estimate of about 584,000 units in 2022.”
Asia, Europe and the Americas - overview
Asia is the world’s largest industrial robot market. In 2018, there was a mixed picture for the three largest Asian markets: Installations in China and the Republic of Korea declined, while Japan increased considerably. In total, Asia grew by 1%. Robot installations in the second largest market, Europe, increased by 14% and reached a new peak for the sixth year in a row. In the Americas, the growth rate reached 20% more than the year before which also marks a new record level for the sixth year in a row.
Top five markets in the world
Five major industrial robot markets represent 74 percent of global installations in 2018: China, Japan, Republic of Korea, the United States and Germany.
China remains the world´s largest industrial robot market with a share of 36% of total installations. In 2018, about 154,000 units were installed. This is 1% less compared to the previous year but more than the number of robots installed in Europe and the Americas together. The value of installations reached 5.4 billion USD – 21% higher than in 2017.
Chinese robot suppliers increased their share of total installations on the domestic market by 5 percentage points (2018: 27% vs. 2017: 22%). This result is in line with China´s policy to promote domestic manufacturers. Installations of foreign robot suppliers on the other hand (including units produced in China by non-Chinese suppliers) decreased by 7% to about 113,000 units (2017: about 122,000 units). This reduction is also caused by a weakening automobile industry.
Japan´s robot sales increased by 21% to about 55,000 units, representing the highest value ever for the country. The average annual growth rate of 17% since 2013 is remarkable for a market with an already highly automated industrial production. Japan is the world´s number one industrial robot manufacturer and delivered 52% of the global supply in 2018.
Robot installations in the United States increased for the eighth year in a row to a new peak in 2018 and reached about 40,300 units. This is 22% higher than in 2017. Since 2010, the driver of the growth in all manufacturing industries in the U.S. has been the ongoing trend to automate production in order to strengthen the U.S. industries in both domestic and global markets. Regarding annual installations, the country has taken third position from the Republic of Korea.
The annual robot installations in the Republic of Korea declined by 5% – about 38,000 units have been sold in 2018. The robot market strongly depends on the electronics industry that had a tough year. Nevertheless, installations have increased by 12% on average per year since 2013.
Germany is the fifth largest robot market in the world and number one in Europe, followed by Italy and France. In 2018, the number of robots sold increased by 26% to almost 27,000 units – a new all-time record. Installations are mainly driven by the automotive industry.
Robot use by industry worldwide
The automotive industry remains the largest adopter of robots globally with a share of almost 30%of the total supply (2018). After a very strong year 2017 that saw a 21% increase of installations, this level was maintained and slightly increased by 2% in 2018. Investments in new car production capacities and in modernization have driven the demand for robots. Using new materials, developing energy efficient drive systems and high competition in all major car markets pushed for investments. 79% of industrial robot installations took place in 5 key markets: China (39,351 units), Japan (17,346 units), Germany (15,673 units), the United States (15,246 units) and the Republic of Korea (11,034 units). Interestingly, India, the world’s fourth largest vehicle producer by OICA´s production statistics, had just about 2,100 industrial robots installed in its automotive industry.
The electrical/electronics industry was about to replace the automotive industry as the most important customer for industrial robots in 2017. However, in 2018, global demand for electronic devices and components substantially decreased. This customer industry is probably the one most affected by the US-China trade crisis as Asian countries are leaders in manufacturing electronic products and components. Robot installations in this industry declined by 14% from their peak level of about 122,000 units in 2017 to 105,000 units in 2018. 79% of the total installations in the electrical/electronics industry were installed in three countries with major production sites: China (43%), Republic of Korea (19%), Japan (17%). Vietnam saw a one-off boost of installations in 2017 driven by a few major projects (7,080 units), but dropped back in 2018 (689 units).
The metal and machinery industry established itself as the third largest customer industry. Installations accounted for 10% of total demand in 2018. Both producers of metal products (without automotive parts) and producers of industrial machinery, have bought substantial amounts of robots in recent years. Installations rose to about 43,500 units in 2018. This is
1% less than in the record year of 2017 (44,191 units). The metal and machinery industry was the largest customer industry in Finland (44%), Sweden (42%), Switzerland (40%), Belgium (30%), Austria (27%), Italy (26%) and Denmark (21%).
Robots designed for collaborative use (Cobots)
For the first time, World Robotics analyses the market for collaborative industrial robots (cobots). Cobots are designed to perform tasks in the same workspace as human workers. The IFR definition implies that a cobot is necessarily an industrial robot as defined in ISO 8372:2012. Despite a very strong media attention of cobots, the number of units installed is still very low with a share of 3.24% only. In 2018, less than 14,000 out of more than 422,000 industrial robots installed, were cobots. The year before that, roughly 11,100 units were cobots. From 2017 to 2018, annual installations of cobots increased by 23%.
The annual global sales value of 16.5 billion USD in 2018 is a projection based on market values reported by various national robotics associations. This encompasses only the robots. If software, peripherals, and systems engineering is included, the value is approximately 50 billion USD.
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Sales value of service robots for PROFESSIONAL USE increased by 32 percent to 9.2 billion U.S. dollars. Logistic systems such as autonomous guided vehicles (AGVs) represent the largest fraction in the professional service robot market (41% of all units sold). The second largest category is inspection and maintenance robots, (39% of all units sold). These two segments account for 80 percent of total market share.
Service robots for PERSONAL AND DOMESTIC use are mainly in the areas of household robots, which include vacuuming cleaning and lawn-mowing robots. Value was up by 15 percent to 3.7 billion U.S. dollars. The IFR outlook predicts a strong sales increase for professional and personal service robots (2019-2022). This is according to the 2019 World Robotics Report – Service Robots, presented by the International Federation of Robotics (IFR).
“In terms of value, the sales forecast for 2019 indicates a cumulative volume of around 12.6 billion U.S. dollars for the professional service robot segment”, says Dr. Susanne Bieller, General Secretary of the IFR. “Robots for logistics, medical and field services are the most significant contributors.”
Service robots for PROFESSIONAL USE – market overview
The total number of professional service robots sold in 2018 rose by 61% to more than 271,000 units, up from roughly 168,000 in 2017.
The sales value of logistic systems is estimated at almost USD 3.7 billion which is 53% more than the year before. In terms of units, almost 111,000 logistic systems were sold in 2018 – this is 60% more than in 2017 (69,000). 7,700 autonomous guided vehicles (AGV) in manufacturing environments and almost 103,000 in non-manufacturing environments are the driving force behind this rapidly growing market. The trend to use logistic systems in non-manufacturing industries has been strongly driven by warehouse solutions for major e-commerce companies. A strong potential can also be found in hospitals running their logistics with the help of professional service robots.
About 106,000 inspection and maintenance systems were sold in 2018. This accounts for 39% of total professional service robot units sold. The category of inspection and maintenance robots covers a wide range of robots from rather low-priced standard units to expensive custom solutions.
Sales of medical robots increased by 50% to 5,100 units. Medical robots account for 31% of the total sales value of the professional service robots. The total value of sales increased by 27% to USD 2.8 billion. Medical robots are the most expensive service robots with an average unit price of USD 548,000, including accessories and services. The demand for supportive robot solutions for the ageing societies in Europe and Asia also represents a considerable growth potential for medical robots.
The sales value of field robots increased by 8% to USD 1 billion, accounting for 11% of the total value of professional service robot sales. A total of 5,800 milking robots were sold in 2018 compared to 5,400 units in 2017, an increase of 8%. Sales of agricultural robots used e.g. for automation of crop farming and horticulture, are expected to grow strongly by an average of some 50% per year. In 2022, sales are expected to reach 2,400 units.
Exoskeletons support ergonomic working by reducing loads on the worker. Sales of powered human exoskeletons were up from 6,700 units in 2017 to 7,300 units in 2018. There is a high growth potential for this kind of robot.
Service Robots for PERSONAL and DOMESTIC USE – Market Overview
At the same time, the market for Personal Service Robots, is developing rapidly. It is projected that sales of all types of robots for personal and domestic tasks could exceed 22.1 million units (valued at USD 4.6 billion) in 2019 and 61.1 million units, with an estimated value of USD 11.5 billion, in 2022.
Vacuum and floor cleaning robots will enter more and more households in the world. It is estimated that in 2019 more than 17.6 million units of domestic robots - including autonomous lawn-mowers, pool cleaners and vacuum cleaners - will be sold. Unit sales are expected to increase by 46% on average per year so that more than 55 million units will be sold in 2022.
Service robot manufacturers for professional use by regions
European and American service robot manufacturers play an important role in the market for professional use: both regions have a market share of about 45 percent. American companies are very strong in logistic systems whereas European companies dominate in the field of medical robotics. European and Asian companies mainly produce the field robots – both with a market share of about 45 percent.
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We are happy to announce the final figures of World Robotics 2019 today: Both the industrial as well as the service robot markets grew considerably in 2018.
We are happy to announce the final figures of World Robotics 2019 today: Both the industrial as well as the service robot markets grew considerably in 2018.
The results for the industrial robots’ market exceeded those of our April forecast. Despite the difficult times for the main customer industries, automotive and electrical/electronics, and the lingering trade conflict between two of the main destinations, China and the USA, imposing uncertainty to the global economy, 2018 has been the sixth consecutive year with a record annual unit sales volume. 422,000 new industrial robots were sold in 2018, a growth of 6% compared to 2017. The global robotics market volume rose to US$ 16.5 billion. The global operational stock rose beyond 2.4 million robots.
This growth also comes as a surprise as two of the 5 major markets for robotics saw a downturn in the number of new installations: China and the Republic of Korea. But this was covered up by an above-average growth by the remaining three, Japan, the United States and Germany.
We are also proud to be able to present the first statistics on collaborative robots this year: Slightly less than 14,000 industrial robots installed were cobots, corresponding to only 3% of the overall industrial robot market. This figures underspins the IFR’s position that the market for collaborative robots is still in its infancy. Users and integrators are still gaining experience on what works and doesn’t in the design and implementation of collaborative applications. Technology developments in sensors and grippers hold promise for expanding the range of actions that the robot end-effector can perform. Programming interfaces will continue to become more intuitive, not just for cobots, but also for traditional industrial robots.
The service robotics market is also growing at high pace: The number of service robots for personal and domestic use increased by 59% to about 16.3 million units in 2018 reaching a value of US$ 3.66 billion (up 15%). The number of professional service robots sold in 2018 rose by 61% to more than 271,000 units, the sales value increased by 32% to USD 9.2 billion.
This flourishing service robotics scene, amongst other examples of robotics technology, can be witnessed during the 14th RobotWorld, which is the biggest specialized robotics exhibition in Korea, held from October 9 to 12 in Seoul.
The IFR community will gather again on December 17, in connection to the iREX exhibition in Tokyo. The 23rd iREX, hosted from December 18 to 21 at Tokyo Big Sight, will showcase next-generation robot technology from robot manufacturers and robot-related companies from around the world and provide the opportunity for business talks exchange of technology. We are looking forward to meeting you there!
Robots are being increasingly utilized in the medical field. For over 30 years, they have been supporting patient care in healthcare facilities worldwide. Despite this “tradition,” however, the age of medical robotics has only just begun, as a new breed of sensitive and collaborative robots is poised to shape the future of robotics in medicine.
The swiss-based company AOT AG has developed an innovative process for bone surgery, using a KUKA robot that is certified in compliance with the relevant standards.
Identification of the task
The greatest stories are based on real life, as they say – and real life sometimes has a way of coming up with the best innovations. Complex orthodontic surgery undergone by his daughter was the catalyst for a personal meeting between laser researcher Dr. Alfredo E. Bruno and Prof. Dr. Dr. Hans-Florian Zeilhofer, Head of the Oral & Maxillofacial Surgery department of the University Hospital Basel and the Canton Hospital Aarau. The technical exchange of this meeting and the combination of the two areas of competence to create robot-guided laser ablation gave rise to Advanced Osteotomy Tools AG, or AOT for short.
„Our goal was to achieve radical improvement in the results of bone surgery by replacing mechanical cutting instruments with non-contact “cold” laser photoablation and medi-cal robots”, explains Dr. Alfredo E. Bruno, now Chief Scientific Officer (CSO) and member of the administrative board at AOT. To achieve a high precision, the system requires not only the laser and the navigation system, but also a robot. This makes the programmed cuts with millimeter precision and meets the requirements in terms of high sensitivity. For this reason, the path from AOT AG lead to the LBR Med from KUKA.
Their joint brainchild was given the name CARLO, which stands for Cold Ablation, Robot-guided Laser Osteotome. How does CARLO work? The surgeon carries out the preopera-tive planning on the basis of data from a CT scan and feeds it into CARLO’s navigation system. An intuitive app guides the surgeon and technical staff through CARLO’s initiali-zation step by step. The robot then performs the operation independently. If anything does not go as planned, the physician merely has to touch the robot gently and the sys-tem stops immediately. “The LBR Med has a whole range of extremely fine sensors. It is quicker than stopping a human assistant,” says Prof. Hans-Florian Zeilhofer. “The robot then moves to a wait position and resumes the procedure from precisely this position as soon as it receives the all clear.” The system is rounded off with complex 3D planning, navigation and control software and hardware. It slots seamlessly into the operating room and works autonomously but provides the surgeon with full control of the proce-dure at all times.
Evaluation of the solution of the challenge
Until now, there was no solution for keeping the bone tissue in the area of the laser cut-ting surfaces intact and alive. CARLO now combines a laser and a robot for bone surgery in the form of the new “cold” laser technology with a small, lightweight, tactile robot designed for direct human-machine cooperation. Because its design was based on the sensitive, seven-axis LBR iiwa, the LBR Med already has sensitivity integrated into it. In the past, manufacturers had to develop this sensitivity for the robots they used for their products themselves, so they could be operated in the immediate vicinity of the patient. Efforts like these are now largely eliminated. “The LBR Med has installed force torque sensors in all seven axes, which makes it sensitive and safe. When there is even a little, unplanned contact, it remains still and interrupts its tasks. This sensitivity can also be used to operate the system intuitively and manually. Another advantage of the LBR Med is that the robot is already certified for integration into a medical product. It is the only robot component that has been certified according to CB Scheme process and can there-fore be easily incorporated into a medical product by medical technology companies. This has saved AOT AG a lot of time in the approval process.
This is all still in the future, however, as far as the laser and robot for bone surgery are concerned, because certification as a medical product is still in progress. “Since CARLO is the first system of its kind, the supervisory authorities are understandably placing very high requirements on its safety,” explains Dr. Alfredo E. Bruno. AOT AG is already work-ing on the development of the second generation of CARLO with enhanced safety and performance features. These are tools that will place further demands on the LBR Med. For Prof. Hans-Florian Zeilhofer, CARLO represents the future of surgery because the software-guided robotic laser system for bone surgery supported by the LBR Med can perform highly precise cuts with any required pattern. “There are far more options open to the surgeon than with previous procedures.”
With over 384,000 industrial robots installed globally in 2018, we again face another record year – according to our preliminary data presented in April. But the growth has slowed down significantly in 2018, compared to the high growth rates of the previous years. This slowdown is caused by several factors: uncertainties over the transition from internal combustion engines to electric vehicles, declining smartphone sales and certain geo-political trends.
Meanwhile, summer is approaching, but the pace in robotics is still not declining. In July, not less than two CEO Round Tables co-hosted by IFR will take place:
On July 9th, during the China International Summit of Robotics and Smart Manufacturing, the IFR-CRIA CEO Round Table will focus on “Robots + Intelligence and 5G”. Representatives of Chinese and international robot manufacturers will discuss how AI and 5G will influence the development of robotics industry and the new business opportunities arising thereof. The China International Summit is held in conjunction with CIROS 2019. This year, CIROS - China International Robot Show - is taking place for the eighth time in Shanghai from July 10 to 13.
On July 10th, the IFR-RAR CEO Round Table will discuss “Robotics as a driver for changes in production process”. Representatives from both Russian and international industrial enterprises, integrators and robot manufacturers will look, among others, at robotics as part of the overall modernization of industrial production, new markets and business models (Robots as a service). This Round Table is hosted during INNOPROM 2019, the main industrial trade fair in Russia, which will be held in Ekaterinburg, Russia, from July 8 to 11, 2019.
Finally, IFR is happy to announce that the 15th Innovation and Entrepreneurship Award in Robotics and Automation - the IERA Award – has been awarded to the UVD Robot by Blue Ocean Robotics. The UV disinfection robot runs autonomously through hospitals to eliminate bacteria and other harmful microorganisms in hospital rooms by emitting concentrated UV-C light. The IFR and IEEE RAS honor this development that reduces risks for patients and hospital staff alike and shows an enormous market potential. Congratulations to Blue Ocean Robotic!
The 15th Innovation and Entrepreneurship Award in Robotics and Automation (IERA) goes to the “UVD Robot” by Blue Ocean Robotics. The collaborative robot autonomously drives around hospitals while emitting concentrated UV-C light to eliminate bacteria and other harmful microorganisms. As a result, hospitals can guarantee a 99.99% disinfection rate – reducing the risk for patients, staff and relatives of contracting dangerous infections.
“The UV disinfection robot by Blue Ocean Robotics shows that robotics has a limitless potential of being applied in new environments,” said Arturo Baroncelli, former President of the International Federation of Robotics which co-sponsors the IERA award. “The combination of ‘classical’ mechatronic disciplines - typical of robotics – with the know-how of medicine and pharmacy is fantastic evidence of this path of progress. The IFR is happy to recognise and support this virtual trend.”
“We are incredibly proud of winning the IERA Award 2019 for a ground-breaking product,” said Claus Risager, CEO of Blue Ocean Robotics. “Everyone can feel safe in rooms that have been disinfected by the robot. Our UVD Robot not only reduces the risk of patients contracting hospital-related infections, but also to a high extent visitors and hospital staff.” Blue Ocean Robotics is a Danish manufacturer of service robots for the healthcare, hospitality, construction and agricultural sectors based in Odense. The UV disinfection robot is sold by its subsidiary, UVD Robots.
UVD Robot disinfects all contact surfaces autonomously
Infections acquired in hospitals cause significant costs in the healthcare sector: In the EU, these costs amount to 7 billion euros. The source of infections can be other patients or staff and even equipment or the hospital environment. The UVD Robot drives around and positions itself autonomously in relation to its surroundings. The machine treats surfaces in a hospital ward with light from several angles and up close. The robot disinfects all contact surfaces, stopping at predefined hotspots that require a longer time of exposure. The UV disinfection robot does not replace the manual cleaning process - it is designed as a complimentary activity and always works in enclosed spaces.
Collaborative robot contains number of safety features
As exposure of UV-C light toward humans should be avoided, the robot contains a number of safety features: for example, a tablet which is placed on the door of the patient room acts as a motion sensor – it automatically disengages the UV-C light if someone wants to enter the room.
The technology has been developed in cooperation with leading hospitals in Scandinavia. First sales have been made in the Middle East and Asia. In future, the robot can also be applied to other environments requiring diligent disinfection such as food production or laboratories.
IERA Award honours collaboration of science and industry
The IERA Award is one of the world’s most prestigious awards in robotics. It honours the collaboration between science and industry in the production of robots and is jointly awarded by the International Federation of Robotics (IFR) and the IEEE Robotics and Automation Society (IEEE/RAS), the world’s largest technical professional organization.
Video of UV Disinfection Robot
Please find a video of IERA Award Winner “UV Disinfection Robot” here
Staubli Robotics / Case Studies Collaborative Robots
At Bischofszell Nahrungsmittel AG, a subsidiary of the Migros Group (Switzerland), the potential of new technologies is currently being explored. In a pioneering MRC pilot project over a fixed period, the management set out to achieve two objectives, namely the efficient production of food and the humanization of the workplace.
Bischofszell Nahrungsmittel AG, a company based in the town of the same name near St. Gallen, specializes in the production of convenience foods. The factory works around the clock making delicious ready-made meals that would not be out of place in a haute cuisine setting. Customer demand for these products, with their quality and convenience of preparation, continues to grow.
Steffen Knoll, Technology Project Manager at Bischofszell Nahrungsmittel AG and dedicated automation expert, is a major advocate of the MRC (Man-Robot Collaboration) concept, and not merely for reasons of increased capacity: “MRC offers a completely new range of possibilities. It obviously gives us the opportunity to expand our capacity relatively easily, but it also enables us to provide targeted support by means of robotics to the strengths of our employees in terms of flexibility and intelligence, thereby minimizing health hazards and the risk of injury to humans arising from stressful activities.”
What Knoll is referring to becomes apparent when the application is observed in operation. It involves taking fully packaged convenience dishes that have come direct from the production line and stacking them in multiple layers on metal trays, which are then slotted into trolleys for transportation to the pasteurization/sterilization unit. The stages of this process, when performed manually throughout, entail injury hazards and health risks for employees.
Maximizing work safety – Minimizing the Risk of Injury
While the distribution of the ready meals on the aluminum trays and the placing of spacers between the individual layers are among the more agreeable jobs on the packing line, stacking the large metal trays on the trolleys is by no means a popular activity. Manhandling the trays, which measure 900 by 900 millimeters and weigh in at a hefty five kilos, over a full eight-hour shift is heavy work. The trays have to be slotted accurately into the trolley, which brings with it the risk of crushed fingers.
“Our employees are very experienced in this work, but risk of injury cannot be ruled out,” adds Knoll. “What could be more appropriate than a division of the entire handling process between man and machine? Also, in direct collaboration at a single compact work station without being separated by a safety barrier, the more agreeable tasks can be assigned to the human employee and the strenuous operations involving risk of injury to the robot. It seemed to us that MRC presented an effective solution.”
Intelligent Solution Developed Inhouse
However, implementing the proposed scenario turned out to be more difficult than expected. After thorough analysis, the system integrators initially consulted expressed doubts about the viability of the application. Risk assessment, interface definitions, zonal sensory protection, selection of a suitable robot – there were a number of concerns that persuaded the cautious plant engineers to withdraw from the pioneering project.
Yet Steffen Knoll and his team were still convinced of its merits, so there was only one thing to do: they would simply have to implement the MRC concept by their own endeavors. The prerequisites for this were met, as the company already uses various robots in other applications and has proven expertise in the field. The MRC application would, however, be uncharted territory.
In the search for a suitable robot provider, Knoll recalled a visit to a trade fair in 2016 at which Stäubli was one of the exhibitors: “At a robotics conference, I saw the new TX2 series. Stäubli were advertising these six-axis machines as the world’s fastest in the safe robot category and, with their modular PLe/SIL3 safety features, as ideally qualified for MRC applications. Fast, easy-to-program robots for direct man-machine interaction with a suitably high payload – we realized that this could be the answer in our particular circumstances.”
The Perfect Robot for Man-Machine Interaction
Contact was immediately established with the Swiss offices of Stäubli at Horgen, and from that point onwards, matters proceeded apace. In consultation with Stäubli, the right robot for this particular instance of man-machine interaction was identified: a TX2-90L with CS9 controller. In contrast to classic cobots (co-robots), this collaborative six-axis machine has the necessary payload for the application in question. What was missing was a suitable universal gripper to handle both the aluminum trays and the spacers. In order not to lose any more time, the Swiss company designed and built the gripper as well as the complete system from its own resources.
The application comprises four main components – robot, tray magazine, spacer feed belt, and stacking trolley. The workflow of the cell is as follows. While a single human employee distributes ready meals on an aluminum tray and then places the spacers for the next layer, the Stäubli six-axis machine operating in SLS (Safe Limited Speed) mode picks up four spacers from the feed belt and places them on the top aluminum tray in the magazine. It then lifts the metal tray plus spacers out of the magazine, swings it in the direction of the stacking trolley and waits at a defined position until its human co-worker finishes distributing the current layer of ready meals, presses a button to confirm that the process is complete and withdraws from the work area. The robot, now operating at high speed, inserts the new tray in the stacking trolley ready for the next layer. A new cycle can begin. As soon as the employee re-enters the defined perimeter of the system, the robot automatically returns to Safe Limited Speed.
Apprentice Programs Complex MRC Application
Visitors who come to see the pioneering MRC concept in Bischofszell can hardly believe that the entire system – including risk assessment, zonal sensory protection, programming, etc. – was developed in just four months without any input from external specialists. Intensive training quickly enabled the Migros team to draw up risk assessments from their own experience and to acquire the relevant expertise to program a complex MRC process. Visitors are also impressed that Raphael Merz, a fourth-year Migros trainee with a passion for automation, was able to program the complete MRC application within a few weeks of completing a four-day VAL3 programming course at Stäubli in Horgen and two days of safety training.
Steffen Knoll is justifiably proud of the achievement of his team in designing the system. What particularly pleases MRC enthusiast Knoll is the thoroughgoing compliance with the most stringent safety standards: “MRC is the future, but only if safety is guaranteed. In my view, the collaborative Stäubli robots are the safest machines on the market capable of handling such a high payload. We were able to cover the complete range of zonal protection specifications with the Stäubli TX2’s unique set of modular PLe/SIL3 safety features – Safe Limited Speed, Safe Stop, Safe Zone and Safe Tool – and with two Sick laser sensors. As a result, our employees were able to work side by side with the robot, and even without a safety barrier at one station.”
With this pilot MRC application, the development team at Bischofszell have shown that man-robot interaction has enormous potential for many of the production and assembly lines in the Migros group. “Some final detailed improvements will, of course, have to be incorporated into the system before it can be rolled out, to ensure durability of service in a production environment,” adds Knoll. “But the prime objective of demonstrating the benefits that flow from this pilot system has been fully achieved.” Migros could therefore soon become one of the first food manufacturers in the world to have MRC applications as standard technology in its production facilities.
Installations of industrial robots in the United Kingdom fell by 3 percent to 2,306 units in 2018. In the previous year, robot sales in the UK had risen by 31 percent. The European Union´s recent sales numbers are still positive - up 12 percent. This is according to the preliminary results of the World Robotics Report 2019.
In terms of robot density by region, Europe has the highest level worldwide, with 106 industrial robots per 10,000 employees installed in the manufacturing industry – Germany (3rd), Sweden (5th), Denmark (6th), Belgium (9th) and Italy (10th) all make the top-10. The UK ranks 22nd worldwide with a density of 85 units, which is equivalent to the global average. China overtook the UK in 2017 and is currently ranked 21st with 97 units.
“The United Kingdom has been adding robot automation at a lower rate than our main competitors in all manufacturing sectors outside of automotive,” says Mike Wilson, Chairman of the British Automation and Robot Association (BARA). “Over many years, the UK has attracted workers from other countries, with businesses preferring to hire people rather than invest in capital equipment. The consequences of the Brexit vote and subsequent political developments are leading to reduced labour availability as the many workers who have come over from Eastern Europe are starting to return home. As a result, businesses have to ensure that they use their workforce effectively and find alternative ways of performing tasks for which they have a shortage of staff - robot automation being an obvious solution.”
What the experts at the IFR CEO Roundtable say
“Robot adoption is central to driving productivity growth and every nation should want faster productivity growth”, says Dr. Robert Atkinson, President, Information Technology and Innovation Foundation (ITIF), USA at the recent IFR CEO Roundtable 2019 in Chicago, where international experts discussed the global robotics and AI race.
“Robots play a major role in manufacturing,” says Junji Tsuda, President of the International Federation of Robotics. “There are so many projects. Everybody is engaged in enhancing the capability of robots. We can apply robots in many areas – so everybody will be a winner. When it comes to AI the developer community is very open and they share the basic logic globally. There is a race for implementation. This implementation has a very close connection with robotics engineering which makes the difference. When it comes to AI for robotics, still Japan and Europe will be the major players for robot applications.”
Focus on implementation
“We need to focus more on the implementation side,” says Dr. Byron Clayton, CEO, Advanced Robotics for Manufacturing, USA. “The US government needs to follow international examples who are putting money and effort in policy towards the implementation and deployment side of high technology and getting it to the factory floor.”
The International Federation of Robotics (IFR) appoints Dr. Susanne Bieller as new General Secretary. The 41-year-old will take office on 1 May 2019 from Gudrun Litzenberger, who is retiring. At the same time, Litzenberger will hand over the management of the IFR Statistical Department to Dr. Christopher Müller.
The rapid rise of robot use and automation has significantly expanded the tasks of the International Federation of Robotics worldwide. “As an `ambassador of robotics`, I am looking forward to supporting the dynamic development of robotics and continue IFR´s successful work in future,” says Dr. Susanne Bieller. “One of my focus tasks will be to ensure a better understanding of the complex industry issues around the globe”.
Dr. Susanne Bieller has up to now worked as a project manager for the European Robotics Association EUnited Robotics for five years. She began her professional career as managing director of the flat-panel display group at the German Engineering Federation (VDMA) in Frankfurt, where she worked for seven years. After completing her academic career, the PhD Chemist went to the European Commission in Brussels where she looked into public relations and communications.
Dr. Christopher Müller (37) is head of the IFR Statistical Department and responsible for worldwide industry data and analyses. In this role, the PhD economist also takes care of the annual “IFR World Robotics Report”. Today, this study is regarded as the most important source for global robot statistics and covers all market-relevant activities of industrial and service robots.
Gudrun Litzenberger took over the responsibility for World Robotics Statistics in 2003 and has been General Secretary of the IFR since 2008. Last summer she received the Joseph F. Engelberger Robotics Award - the world’s most important industry award. The jury honored her outstanding commitment. She has developed the robot statistics and established the International Federation of Robotics as the voice of robotics worldwide.
The International Federation of Robotics represents more than 50 members like robotic companies, institutes and universities and national robot associations from over twenty countries and was founded in 1987 as a non-profit organization.
The preliminary statistics of the World Robotics Report shows that a new record high of 384,000 units were shipped globally in 2018 – an increase of one percent compared to the previous year. This means that the annual sales volume of industrial robots increased for the sixth time in a row (2013-2018) – but only just.
Please watch Steven Wyatt´s outlook video from the AUTOMATE 2019 in Chicago
Robot sales in the United States hit a new peak of almost 38,000 units, setting a record for the eighth year in a row (2010-2018). Today, robot density in the US manufacturing industry is now more than double that of China and ranks seventh worldwide.
Robot density in the US manufacturing industry reached 200 robots per 10,000 employees vs. 97 in China (2017). The trend to automate production in both domestic and global markets is the main driving force of robot installations in the US. The general industry sector, particularly the food and beverage industry (+64%) and the plastic and chemical products industry (+30%), had the highest growth.
In terms of market share, the automotive sector is the most important customer for robots. The US car market is the second largest car market in the world after China. Within the US automotive sector, part suppliers account for two thirds of installations: Sales went up by 9 percent (2017-2018). However, car manufacturers (OEM) invested less in automation – installations went down by 26%. The average annual growth rate of robot sales to the US automotive industry between 2013 and 2018 was 7%. From a peak of 16,311 units in 2016, robot sales decreased by 5% from 15,400 units in 2017 to 14,600 units in 2018 - accounting for a share of 38% of total installations.
„Robot density in the automotive industry increased by 52% between 2012 and 2017, from 790 to 1,200 industrial robots in operation per 10,000 employees (robot density China 2017: 539 units). According to the Bureau of Labour Statistics USA, employment in the automotive industry increased by 22% from 824,400 to 1,005,000 jobs (2013-2018).
The electrical/electronics industry was the second most important customer in 2018 with a market share of 18% of the total supply. From 2013 to 2018, robot installations increased by 15% on average per year.
The number of installations rose by some 2% to almost 6,700 units in 2018. In terms of new developments, several production sites for lithium ion batteries as well as for chips and sensors have been created in recent years and more will be established in years to come.
North America – USA, Canada, Mexico
“The North American countries (United States, Canada, and Mexico) represent the second largest operational stock of industrial robots in the world after China,” says Junji Tsuda, President of the International Federation of Robotics. “Whilst numerous important robot system integrators come from North America, most big robot manufacturers are based in Japan, Korea and Europe. At North America’s number one robot and automation event ”Automate 2019” in Chicago, from April 8–11th, you will be able to see the latest innovations in robotics, vision, motion control and automation technologies from around the world.
AUTOMATE 2019 - April 08-11, 2019 | McCormick Place, Chicago, IL
The Automate show will take place from 8th to 11th April 2019 at McCormick Place in Chicago. The IFR will present the first results on the global robot sales at the IFR CEO Round Table on 8th April.
On April 8th, the IFR will present the first results of the global industrial robot sales in 2018 at the Automate 2019 in Chicago. The IFR CEO Round Table will follow with a discussion on “Global race for leadership in robotics and AI”. We are proud to have these distinguished experts on the panel:
Dr. Robert Atkinson, President, Information Technology and Innovation Foundation (ITIF), USA
Dr. Byron Clayton, CEO, Advanced Robotics for Manufacturing (ARM), USA
Junji Tsuda, President, IFR and Representative Director Chairman of the Board, Yaskawa Electric Corp., Japan
Henry Sun, Director of Strategy, Guangzhou MINO Automotive Equipment Co, China
Thomas Visti, CEO, MIR, Denmark
Don’t miss this high-level eventat the Automate 2019!
“Win the Future” is the theme of the 51st International Symposium on Robotics, the ISR, at the Automate 2019, April 8 to 11, in Chicago. More than 110 conference sessions will explore how automation secures a company’s success in a technologically fast-paced world where artificial intelligence (AI), Industrial Internet of Things (IIoT), smart manufacturing, collaborative robots (cobots), machine vision and other innovations are rapidly shifting the dynamic of today’s manufacturing.
Furthermore, we will see a great cross section of the entire automation industry at the Automate 2019 fairground. The Automate is the most important robotics and automation exhibition of North America.
The Engelberger Award 2019 will be presented on April 10th. We congratulate Catherine Morris, group leader and director of automotive sales at ATI Industrial Automation, honored in the category of Leadership and Dr. Howie Choset, professor at Carnegie Mellon University and co-founder of the Advanced Robotics for Manufacturing (ARM) Institute, honored in the category od Education.
We are looking forward to exciting days ahead with robotics and automation in Chicago!
The Robotic Industries Association (RIA), the industry’s North American trade organization, announced the winners of the 2019 Engelberger Robotics Awards, the world’s most prestigious robotics honor.
At a special dinner in conjunction with the Automate 2019 Show and Conference in Chicago on April 10, RIA will honor Catherine Morris, group leader and director of automotive sales at ATI Industrial Automation, along with long-time RIA board member and former chairperson; and Dr. Howie Choset, robotics professor at Carnegie Mellon University and co-founder of the Advanced Robotics for Manufacturing (ARM) Institute.
The award is named for Joseph F. Engelberger, known throughout the world as the ”father of robotics.” Engelberger was founder and president of Unimation, Inc., the world’s first industrial robot manufacturer. The Engelberger Robotics Awards are presented to individuals for excellence in technology development, application, education and leadership in the robotics industry. Each winner receives a $5,000 honorarium and commemorative medallion with the inscription: “Contributing to the advancement of the science of robotics in the service of mankind.” The awards recognize outstanding individuals from all over the world. Since the award’s inception in 1977, it has been bestowed upon 128 robotics leaders from 17 different nations.
2019 Engelberger Robotics Awards Winners
Catherine Morris is honored in the category of Leadership. “I can think of very few people in the history of the robotics industry who have been as committed to the growth of our industry as Catherine,” said Jeff Burnstein, RIA President. “In addition to helping build ATI into a global leader in robotic accessories and robot arm tooling, she has been a tireless advocate of robotics and the important role that groups like RIA play within it. In fact, over the past two decades she’s found time to hold virtually every key position in our trade group, from Membership Committee Chair, to Automate Show Committee Chair, to overall Chair of RIA (the first and only woman to hold that role to date), and now serves as a board member of our parent group, the Association for Advancing Automation. She’s also been an outstanding role model and mentor for women in robotics—getting more women involved in robotics will be a key to the long-term success of the industry. In her role at ATI since 1995, she has positively impacted the success of robotics end users, robot manufacturers, and system integrators through her high degree of process and mechatronic knowledge.”
Dr. Howie Choset will receive the award for Education. “In addition to being an inspiring professor in the Robotics Institute at Carnegie Mellon, Dr. Choset has lead key research efforts to help solve significant problems in diverse areas such as surgery, manufacturing, infrastructure inspection and search rescue,” Burnstein said. “Additionally, he has co-founded several companies, including Medrobotics for surgical system, Hebi Robotics for modular robots, and Bito Robotics for autonomous guided vehicles. His FDA-approved surgical snake robot has been in use in the U.S. and Europe since 2015. Add to that his role as a co-founder of the ARM Institute that is aimed at advancing technology development and education for robotics in manufacturing, and his role as a founding editor of the journal Science Robotics, and you see that Dr. Choset is well-deserving of our industry’s highest honor.”
The award dinner will be held on Wednesday, April 10 from 5:30 p.m. to 8 p.m. at the McCormick Place – Vista Ballroom. Tickets for the event may be purchased when registering for the Automate 2019 show and conference.
Swiss household device manufacturer V-Zug, was looking for a safe, innovative and cost-efficient automated solution to help its human operatives assemble and test control panels. It found it in the FANUC CR-7iA/L collaborative robot.
As part of an automation system, the robot completes tasks such as button and control knob testing more accurately than humans using its sensitive Touchfinger. The benefits are increased efficiency and improved quality.
Identification of the task
To spearhead a new automated future for the company and keep it competitive, V-Zug launched a pilot project designed to improve the assembly and testing of the control panels for electric cookers and other household devices it manufacturers. After the panels are assembled manually and software is installed, the panels must be tested. Up to now, humans have done this. Thanks to their excellent repeatability and sensitive touch capabilities however, FANUC CR-7iA/L collaborative robots were identified as providing a more efficient solution.
Why human-robot collaboration was selected as a solution
Collaborative robots were introduced to improve quality and make processes more efficient. Before their introduction, the workers had to wait for the software download, which took about two minutes, before they could press the keys to test them themselves. All waiting times have now fallen away thanks to the collaborative robots. In addition, process quality has improved because the collaborative robot deals with the sensitive testing using a touch finger with an adjustable, always consistent pressing force, which is not possible for a human. The quality of the test results is now greater as a result.
How is it solved (configuration of the workplace and different steps of operation)
To launch the project, Patrick Meyer from V-Zug contacted the Swiss branch of FANUC, among others: “We are familiar with FANUC as a large robot manufacturer, which has been working with collaborative robots for years and offers a special model series.” Besides the requirements for the robot - it should possess process reliability and be easy to maintain - it was important to those making the decision to have a reliable partnership with good, rapid service.
A suitable model was found in the CR-7iA/L, a 6-axle robot with a range of 911 mm and 7 kg payload. For the specific project work at V-Zug, FANUC brought along an experienced industrial partner, R. Wick AG from Küssnacht, just a few kilometres away. For more than 15 years, the systems company has focussed on the development of automation solutions for small and medium-sized enterprises, whereby robotics technology plays a fundamental role.
Guido Lüönd, COO of Wick AG, explains: “Our main objective is to develop automation solutions which significantly increase productivity so that our customers also remain competitive in Switzerland as a place of production.”
Evaluation of the solution of the challenge
V-Zug is very satisfied with the procedure and result. Since the “panel testing” project certainly had a pilot character to it, the realisation that collaborative robots are actually suitable for direct collaboration with humans was important. Head of Planning Patrick Meyer says “… for our coming projects we will always consider collaborative robots because entirely new automation solutions are possible with this technology.”
Sales of industrial robots in India reached the new record of 3,412 new units installed in 2017. That is an increase of 30 percent compared to the previous year (2016: 2,627 units). Between 2012 and 2017 India saw a compound annual sales growth rate (CAGR) of 18 percent.
Broken down by industry, India´s automotive sector is the main customer with a share of 62 percent of the total supply 2017. Sales rose by 27 percent compared to the previous year.
India´s automotive industry announces expansion
“The automotive industry will remain the main driver of the increasing robot installations in India,” says Junji Tsuda, President of the International Federation of Robotics. “Numerous new projects are announced by the international and domestic car manufacturers aiming to expand production capacities. Moreover, OEMs increasingly require local supply of automotive parts.”
General industry is catching up
A clear sign that the general industry is catching up with the automotive sector can be seen by the sales numbers of industrial robots in i.e. the rubber and plastics industry, the metal industry and the electrical and electronics industry, which increased by 46 percent in 2017.
“The general industry will further invest in production capacities and modernization to serve this growing consumer market,” says IFR President Junji Tsuda. “Therefore, an accelerated and strong robot sales growth is expected between 2018 and 2021.”
India´s robot success story started in 2009 – robot density still low
India is one of the strongest growing economies among the Asian emerging markets. Since 2009, the number of robot installations has been growing rapidly. In 2017, India ranked No. 14 regarding the global annual supply, following Thailand and Spain. Regarding the operational stock, India ranked thirteenth following Canada, Spain and Singapore.
India´s automation potential is illustrated by a rather low robot density figure: 85 industrial robots per 10,000 employees in the automotive industry is less than a fourth of Indonesia´s density (378 units) and far away from China´s (505 units).
German chainsaw manufacturer STIHL, already uses hundreds of robots in its manufacturing facilities. Now it’s added collaborative robots to one of its production lines.
With the introduction of the FANUC CR-35iA, STIHL has taken a clear step forward in the development of production processes. Designed to work alongside humans, the FANUC CR-35iA is the world’s strongest collaborative robot and does all the lifting for staff on the disc cutter packaging line.
Identification of the task
The well-known German chainsaw manufacturer STIHL also manufactures a range of cut-off machines. A cut-off machine weighs around 10 kg, and without the assistance of the FANUC CR-35iA, the human operator has to lift each one single-handedly. Up to now, this has proven to be a considerable burden for the operator. Designed to do all the lifting and positioning work while interacting safely with humans, this is where the FANUC CR-35iA collaborative robot comes in.
Why human-robot collaboration was selected as a solution
Collaborative robots were introduced to reduce the physical strain on human operators and make processes more efficient. On STIHL’s new cut-off machine inspection and packaging line, the task of the robot is to remove the disc cutter from a suspended conveyor, carry out the shake test, and keep it suspended until a final visual inspection is completed. Subsequently, the robot then places the cut-off machine in a shipping box. To get the best results, the packing line staff were involved in the project from the outset. Not only were they able to give an expert assessment of the test set-up, but they also influenced the design and ergonomics, leading to the optimal solution.
How is it solved (configuration of the workplace and different steps of operation)
STIHL has taken a clear step forward in the development of technology using the FANUC CR-35iA. The start-up of production only took three days. This was due to the good preparation behind the deployment of STIHL’s first collaborative robot. Even on the first night shift, the robot ran without a single hitch. This is where the team of Group Leader, André Lange, who is responsible for service and hardware planning, benefited from the close familiarity with FANUC robot technology that they have developed over many applications.
The ability to use the FANUC CR-35iA with the normal FANUC control system, just like its yellow “colleagues”, proved to be one of the major advantages for STIHL since the control technology and user interface are all the same. The system components used, like the FANUC “Line Tracking” software, which is particularly useful for synchronisation with the suspended conveyor system, the integration of camera systems or the proven “Collision Guard” software option, are already well-known and appreciated by STIHL.
This has huge benefits for STIHL. Since the first introduction of robotics in the mid-nineties, STIHL has accumulated a great deal of robotics engineering know-how, particularly with the hundreds of FANUC robots operating in across STIHL plants worldwide.
André Lange emphasises that “we adopt and follow relatively uniform production concepts at all locations. Production equipment, which is utilised worldwide, such as FANUC robots, makes life easier for us at various levels, from engineering and programming, right through to service.”
Evaluation of the solution of the challenge
The FANUC CR-35iA has been in daily operation for more than half a year, and it’s not just project managers André Lange and Markus Wahl that are satisfied with the robot. It has also been fully accepted by the workforce. Affectionately referred to internally as the Hulk, the collaborative robot is something that none of STIHL employees wants to do without.
Designed for use in Small Parts Assembly, YuMi will work side-by-side with a human counterpart at ABB Elektro-Praga on its socket lid assembly line.
Thanks to its inherently safe design, the collaborative dual arm robot solution will ensure the safety of those around it and elevate the nature of work at the plant by performing repetitive tasks to perfection.
“We are very excited to add YuMi to our production line. The robot solution brings unique advantages to this assembly process including greater flexibility, improved quality, increased safety and better workplace ergonomics,” says Tanja Vainio, Country Manager, ABB Czech Republic. “YuMi’s outstanding features for collaborative small parts assembly is the perfect solution for Elektro-Praga which wanted an easy to use robotic solution capable of working side-by-side with humans on similar tasks.”
YuMi will utilize connected services developed by ABB which will monitor the robot during production and operation. The ability to monitor YuMi in this manner will increase its efficiency, reduces service costs, secure uptime and extend its lifetime. Thanks to these diagnostic technologies a once reactive approved to fleet management is replaced by a predictive, proactive, and immediate one. Prior to the advent of the Internet of Things Services and People, robots were maintained according to a schedule.
“YuMi, short for you and me, will open up more opportunities for Czech businesses like Elektro-Praga to improve their productivity. Task sharing between humans and robots is a great way to accelerate production,” said Vainio.
YuMi, the world’s first truly collaborative dual arm robot, represents another step in ABB’s Next Level strategy aimed at accelerating sustainable value creation. The strategy is building on ABB’s three focus areas of profitable growth, relentless execution and business-led collaboration.
The collaborative workstation consists of YuMi, a human operator, sensor devices, conveyors, vibration feeders, and a spring disentangling system. YuMi handles springs, child locks and child lock covers. The assembly process is triggered by the human operator who places two socket lids and two child lock covers in front of the robot.
YuMi uses its suction grippers to grasp the child locks which it then places into prepared socket lids. Next, YuMi takes springs from the feeder (two pieces per each socket), and puts them into the space between the child lock and the socket lid. The robot then grasps the child lock cover with its gripper and places it on the socket lid which is equipped with a child lock and spring. The socket assembly is completed by pushing the child lock cover into the socket lid. The operator inserts a screw into the lid and sends the completed socket for packaging. In addition to parts handling, the human operator is responsible for supervision of the overall assembly process.
Since 2013, global sales of industrial robots have accelerated reaching an all-time high of more than 380,000 units, twice as much as in 2013. After this period of high demand, installations of industrial robots only slightly increased in the first half of 2018.
This was a normal cyclical effect after continued large investments of the automotive industry and the electronics industry. But in the past months, uncertainties loom over investment plans in North America, China, and other Asian countries mainly due to protectionists measures damaging free trade. However, incentives for robot installations remain excellent. Numerous investment plans are aimed at using robotics and automation in almost all industries. Investments in automation may be restrained due to the increasing uncertainties of the global economy, but investments will continue perhaps shifted to a later point in time.
Automation is changing the way we work and, to an increasing extent, the way we live. Automation improves productivity and enables companies, and nations, to remain or become competitive. It enables new business models focused on providing new goods and services, and helps companies improve the efficiency and flexibility of supplying those goods and services. Economists agree that increased productivity is key to improving Gross Domestic Product, the value of goods and services produced in a country, and in turn, jobs and wages.
We will meet from 8 to 11 April 2019 at the Automate in Chicago. The theme is: Win the Future! Automate 2019 will explore how automation secures a company’s success in a technologically fast-paced world where artificial intelligence (AI), Industrial Internet of Things (IIoT), smart manufacturing, collaborative robots (cobots), machine vision and other innovations are rapidly shifting the dynamic of today’s manufacturing.
The robotics industry is still at the beginning of a demanding and exciting future. The best is still to come!
Automate 2019, North America’s largest showcase devoted to automation industry trends, leading-edge technology and business innovation, returns to Chicago’s McCormick Place April 8–11. Produced by the Association for Advancing Automation (A3), Automate hosts many of the industry’s leading manufacturers and system integrators of robotics, machine vision, metrology, software, safety, motion control and motors.
Highlights of the biennial show and conference include:
Examples of how the latest innovative automation solutions, including robots, machine vision and motion control, can solve real-world challenges.
The $10,000 Launch Pad Startup Competition, which seeks out automation-focused companies that have launched in the last five years; generated less than $2 million in revenue and are not affiliated with a larger group. Call for participants will be announced soon.
Small group discussions in the theater covering a wide variety of topics important to the automation industry.
Win the Future
Focused on the theme of Win the Future, Automate 2019 will explore how automation secures a company’s success in a technologically fast-paced world where artificial intelligence (AI), Industrial Internet of Things (IIoT), smart manufacturing, collaborative robots (cobots), machine vision and other innovations are rapidly shifting the dynamic of today’s manufacturing. Automate attracts more than 20,000 attendees, including corporate decision makers across the United States and more than 80 countries as well as press and analysts.
“Automate attendees come seeking ways automation can help improve productivity and product quality, reduce costs, speed time to market and augment their workforce,” said Jeff Burnstein, A3 president. “Collaborative and mobile robots, along with AI, machine vision and motion control, are among the many technologies that will be showcased at Automate, all helping decision makers identify ways automation can fill workforce gaps by working alongside employees who are focused on more critical tasks. These innovations better equip companies to improve their competitive positioning in today’s global market.”
More Features of Automate 2019 Show & Conference
In addition to the highlights previously mentioned, Automate 2019 will include:
The Engelberger Robotics Awards presented in the categories of Leadership and Education
Full integration with the 51st International Symposium on Robotics-Americas (ISR), a prestigious event that brings together thought leaders from around the globe to discuss the latest applications and research in the field of robotics and other automation technologies
All coursework and exams required for the AIA’s Certified Vision Professional (CVP) basic and advanced certifications and Motion Control & Motor Association’s (MCMA) Certified Motion Control Professional (CMCP) training. Interested attendees can visit Automate 2019 to register.
One Badge, Two Shows
Automate 2019 attendee badges also gain admittance to ProMat 2019, held at the same location. ProMat is the largest exposition for material handling, logistics and supply chain professionals in North America, including over 950 exhibitors.
Attendee registration for both the expo and conference, with free access to the show floor, is now open. Prospective exhibitors can find more information on exhibition opportunities on the event website. Press passes and exhibitor news are available at the Automate press site.
Universal Robots / Case Studies Collaborative Robots
Specialist glass maker Saint Gobain uses a collaborative robot equipped with a force-torque sensor for glass polishing, reducing production time by one third and freeing workers from the constant vibration of manual polishing. Employees now program the robot by guiding the arm, prepare the glass and also wash the polished glass.
Saint-Gobain’s plant in Sully-sur-Loire, France, focuses on glass production for the armoured and aeronautical industries, and the civil market. In their shift towards industry 4.0, management has deployed collaborative robot cells to free employees from tedious, repetitive tasks. Robotiq’s FT 300 Force Torque Sensor has proven essential to automate the grueling glass polishing process.
Saint-Gobain was founded in 1665 as a public society manufacturing luxury mirrors and glass under King Louis XIV’s reign. The corporation kept high quality standards through the centuries, expanding its business throughout the whole housing industry. Now a global company, it employs more than 185,000 people worldwide.
Near its original headquarters in the outskirts of Paris, Saint-Gobain still works on high-end glass production. Human labor provides high-value work to the finished product. But some tasks are more tedious than others. This is why the Sully-sur-Loire factory, like many other Saint-Gobain plants, began to deploy collaborative robot cells into their process about a year ago.
Building the factory of the future
Freeing employees from those grueling tasks begins with finding a technology that would do the job on their behalf. Saint-Gobain’s Digital Manufacturing Manager, Ignacio Sanchez, had to find a solution for a difficult glass polishing process. The operation is painful, frequently causing musculoskeletal disorders for workers.
“The operator had to polish all of the glass surface, repeating the same movement on and on,” Sanchez explains. “He then does the surface preparation of the glass before it becomes one of many layers of an armoured glass. This second step is a lot easier. We wanted an automated solution for the polishing part of the process.”
“We naturally chose to work with Universal Robots on this project considering safety requirements, the ease of use that was required, all this in a small space.”
Saint-Gobain turned to local automation solutions provider, HMI-MBS engineering and services, for expert advice. Their representative Nicolas Bouhet quickly presented a first option. “Saint-Gobain’s application had a very important diversity of reference points. There was also a problem of production space, since the cell had to be deployed in a small area in order to work in collaboration with the operators. We naturally chose to work with niversal Robots on this project considering safety requirements, the ease of use that was required, all this in a small space. We chose the UR10 model to be able to reach every area of every type of glass.”
A different path for each glass
HMI-MBS performed many tests at their lab, which is about 15 minutes from Saint-Gobain’s plant. The first proofs of concept did not deliver viable options. “We ended up in a dead-end,” recalls Bouhet. “Then we had the idea to use the FT 300 module with the path recording function. We managed to integrate it into the robot and continued with tests at our offices. We then moved to Saint-Gobain and worked with the operator to see if the product met Saint-Gobain’s expectations.”
“Programming a robot movement that must follow a volume in space is a complicated thing to do. We were able to do it with the path recording function of the FT 300”. Testing at HMI-MBS helped minimize the time needed to implement the robot into production. When everything was ready, the UR10 and FT 300 combo took part of the work over from the operator, and both started working together*. “Without the FT 300, this operation would have been quite complex since the programming of a robot movement that must follow a volume in space is a complicated thing to do,” adds Bouhet. “With the path recording function of the FT 300, the operator can grab the device and make the movement; the Universal Robots UR10 then records and reproduces the operator’s motion.”
We’re able to produce the same amount of work in two 8-hour shifts instead of three, before the robot arrived.” For Christophe Legeay, Methods Technician at Saint-Gobain Sully-sur-Loire, automating the polishing process of each layer of armoured glass gave relief to operators who were previously assigned to this task. “It allowed them to no longer experience vibrations in their shoulders or perform repetitive movements. The installation of the robot was more than welcome,” he explains.
From now on, all the operator has to do in the polishing process is program the proper path for the product and set the glass for polishing. “The robot asks us to place reference marks to check the positioning. You cannot run your application until you have validated your positions. As soon as the validation is done, you press start and the robot starts running.”
While polishing is in progress, the operator simultaneously washes the glass that was previously polished. Then it’s time for surface preparation, a process in which human labor brings much more value into the product. “We assigned the robot to the hardest part of the polishing process,” recalls Sanchez. “During this time, the operator can focus on surface preparation. We’re able to produce the same amount of work in two 8-hour shifts instead of three, before the robot arrived. We’ve achieved ROI in less than a year.”
Rosborg Food Holding, Denmark's largest producer of herbs and miniature plants, uses a collaborative robot in its packaging operations to pick up pots of herbs from a conveyor belt and place them in cartons. The robot is also used to pick up and position cardboard boxes in place for another machine to insert pre-packaged salad
The use of herbs was already common in Babylon about 4,000 years ago. The ancient Egyptians and Greeks developed and refined the cultivation of herbs for the up-and-coming art of healing and as a culinary delicacy. In the 21st century, it is robotic technology that increasingly provides us with herbs as a fragrant, tasty food.
In Odense, Denmark, Rosborg Food Holding’s greenhouses cover around 120,000 square metres. Mint, dill, tarragon and other delicious plants as well as miniature roses thrive in a state-of-the-art production facility. Here, a total of 130 employees produce, pack and sell 28 million herbal plants and 12 million miniature plants, which go by product names such as Gloria Mundi, Økologihaven or Eurostar. The Danish plant breeding company has been producing spices and mini flowers for retail and catering sectors since 1980. However, it can only meet the constantly growing demand for its broad product range subjected to a high degree of seasonality by comprehensive rationalization and automation measures.
Better working conditions with higher productivity
“We are continuously working to improve the productivity and efficiency of our processes,” says Henning Jørgensen, partner and plant manager of Rosborg Food Holding. “By finding automation solutions for monotonous, physically demanding tasks, we can relieve our employees. At the same time, it helps us to reduce the number of overtime hours and the employment of temporary staff”.
The executives at Rosborg were looking for a way to increase available capacities in day-to-day operations to be able to double production at peak times such as Christmas, New Year’s Eve or Easter without losing revenue due to overtime and replacement workers. “So far, our profit margins have been shrinking at such times with high production volumes. That’s why our employees have a positive attitude towards the prospect of using collaborative robot technologies as production support in order to work more efficiently and reduce overtime,” Jørgensen describes the situation.
In 2013, a new owner initiated a fundamental modernization process of the company’s entire production. 37 million Danish crowns were invested in new, highly efficient greenhouses equipped with automation technology and robots. At the same time, Rosborg has expanded its product range to meet the growing demand for herbs other than those traditionally used in Scandinavian cuisine. In addition to robots and employees, ten different types of useful insects operate in the greenhouses to keep pests away from the plants.
Robot hand with a sense of touch
One of the latest automation investments is a flexible packaging line with a so-called “Cobot” from Universal Robots, a collaborating robot equipped with an RG6 gripper from OnRobot. The two “fingers” of the robot gripper feature intelligent, advanced technology, that mimics the human sense of touch when intuitively gripping and moving objects.
“We were looking for a gripper that could gently lift the herbs and flowers without crushing them,” explains plant manager Jørgensen. “We chose an R6G gripper, which is characterized by gentle and careful gripping movements as well as precision and flexibility. Our new solution automates the folding of packaging cartons and the placement of herbal fine cuts in the folding boxes.”
The new generation of collaborative robots places extremely diverse demands on the robot hand at the end of the robot arm. “What the gripper needs to be capable of depends entirely on the selected task,” says Enrico Krog Iversen, CEO of OnRobot. “The more user-friendly, flexible and careful the gripper is, the greater the variety of tasks that can be automated, and the faster the robots and grippers pay off for the buyer.” This is also confirmed by Jørgensen: “When choosing our solution, the best possible payback period was of course a crucial factor.”
A playful and successful start
Rosborg Food chose a playful, interactive approach for the introduction of robotics in Denmark. “Before we even knew what exactly we wanted to automate, we purchased a robot arm and a gripper via the MELCNC integrator,” says Jørgensen. “We’ve experimented with it and invented some funny applications.” In this way, the employees got to know the robot arm and gripper right from the start as an easy-to-use, helpful tool. “Once we programmed the Cobot so that it could write the boss’s name on a blackboard on his birthday. And at the official inauguration of a new greenhouse, the robot handed over the scissors to Jane Jegind, member of Odense City Council, so that she could cut the red ribbon,” recalls the plant manager.
Configurating the applications and the automated packaging solution is so intuitive that even employees without prior experience can do it. It is sufficient to simply adjust the settings on the touch screen of the robot arm, for instance to configure the application for packaging other types of products. The software for controlling the RG6 gripper is extremely user-friendly, too. At the touch of a button, it can be installed on the robot arm like an app on a smartphone.
Henning Jørgensen is already planning the next steps regarding the automation of Rosborg Food Holding: “The next project will be the acquisition of a further collaborating robot with a gripper suitable for equipping a cutting machine for the herbs.” Perspectively, arm and gripper are supposed to carefully pick up the plants, turn them and then place them on the conveyor belt to the cutting machine.
Plastic component manufacturer Weiss Kunststoffverarbeitung uses collaborative robots to assemble complex components containing metallic parts as well as plastic parts moulded by Weiss. Workers place some of the parts into a fixture, then the robot inserts additional parts, and places the assembled valve in a device for pressure testing.
The collaboration of humans and robots is a hot topic in the field of automation technology. Weiss Kunststoffverarbeitung GmbH & Co. KG has developed a robot cell ‘by its own resources’ in which the operator and robot share the complex assembly of a miniaturized safety valve.
The division of labour between plastics processors and their customers is changing. Rather than injection-moulded parts, customers are frequently asking for complete, ready-to-install components. That applies not only to the automotive industry, but also to other sectors, e.g. the household appliance and mechanical engineering industries.
For this reason, the assembly sector at Weiss Kunststoffverarbeitung GmbH & Co. KG has been constantly expanding over the past few years. As an engineering-oriented enterprise, Weiss is striving to meet the latest trends in this sector.
The robot cell that was recently put into operation at the Illertissen plant is a good example. A safety valve with a height of only 15 mm is being assembled in the cell where, in addition to injection-moulded parts, filigree metallic bought-in parts such as springs, washers, valve tappets and balls are also used.
In doing so, the company’s assembly specialists implemented the principle of division of labour between humans and robots in practice.
Dipl.-Ing. Robert Heller, responsible among other things for the construction of production and automation technology at Weiss: “The robot works extremely accurately and reliably, while the worker – although he may make mistakes – is more flexible.”
The cell is designed so that each ‘colleague’ can leverage his respective strengths. In the first step the worker, standing in front of the cell, places the key components into an assembly fixture. The robot, situated in the cell, takes over by inserting further small parts, e.g. a tiny ball. The worker then gives the signal to compress the parts, and this takes place pneumatically by means of a cylinder.
Now it is the turn of the robot. It removes the assembled valve from the fixture and inserts it into a testing device, where it is subjected to two pressure tests at 0.9 and 2 bar. Following this 100% test (by which the valve remains closed for the 0.9 bar test and must open when a pressure of 2 bar is applied) a certification stamp is applied with a marking system, and the valve is ready for shipping.
The principle of human-robot-collaboration was put into practice by Weiss in a simple yet elegant way: human and robot each have access to the common workspace. They dispensed with a safety guard or other form of spatial separation of worker and robot. Instead, the workspace is secured on both sides by a photoelectric cell. The two photoelectric cells are interconnected for control and safety purposes, so that the robot does not reach into the joint workspace when the operator is inserting or removing parts. Conversely, the robot is stopped if the worker reaches into the workspace while it is operating there.
It goes without saying that the control of the robot is also integrated into this quite simple and practical safety concept. Robert Heller: “We took advantage of the robot manufacturer’s ‘Function Safety Unit’ that is now available as an option: a slot-in card with which, for example, safety zones can also be programmed.”
With the collaborative robot cell, the engineers at Weiss have once again demonstrated that innovative and highly efficient production solutions can be developed in-house – not only in plastics processing or tool and mould making, but also in the downstream processes of assembly and testing technology.
Force-feedback technology in cobots enables the automation of applications such as polishing that require fine-tuning of applied pressure. Paradigm, a manufacturer of high-performance loud speakers and subwoofers achieved a 50% productivity increase with a collaborative robot working alongside an employee to polish and buff lacquered speaker cabinets.
Paradigm Electronics is a manufacturer of high performance loud speakers and subwoofers. In trying to meet demand on labor-intensive products, Paradigm has now implemented Universal Robots in polishing applications, resulting in significantly increased production throughput eliminating bottle necks while improving the work environment.
When Paradigm launched the “Midnight Cherry” finish on a line of new speakers, the market quickly embraced the new product made entirely in-house at the Toronto-based manufacturer now faced with a challenge to make even more than anticipated of the new cabinets.
“In order to produce that finish, you have to apply multiple layers of lacquer and between each layered application, you have to sand and buff, sand and buff. There’s a lot of manual labor involved in that. The problem is to find people who can do that, we just couldn’t find enough skilled people,” says Director of Operations Oleg Bogdanov.
The company had already implemented one robotic cell with a cartesian type robot, but it required a lot of safety guarding around it for the protection of the worker.
“It really didn’t allow for an employee to work in conjunction with the robot at all. The application of buffing is one that requires a lot of observation and collaboration by the operator, so having the work being done in a remote cell just didn’t seem to be a workable solution,” says Senior Manager of Production Services at Paradigm, John Phillips.
Paradigm had an industry expert with a specialty in robotics applications come in, making the company aware that collaborative robots from Universal Robots could be a solution to the Midnight Cherry challenge.
“Collaborative robots was a new technology and it lead to further investigation. This kind of robot allowed us to have a human and a robot working in the same workspace. They’re now working in a pendulum type of an operation where they can safely interact, allowing the human to check whether the robot has done an adequate amount of work before the final polishing is handed over to the human. It’s a very hand-in-hand kind of operation,” says Phillips, emphasizing the simplicity of the robot cell.“Usually with all of the physical guards that are required in order to make the work cell safe for the human, there’s a long implementation period. The cartesian robot took five months. The implementation from the time of the receipt of the UR robot was just over a month.”
The implementation solved Paradigm’s back log on the popular cabinets by increasing throughput by 50%. Before choosing the UR robot, Paradigm conducted a thorough research of the collaborative robot market.
“Once we realized that a collaborative robot was a viable alternative for us, we did our homework and checked around the rest of the opportunities that were out there from different manufacturers. We found that for our application, the UR robot was not only the best robot for the application, but it was also the most cost efficient,” says Phillips, mentioning the UR robots’ built-in, adjustable force mode feature as another deciding factor.
“If too much force is applied, the surface heats and the results go the opposite direction to what you’d hoped. So having the robot work with a specific force was a huge advantage. We were aware of technologies that allowed for a force feedback system but they were actually as expensive as the entire UR robot. So it was quite exciting to find that it had capabilities of force feedback within its inherent structure,” says Paradigm’s Manager of Production Services, who is now investigating future applications for the UR robots. “We’re looking forward to being able to use Universal Robots in our various paint spraying processes and we’re also bringing in a new line of speakers that have a parabolic shape where we could utilize the adjustable force mode that allows us to determine a specific force at a particular point in the path of the robot. This will be very useful when it comes to sanding those non-plane facets.”
Automotive manufacturer, Škoda uses collaborative robots in the assembly of automatic transmission systems. Workers bring gear actuator pistons to a collaborative robot which inserts them into the transmission housing. Torque sensors provide feedback on resistance, enabling the robot to insert the components without forcing them into place.
KUKA and MATADOR Group are partnering with Škoda Auto in an Industry 4.0 venture that involves hardware, software and people. Collaborative robotics, a concept that is transforming 21st-century industry, is a determining factor as well.
Identification of the task
In 2011, Volkswagen decided to convert the 1,000-employee Škoda Auto factory in Vrchlabí in the Czech Republic into one that exclusively produces its DQ200 seven-gear, dual-clutch, direct-shift automatic transmission, regarded as one of the most innovative in the car industry. KUKA and MATADOR Group played a unique role in the transformation.
Why HRC was selected as a solution
“This kind of transmission has very high requirements for precision,” says Ivan Slimák, General Manager at the Vrchlabí plant. “For example, we have a lot of moving parts with very, very tight tolerances. We have tolerances in the range of three to five micrometre. A human hair is about 60 micrometres, so our tolerance is only a fraction of the width of a human hair.” This kind of precision is what the collaborative KUKA LBR iiwa does best. Then, there’s the other LBR iiwa advantage: safety and its related payoff.
How is it solved (configuration of the workplace and different steps of operation)
The KUKA LBR iiwa inserts the gear actuator pistons precisely using input from the sensors on each of its seven axes. These sensors register any possible contact with humans and other potential barriers, ensuring both maximum safety for the workers as well as maximum protection for part quality. It is the unique sensitivity of the LBR iiwa that allows it to “feel” where the components need to be inserted rather than forcing them into place. This is invaluable for handling delicate parts that are prone to damage during assembly – parts with tolerances of three to five micrometres, for example.
Then, there’s the other LBR iiwa advantage: safety and its related payoff. “Conventional robots must be inside a protective cage and cannot work directly with people,” says Jiří Svatý, Process Planning Assembly at the Vrchlabí plant. In comparison, the LBR iiwa offers easy and free access. “In this cell we don’t need or use laser scanners or other devices for worker safety, so it gives us more space for developing the process, and it gives us an opportunity to save time for assembly and integration.” This elimination of safety fencing around the robot enables the automation of processes in limited spaces without having to modify existing production lines. The LBR iiwa benefits extend beyond the hardware kingdom and into the digital empire.
Evaluation of the solution of the challenge
“I think the most challenging job was to learn the Java programming language and to change the meaning of how robots are programmed in the application,” says Stanislav Korec, Head of Robotics and PLC Programming at MATADOR Group.
MATADOR Group was tasked with including the KUKA LBR iiwa in its concept for the Škoda plant in Vrchlabí and this was a valuable learning experience for the Slovakian company. The learning curve for MATADOR Group included an understanding of the KUKA Sunrise control system, which combines motion and sensor systems in response to present-day programming requirements for service robotics. Together with the use of Java as the programming language, the upside is that there is almost no limit to the variety of automation options.
The Škoda plant was rewarded for its work when the consulting firm A.T. Kearney and the trade journal Produktion named it the 2015 Factory of the Year for “global excellence in operations.” In other words, human-robot-collaboration on the Škoda factory floor is viable and successful.
In this example of screw tightening at Chinese automotive manufacturer CSVW, a collaborative robot picks up a screw tightening gun to tighten three screws on an engine, puts down the first gun, then picks up a second in tighten two other screws. A worker meanwhile performs other tasks on the engine.
Identification of the task
The automobile engine assembly process is flexible and complex and the Operator’s station is relatively compact. This project is conducted using SIASUN SCR5 collaborative robot to complete the screw tightening task of automobile engine assembly line. There is no need to install protective fencing on the site, operators and SCR5 robot are in the same workspace to complete the various tasks. The SCR5 robot holds the tightening gun to tighten 5 screws of 2 types and the robot can change the tightening gun automatically by equipping a changing gun plate at the end. While the robot is tightening the screw, the operator on site completes the operation of lubricating and other parts assembling.
Why human robot collaboration is the optimal solution?
In the automotive industry, the automation rate of pressing, welding, painting and final assembly processes is already very high, but the engine and final assembly plants are unable to use traditional automation equipment to realize automatic reformation due to the complex and flexible assembly processes of the engine and the whole vehicle and the compact workspace. However, collaborative robots have unique advantages over traditional industrial robots, and can effectively help automobile manufacturers to achieve the goal of automatic reformation.
The advantages are as followed. First of all, the collaborative robot has the safety features of collision detection, so there is no need to install protective fencing to ensure the safety of operators, and the robot footprint is quite small which effectively saves the operation space. Secondly, the collaborative robot is designed with light weight to better adapt to the complex and flexible process in the production site. Thirdly, collaborative robot has the function of traction and demonstration in programming. It can be programmed by manual dragging, which greatly reduces the time of instruction and reduces the difficulty of operation and makes it easier to use.
How is it solved (configuration of the workplace and different steps of operation). This project uses one SIASUN SCR5 collaborative robot and robot base, two tightening guns, one changing gun tray and other necessary fixtures to realize screw tightening.
Here are the following steps
After the engine is in place, and jacked to the right position, the signal is given to the robot. The SCR5 robot holds 1 tightening gun by the changing gun tray to complete the tightening task of 3 screws on the engine sequentially. The tightening torque is controlled by tightening gun.
SCR5 put down the first gun and replace the second gun to tighten the other two screws in order.
When the screws are being tightened, the cooperative robot and the on-site workers are in the same operating position to share workspace. The on-site workers install the back oil seal to the cylinder block and then pre-tight 8 bolts combined with oil seal and cylinder block.
The SCR5 robot puts down the tightening gun and returns to its original position.
After the robot is in place, the completed signal is given to the work station, the production line is released into the next process
Comment to the project solution
The project used the domestic collaboration robots with completely independent intellectual property rights, completed engine assembly screw task. With no fences and a small working space, this project realizes the task with the cooperative safety operation between human and robots, completes the designated operation tasks stably and efficiently, helps customers improve product quality and saves labor costs. This truly reflects the collaboration function of collaborative robot, and helps revolutionizing the automobile manufacturing mode.
Schunk, a manufacturer of robot grippers, uses a collaborative robot in the pre-assembly process. A robot equipped with a camera takes base housings from a container and brings them to the worker. The robot also tightens screws, closes air connections on the gripper and strips excess glue. Meanwhile, workers complete tasks requiring high dexterity.
In the production of modern gripping systems numerous product variants are being manufactured, and provided in different batch sizes. The grippers were assembled manually on conventional assembly workstations up to now. Associated with this are one-sided physical strain, the danger of injuries, for example during chamfering, and comparatively high costs for purely manual activity. The goal of one HRC project at the SCHUNK smart factory was to use HRC systems to increase employee flexibility, reduce workplace monotony, improve ergonomics, and reduce manual cost per item.
Instead of completely automating processes, partial automation is currently gaining in importance, in which the strengths of humans and the strengths of robotics are brought together synergistically. The driving forces behind human/robot collaboration (HRC) are relieving the workforce of stressful or monotonous work steps, improving ergonomics in the workplace, especially against the background of demographic change, making work processes more flexible, increasing efficiency and optimizing logistics, handling and loading processes. This need for change also affects the production of SCHUNK, the competence leader for gripping systems and clamping technology.
Careful workplace analysis as a starting point
Before the project started, the SCHUNK team analyzed which change processes are associated with the introduction of an HRC application. On the one hand, it is important to create the technical prerequisites for standard-compliant workplace operation and thus legal certainty for the operators and, on the other hand, to gain the acceptance of the employees for the robot as a colleague.
In the course of a work process evaluation, SCHUNK identified workplaces and work steps, which are suitable for the conversion to an HRC application. Assessment criteria were the required programming effort, the integration effort within the entire process chain, and the controllability of the hazard analysis. At the same time, jobs with moderate-duty cycle requirements and process chains of manageable complexity were preferred. Stations were selected, where a particularly effective ergonomic and mental relief is achieved and collaboration times and interventions are initially rather low. Another key factor in the selection of jobs was the fact that the special strengths of the robots and the workers could be clearly distinguished from each other. Because if employees can continue to bring their strengths into the overall process in a secure manner, this promotes acceptance. For the pilot projects, employees were selected and included at an early stage, who have a high degree of technical affinity and curiosity.
Division of labor based on strengths
One of the use cases is the pre-assembly of gripping tools. In this application, a 7-axis lightweight KUKA LBR iiwa 7 R800 robot, on whose DIN ISO 9409-1-A-50 flange a modified SCHUNK Co-act EGP gripper is equipped with an integrated black-and-white industrial camera, removes various base housings from a universally usable transport container, and takes them to the worker. The camera detects the exact position of the basic housing, and it is transferred to the robot in the form of correction signals. Workpiece clamping is form-fit from the inside. The gripping force of the gripper with an inherently safe design is limited to a maximum of 140 N. The different sizes of the supplied workpieces are recognized, the corresponding product is classified, and the processing parameters adjusted. Other monotonous and so far purely manually executed subtasks are the screwing in of set-screws, the closing of air connections on the gripper, and the stripping of screw glue. In a second implementation phase, these steps were automated. This eliminates the worker’s least favored steps and reduces the risk of injury. Between the delivery of the blanks and the finishing of the workpiece, additional assembly tasks have to be carried out which are completed more effectively by the worker: The insertion of spring elements and sealing rings, an initial haptic functional test and the attachment of further individual components. They all require situational adaptation, which is one of the essential strengths of humans.
Regular safety checks, training, and acceptance analyses
For ensuring the standard compliant equipment of the workplace risk assessments and space-related safety assessments were carried out. Moreover, the acceptance by the DGUV, and the occupational safety monitoring measures during operation were examined, on whether the biometric limit values were complied with in the event of a collision. In addition, employees deployed at the HRC position receive regular training in handling the robot, and in the effectiveness of the safety measures. In addition, satisfaction is determined in regular survey rounds. It has shown that above all the first contact with the robot has a considerable influence on the acceptance of the employees. The appearance of the robot as well as the subjective feeling of safety are decisive in this respect.
Conclusions and recommended actions+
The experience gained from this use case has shown: Workers must be able to experience with HRC solutions right from the start that they can master the work processes, determine the processes, and rely on the function of the safety systems. Anyone, who begins with too fast robot movements, or who irritates employees with constant error messages, will suffer an uprising within a very short time. The decisive factor is that the human always sets the pace. He/she must not be driven or limited in any way by the robot. And most importantly: The area of occupational safety and the works council must be included in the considerations right from the start.
In the economic evaluation of HRC projects, SCHUNK considered other factors besides the immediate efforts and costs:
Transition to more flexibility in production in the form of multi-machine operation
Minimizing the overhead of workpiece feeding and steering, which would generate high costs in full automation of mass production
Increased system availability through the possibility of rapid response and courageous safe intervention, as well as by avoiding mini-stops due to terminals or small faults
Reduction of quality costs through process optimization
Robotic use for process steps that are monotonous, mentally demanding, but essential for the overall quality, such as gluing and automated testing.
Increased employee satisfaction and positive health effects for the workers
An additional benefit opens up by a partial automation, as it extends the sphere of activity of a worker or avoids the conversion of entire existing systems. Likewise, if increased process efficiency and quality are achieved by humans by taking over set-up, commissioning, or control tasks.
Robots can apply adhesives far more accurately than human workers and are used for this task in a range of manufacturing environments. Machine manufacturer Dürr uses collaborative robots for adhesion, enabling robot and worker to operate at the same time in the same space – the robot does not have to be shut down each time the worker needs to perform a task.
Duerr AG is a leading global machine and systems builder. As a supplier of turnkey systems for automated adhesive bonding processes, Duerr develops robots cells with human-robot-collaboration (HRC) for the automotive industry. About 60 percent of sales are generated through business with automotive manufacturers and suppliers.
Identification of the task
The human operator and robot work together in final assembly without the need for physical safeguards: Sensitive LBR iiwa lightweight robots from KUKA are used for adhesive bonding of GPS antenna covers and tanks in the vehicle body.
Why HRC was selected as a solution
Duerr uses two sensitive LBR iiwa lightweight robots from KUKA 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.
How is it solved (configuration of the workplace and different steps of operation)
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 LBR iiwa 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.
Precise adhesive bead and individual fitting of the tank into the vehicle body
Here is how the system concept for automated tank gluing with the LBR iiwa works: In final assembly, the skilled worker moves the tank to a turntable with the aid of a manipulator, cleans it, moves it into the correct position and transfers it directly to the robot for further processing. To prevent the adhesive nozzle from drying out, the application nozzle is located in a seal reservoir. Following a signal, the robot moves out of the reservoir into the home position. Here, the adhesive flows into a collection container and adhesive nozzle is cleaned manually. 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 and ensures that the bead allows for an accurate fit using sensors on the application head.
“It is definitely possible to apply an adhesive bead by hand, but the result cannot match the precision of a robot,” explains Ahlborn.
A robot-based solution can – as opposed to a linear gantry – map the three-dimensional complexity of the bead geometry. Thanks to its seventh rotating axis, an HRC-capable robot like the LBR iiwa glues in a radius of 360 degrees – without re-orienting or having to set parts down. Once the robot has completed its task, the skilled worker takes over again by fitting the tank into the vehicle body at the specified position. This complex operation requires the individual skills of the human operator. The manipulator supports the operator during ergonomically unfavorable motion sequences.
Evaluation of the solution of the challenge
Despite the absence of fencing and enclosures for the adhesive bonding processes, the safety requirements are high. The entire safety concept must meet stringent specifications and norms based on a risk assessment. Among other things, the robot is also positioned so that direct contact with the human operator is minimized. The robot must also switch off within milliseconds when contact is registered. The design of the adhesive bonding cells is such that the robot operates below the human worker’s head and chest area as a general rule. The application technology, consisting of the lightweight applicator and the lightweight robot, has a soft, rounded design with a large surface area so that only low forces are generated upon contact with the robot. “We deliver system technology for the new reality of human-robot collaboration from a single source,” says Ahlborn.
HRC solutions: the market of the future
HRC systems is a dominant theme in the automotive industry. “In the field of adhesive bonding, we have already sold ten systems,” reveals Ahlborn. The first system with the tank application was put into operation by the first customer in March 2016. This is why Duerr looks optimistically toward the future. “Thanks to our HRC-capable solutions using the KUKA LBR iiwa, we hope to win further orders,” states Ahlborn. Beyond this, HRC solutions for the robot-based adhesive bonding of small washers and other components are being worked out in Bietigheim-Bissingen.
BMW uses collaborative robots in the assembly process to lift heavy differential cases for assembly of front-axle transmissions. The operator places small and lightweight parts, such as spacers and ball bearings, into the transmission case, then presses a button to activate a ceiling-mounted robot, which fits the 5kg differential case in place.
The employees at BMW Group’s Dingolfing Plant have a new, highly responsive assistant: an LBR iiwa lightweight robot from KUKA, which primarily takes over monotonous and physically demanding tasks.
Identification of the task
Where an operator previously had to lift up to 5.5kg-heavy and not easy to reach differ-ential cases for the front-axle transmission by himself, the operator now works hand in hand with the robot assistant in a confined space - without any protective fences or additional safety equipment.
Why HRC was selected as a solution
Automation specialist KUKA has made it possible. For this human-robot collaboration (HRC) project, the experts designed a system which makes extremely efficient use of space through overhead installation and which can be integrated into the existing production line without having to redesign it.
For about a year, the specialists from the Application Engineering Team at KUKA tinkered away together with their colleagues at BMW in order to find this HRC solution. First implemented as a feasibility study at KUKA in Augsburg, it was then tested in operation at the plant in Dingolfing. Since June 2016, the system has been in regular production operation. Where BMW employees previously had to lift and fit cumbersome differential cases weighing up to 5.5 kilograms with millimeter precision when assembling front-axle transmissions, the robot now performs this ergonomically challenging work.
How is it solved (configuration of the workplace and different steps of operation)
The special challenge when designing the system was the limited space available for the HRC design. It had to fit into the production line for the assembly of front-axle transmissions for various vehicle models with all-wheel drive. “In contrast to a classic full automation solution, for which we would entirely redesign and then build the system, the layout here was determined by the space available,” explains Juergen Seifert, Project Manager for Sensitive Robotics at KUKA. Between the upstream and downstream stations, where further KUKA robots operate fully automatically, only the space occupied by the manual workstation was left. “That’s why we could not use a standard product like the KUKAflexFELLOW, but rather had to find another alternative for this area.”
The solution developed by KUKA: a sleek, gallows-shaped steel structure on which a sensitive lightweight robot is mounted. In this way, the LBR iiwa is able to work from an inverted position. That saves space. And since the LBR iiwa has joint torque sensors in each of its seven axes, no external sensors are required. This feature, combined with the robot’s systematically lightweight construction, enables work from an inverted position. Beyond this, the gripper, as the end effector of the robot, has been equipped with an edge-free HRC case with a rounded design so that the gripper too is HRC-compatible and the operator is protected from injury at all times. The compact control cabinet too found a place in the existing production line, thus providing the interface to the system controller.
Here, the human operator and the robot now collaborate to install the differential cases for the front-axle transmissions – in less than 30 seconds. The components are fed to the system automatically along a conveyor with friction rollers and prepared by the operator, who places all of the small and lightweight parts, such as spacers and ball bearings, into the cast aluminum transmission case and the cover. The operator then presses a button to activate the robot, which carefully fits the heavy differential case in place. Here, the robot’s responsive properties play a key role. After all, the sensitive tooth flanks must not be damaged by impacts when meshing the gears. The operator then fastens the cover to the transmission.
Evaluation of the solution of the challenge
Within differential production at the BMW Group plant in Dingolfing, this is the first workstation at which the human operator and the robot are able to work together in the same workspace without any safety fencing or additional safety equipment. Juergen Seifert, KUKA Project Manager, is sure that this is just the beginning:“We will see significantly more applications of this kind in the automotive industry in the future,” notes Seifert, who credits technological advances for making this possible. As an example, this technology enables companies to adapt to the needs of an aging workforce. This is an important aspect as the working lifetime of employees increases. And it allows ergonomically unfavorable work steps to be transferred to the mechanical assistant. The advantage: the operators can carry out their jobs for longer.
“We are able to significantly improve the quality of jobs through HRC solutions,” says KUKA expert Seifert.
In Seifert’s opinion, the future requirements placed on industrial manufacturing will also make a combination of manual and automated activities essential. In times of an increasing number of variants, optimally adapting production to provide the capacity required at any particular time is a clear competitive advantage. This can be achieved, for example, thanks to flexible HRC units.
At the BMW Group’s Dingolfing Plant, the system is running smoothly. From programming to commissioning and safety inspection, KUKA performed all of the relevant steps.
The new World Robotics Report shows that a new record high of 381,000 units were shipped globally in 2017 – an increase of 30 percent compared to the previous year. This means that the annual sales volume of industrial robots increased by 114 percent over the last five years (2013-2017). The sales value increased by 21 percent compared to 2016 to a new peak of US$16.2 billion in 2017.
“Industrial robots are a crucial part of the progress of manufacturing industry,” says Junji Tsuda, President of the International Federation of Robotics. “Robots evolve with many cutting-edge technologies. They are vision recognition, skill learning, failure prediction utilizing AI, new concept of man-machine-collaboration plus easy programming and so on. They will help improve productivity of manufacturing and expand the field of robot application. The IFR outlook shows that in 2021 the annual number of robots supplied to factories around the world will reach about 630,000 units.”
Top five markets in the world
There are five major markets representing 73 percent of the total sales volume in 2017: China, Japan, South Korea, the United States and Germany.
China has significantly expanded its leading position with the strongest demand and a market share of 36 percent of the total supply in 2017. With sales of about 138,000 industrial robots (2016-2017: +59 percent) China´s sales volume was higher than the total sales volume of Europe and the Americas combined (112,400 units). Foreign robot suppliers increased their sales by 72 percent to 103,200 units, including robots produced locally by international robot suppliers in China. This is the first time that foreign robot suppliers have a higher growth rate than the local manufacturers. The market share of the Chinese robot suppliers decreased from 31 percent in 2016 to 25 percent in 2017.
Japan´s manufacturers delivered 56 percent of the global supply in 2017. This makes Japan the world´s number one industrial robot manufacturer. The export rate increased by 45 percent (2016-2017). North America, China, the Republic of Korea, and Europe were target export destinations. Robot sales in Japan increased by 18 percent to 45,566 units, representing the second highest value ever witnessed for this country. A higher value was only recorded in the year 2000 with 46,986 units.
The manufacturing industry of the Republic of Korea has by far the highest robot density in the world – more than 8 times the global average amount. But in 2017, robot supplies decreased by 4 percent to 39,732 units. The main driver of this development was the electrical/electronics industry that reduced robot installations by 18 percent in 2017. The year before, industrial robot installations peaked at 41,373 units.
Robot installations in the United States continued to increase to a new peak in 2017 – for the seventh year in a row - and reached 33,192 units. This is 6 percent higher than in 2016. Since 2010, the driver of the growth in all manufacturing industries in the U.S. has been the ongoing trend to automate production in order to strengthen the U.S. industries in both domestic and global markets.
Germany is the fifth largest robot market in the world and number one in Europe. In 2017, the number of robots sold increased by 7 percent to 21,404 units - a new all-time record - compared to 2016 (20,074 units). Between 2014 and 2016, annual sales of industrial robots stagnated at around 20,000 units.
Robot use by industry worldwide
The automotive industry remains the largest adopter of robots globally with a share of 33 percent of the total supply in 2017 - sales increased by 22 percent. The manufacturing of passenger cars has become increasingly complex over the past ten years: a substantial proportion of the production processes nowadays require automation solutions using robots. Manufacturers of hybrid and electric cars are experiencing stronger demand for a wider variety of car models just like the traditional car manufacturers. Furthermore, the challenge of meeting 2030 climate targets will finally require a larger proportion of new cars to be low- and zero-emission vehicles.
In the future, automotive manufacturers will also invest in collaborative applications for final assembly and finishing tasks. Second tier automotive part suppliers, a large number of which are SMEs, are slower to automate fully but we can expect this to change as robots become smaller, more adaptable, easier to program, and less capital-intensive.
The electrical/electronics industry has been catching up with the auto industry: Sales increased by 33 percent to a new peak of 121,300 units - accounting for a share of 32 percent of the total supply in 2017. The rising demand for electronic products and the increasing need for batteries, chips, and displays were driving factors for the boost in sales. The need to automate production increases demand: robots can handle very small parts at high speeds, with very high degrees of precision, enabling electronics manufacturers to ensure quality whilst optimising production costs. The expanding range of smart end-effectors and vision technologies extends the range of tasks that robots can perform in the manufacture of electronic products.
The metal industry (including industrial machinery, metal products and basic metals industries) is on an upswing. Share of total supply reached 10 percent with an exceptional sales growth of 55 percent in 2017. Analysts predict an overall growth in demand in 2018 for metals, with ongoing high demand for the cobalt and lithium used in electric car batteries. Large metal and metal product companies are implementing Industry 4.0 automation strategies, including robotics, to reap the benefits of economies of scale and to be able to respond quickly to changes in demand.
Automation degree by robot density
85 robot units per 10,000 employees is the new average of global robot density in the manufacturing industries (2016: 74 units). By regions, the average robot density in Europe is 106 units, in the Americas 91, and in Asia 75 units.
Sales value of service robots for professional use increased by 39 percent to US$6.6 billion. The total number sold in this robot category rose by 85 percent (2017). Logistic systems show the strongest demand, accounting for 63 percent of the total units and 36 percent of the total sales (in value) of professional service robots. Prospects for service robots remain positive, as it is also a primary field for start-ups.
“In terms of value, the sales forecast 2019-2021 indicates a cumulative volume of around US$46 billion for the professional service segment”, says Gudrun Litzenberger, General Secretary of the IFR. “Robots for logistics, medical and field services are the most significant contributors.”
Service robots for PROFESSIONAL USE – market overview
69,000 logistic systems were installed in 2017 – this is 162 percent more than the number of units in 2016 (26,300). 6,700 automated guided vehicles in manufacturing environments and 62,200 in non-manufacturing environments are building up this increase compared to automated guided vehicles sales numbers in 2016. The value of logistic systems sales is estimated at about US$2.4 billion – an increase of 138 percent compared with 2016.
Medical robots are also well-established service robots with a considerable growth potential. The total value of sales of medical robots increased to US$1.9 billion, accounting for 29 percent of the total sales value of the professional service robots in 2017. Most important applications are robot assisted surgery or therapy and rehabilitation robots which assist people who have a disability with necessary activities or they provide therapy to people with the aim of improving their physical or cognitive functions.
The sales value of field robots, which mostly comprise milking robots, account for about 15 percent of the total value of professional service robot sales. Their share slightly decreased by 2 percent to US$966 million. The total number of field robots sold in 2017 was 6,375 units, accounting for a share of 6 percent of the total unit supply. A total of almost 5,400 milking robots were sold in 2017 compared to almost 5,300 units in 2016, representing a 2 percent increase. In 2016, sales decreased due to financial problems of the dairy farmers. The market is still showing the effects of this in 2017. Agricultural robots (broad acre farming for crop, vegetable and fruit cultivation, harvesting) are getting grounded in the market. Sales increased from 190 units in 2016 to 520 units in 2017.
Service robots for PERSONAL and DOMESTIC USE – market overview
At the same time, the market for personal service robots, which assist or entertain humans in their everyday lives, is progressing rapidly. Value was up by 27 percent to US$2.1 billion. The total number increased by 25 percent to about 8.5 million units in 2017. It is estimated that nearly 6.1 million robots were sold for domestic tasks, including vacuum cleaning, lawn-mowing, window cleaning and other types – an impressive 31 percent increase compared to 2016. The actual number might, however, be significantly higher, as the IFR survey is far from having full coverage in this domain. The value was about US$1.6 billion. Compared to 2016, this represents an increase of 30 percent.
“Robotics in personal and domestic applications has experienced strong global growth,” says Martin Haegele, Chairman of the IFR Service Robot Group and longtime author of the report. “Floor cleaning robots, robo-mowers and robots for edutainment (the latter increasingly referred to as social robots), have increasingly become part of our lives. Future product visions point to domestic robots of higher sophistication, capability and value, such as assistive robots for supporting the elderly, for helping out with household chores and for entertainment.”
Service robot manufacturers by regions
European service robot manufacturers play an important role in the global market: about 300 out of the meanwhile more than 700 registered companies supplying service robots come from Europe. North America ranks second with about 250 manufacturers and Asia third with about 130. Furthermore, about 30 percent of the service robot suppliers are considered as start-ups with a maximum age of five years therefore indicating the dynamics of this emerging and progressive segment in robotics.
Today, World Robotics 2018 Industrial Robots and Service Robots are published. Both reports show the successful development of the robot market in the past years as well as promising forecasts. A new record high of 381,000 units of robots were shipped globally in 2017 – an increase of 30 percent compared to the previous year. This means that the annual sales volume of industrial robots increased by 114 percent over the last five years (2013-2017).
Industrial robots are a crucial part of the progress in manufacturing industry. Robots continue to evolve thanks to an array of cutting-edge technologies, such as vision recognition, skill learning, failure prediction utilizing AI, new concept of man-machine-collaboration plus easy programming and so on. These developments will help improve productivity of manufacturing and expand the field of robot application. The IFR outlook shows that in 2021 the annual number of robots supplied to factories around the world will reach about 625,000 units.
Service robots have successfully entered our daily lives at home, in shops, in hospitals, in barns and fields, in museums and other public areas. Prospects for service robots remain positive, as it is also a primary field for start-ups.
This week, we are participating at the World Robot Summit in Tokyo, a challenge and an expo. Under the theme “Robotics for Happiness”, it brings together Robot Excellence from around the world, to promote a world where robots and humans successfully live and work together. It strives towards achieving a society where humans and robots cooperate and coexist.
Robots have certainly transformed industrial manufacturing. And without a doubt, the acceptance of robots as assistants in factories and in our daily lives is also on the rise.
SHAD, the leading European manufacturer of top and side cargo cases for motorcycles installs its first UR5 from Universal Robots in its factory in Mollet del Valles (Catalonia, Spain). The collaborative robot arm has streamlined production, enabling the cases to be assembled in half the time, while also enhancing the work environment for employees.
The Spanish company NADSL, best known for its SHAD brand of top and side cargo cases for motorcycles, manufactures original equipment (seats and cases) for the world’s leading motorbike manufacturers. The company chose Universal Robot’s collaborative robots to optimize its production processes thanks to their ease-of-use and the fact that they can be operated without the need for safety barriers. The UR5 six-axis robot works side by side with plant personnel in a shared environment, where it frees them up from having to do the more repetitive tasks such as screwing in screws on the cases, thereby enhancing production cycle time and quality, as well as helping to improve the work area.
The NADSL factory in Mollet del Valles, Barcelona, has 40 years experience in manufacturing original equipment for motorbikes, mainly seats and top and side cases for OEMs such as Yamaha, Honda, Suzuki, Piaggio, Peugeot and BMW. The company also manufactures and markets cases and seats under its own SHAD brand and has been expanding its product catalogue in recent years to include bags for motorbikes, top cases for quadbikes, custom-made seat backs for scooters and communication accessories such as Bluetooth hands free kits and holder mounts for smartphones.
Staubli Robotics / Case Studies Collaborative Robots
Stäubli Electrical Connectors uses a mobile industrial robot with an automatic tool changing system to tend multiple machines. The robot navigates between machines, selects the appropriate tool and completes a task, such as loading a rotary table for the manufacturing of pneumatic couplings, and moves on. The robot stops automatically if a human approaches.
Mobile robot systems are a popular topic of discussion but rarely found in practice, and they are high on the wish list of many industrial companies. Meanwhile, Stäubli Electrical Connectors is already using them to great effect. Senior management there is delighted by the flexibility that mobile robot assistants bring to the assembly line. Stäubli Electrical Connectors is one of the world’s leading manufacturers of electrical connectors for all industrial sectors.
The company not only sets the benchmark in terms of product quality but also leads the way in innovative production technologies. In the manufacture of their broad-based product range, the Swiss-based specialists favor hybrid assembly systems that combine fully automated and manual workstations. The only downside to this strategy is that, if an operator is absent due to illness, the complete line comes to a standstill. In addition, unmanned night shifts are not possible.
The company now has the optimal solution for such scenarios: the HelMo mobile robot system from Stäubli Robotics. Once trained, HelMo can handle almost any manual job on the various assembly lines. This production assistant navigates to its own workplace, decelerates or stops when human colleagues come too close, and then continues its journey as before.
More of a flexible production assistant than a robot
As soon as HelMo arrives at its workplace, it spends a few minutes prepping itself for the task in hand. The robot positions itself precisely within a tenth of a millimeter by referencing three permanent orientation points at the workstation. HelMo then connects itself to the fixed supply sockets for electricity and compressed air by means of a multi-coupling – also from Stäubli of course – and starts its shift. To enable HelMo to operate flexibly, its designers equipped it with an automatic tool change system from Stäubli Connectors. So, today it could be the placement of connector housings and contact pins, whereas tomorrow it might be some other stage in the assembly process, which HelMo will perform if called upon. In the factory at Allschwil, HelMo is regarded less as a robot and more as an assistant who is flexible enough to help out where needed.
The intention is not to replace human labor with mobile robots – that would make no sense from either a production or an economic perspective – but to deploy HelMo as a flexible stand-in and thereby increase the availability of hybrid assembly lines or cope with peak demand. Illness-related or other unforeseen absences among the human workforce are no longer a cause for consternation at Allschwil. Thanks to HelMo, the delivery capability of the company has been significantly optimized.
The General Secretary of the International Federation of Robotics, Gudrun Litzenberger, has received the Joseph F. Engelberger Robotics Award. The jury honored her achievements in robotics with the world's most important industry award in the "Leadership" category.
As head of the IFR Statistical Department, Litzenberger advanced the World Robotics Statistics and has been working for more than a decade to improve our understanding of the global robotics market. “Gudrun Litzenberger has spent much of her career helping our industry better understand the size and scope of the global robotics market,” said Jeff Burnstein, RIA president. “Her work has established the IFR as the leading source of global robotics statistics during an era when the interest in robotics is growing exponentially. Furthermore, Gudrun has been a tireless advocate for our industry throughout the world.”
Ambassador of Robotics
“The Engelberger Robotics Award is a success for my entire team,” says Gudrun Litzenberger, General Secretary of the International Federation of Robotics. “We all share a great passion for robotics. We are very proud to know that organizations around the world and governments use our statistics. IFR’s valid data are very important because they provide clear insights into the use of robots all over the world and their effects on the economy.“Gudrun Litzenberger has been working for the German Engineering Federation (VDMA) since 1986. In 2002, she transferred to the VDMA Robotics and Automation Association, where she was responsible for statistics. Litzenberger then took over the responsibility for World Robotics Statistics in 2003 and since 2005 has been in charge of the annual IFR World Robotics Report. Today, this study is considered the most important source for global robot statistics and covers all market-relevant activities of industrial and service robots. Gudrun Litzenberger has been General Secretary of the IFR since 2008. The International Federation of Robotics represents more than 50 manufacturers of industrial robots and national robot associations from over twenty countries and was founded in 1987 as a non-profit organization.
About the Joseph F. Engelberger Robotics Award
The award is named for Joseph F. Engelberger, known throughout the world as the ”father of robotics.” Engelberger was founder and president of Unimation, Inc., the world’s first industrial robot manufacturer. The Engelberger Robotics awards are presented to individuals for excellence in technology development, application, education and leadership in the robotics industry. Each winner receives a $5,000 honorarium and commemorative medallion with the inscription, “Contributing to the advancement of the science of robotics in the service of mankind.”
The 14th International IERA Award for Robotics and Automation has three winners on the top of the podium this year:
Perception Robotics (USA) wins with the “Industrial Self-Cleaning Gecko Gripper”, a Gecko-style gripping solution that uses NASA technology for industrial automation.
KUKA Deutschland wins with “LBR Med”, a collaborative robot assistant for medicine & research as well as new applications.
Lely International (Netherlands) wins with the “Discovery 120 Collector”, a barn floor cleaning robot that cleans solid floors in the dairy industry
“The close cooperation between research and industry is very important for the robotics industry,” says Junji Tsuda, President of the International Federation of Robotics. “Based on modern scientific research, world-class products are being developed - this has been demonstrated by all three winners.”
“This year a number of excellent applications competed for the IERA Award,” says Dominik Boesl of IEEE-RAS. “Our winners in 2018 offer excellent technological innovations in various industries. Therefore, this year the jury decided to award first place to three winners.”
Perception Robotics (USA): Gecko Gripper
The technology underlying the gecko gripper is based on the model of the gecko, which can climb on smooth surfaces. The reptile uses physical forces of attraction between foot and surface (van der Waals forces). Based on the work of NASA (JPL) and Stanford University, Perception Robotics has developed a gripping solution for the manufacturing industry using this natural model in collaboration with NASA-JPL. In contact with smooth and rough materials, millions of tiny stalks on the robot arm produce a highly adhesive effect, with which, for example, sheet metal or glass pieces can be moved. The gecko gripper arm was deployed in sheet metal processing in 2017 - Perception Robotics sees an important future market in the manufacture of solar panels.
KUKA (Germany): LBR Med, lightweight robot
The LBR Med Robot Assistant from Kuka Deutschland supports a variety of tasks in medical research and practice and works in close proximity to humans. In laboratories, clinics or operating theatres, the lightweight robot takes over various tasks depending on the tool and program - for example, during medical interventions, treatments or scientific test procedures. The LBR Med has seven axes and particularly sensitive sensors that are suitable for human-robot collaboration. The robot component can be integrated into medical devices worldwide and has been tested and certified to international safety and quality standards. LBR Med, for example, has biocompatible and corrosion-resistant surfaces and, with internal connections, meets the hygiene standards in medical practices, clinics or operating theatres.
Lely International (The Netherlands): Barn floor cleaning robot
The Discovery 120 Collector navigates a programmed route through the barn and is controlled on its way by built-in sensors. The robot vacuums up the manure on solid walkways. The machine can spray water at the front and the back for dilution and cleaning. The in-built vacuum pump sucks the manure inside - once the tank is full, the Discovery drives to the dumping location. Here, the cleaning robot empties the tank and refills the water bags before returning to the charging station. Lely launched the Discovery 2017 in several European countries as well as the USA. In the future, additional countries will be added.
Global sales of industrial robots reached the new record of 387,000 units in 2017. That is an increase of 31 percent compared to the previous year (2016: 294,300 units). China saw the largest growth in demand for industrial robots, up 58%. Sales in the USA increased by 6% - in Germany by 8% compared to the previous year. These are the initial findings of the World Robotics Report 2018, published by the International Federation of Robotics (IFR).
Broken down by industry, the automotive industry continues to lead global demand for industrial robots: In 2017, around 125,500 units were sold in this segment - equivalent to growth of 21 percent. The strongest growth sectors in 2017 were the metal industry (+55 percent), the electrical/electronics industry (+33 percent) and the food industry (+19 percent).
In terms of sales volume, Asia has the strongest individual markets: China installed around 138,000 industrial robots in 2017, followed by Japan with around 46,000 units and South Korea with around 40,000 units. In the Americas, the USA is the largest single market with around 33,000 industrial robots sold, and in Europe it is Germany with around 22,000 units sold.
“The growth of industrial robots continues at an impressive pace worldwide,” says Junji Tsuda, President of the International Federation of Robotics. “Key trends such as digitalisation, simplification and human-robot collaboration will certainly shape the future and drive forward rapid development.”
In the course of digitalisation, real production is becoming increasingly connected with the virtual data world, opening up completely new possibilities for analysis - right through to machine learning. Robots will acquire new skills through learning processes. At the same time, the industry is working to simplify the handling of robots. In the future industrial robots should be easier and faster to program using intuitive procedures. Such a technology is not only attractive to established users, but also to small and medium-sized companies, for example, companies who can use it to introduce automation without the need for highly experienced or expert personnel. This development also paves the way for the third major robotics trend: collaboration between humans and robots without protective barriers offers new approaches to new flexible production processes. In the future human-robot collaboration will support the flexible production of small quantities with high complexity.
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Nearly 70 percent of employees believe that robotics and automation offer the opportunity to qualify for higher skilled work. This is the result of a worldwide automatica survey of 7,000 employees in seven countries. The technological change calls for targeted training and further education for employees. More than 3 million industrial robots will be in use in factories around the world by 2020. This means that the operational stock will more than double within seven years (2014-2020).
According to the International Federation of Robotics, more than 3 million industrial robots will be in use in factories around the world by 2020. This means that the operational stock will more than double within seven years (2014-2020).
„IT like robotics process automation is by far the biggest contributor in transforming people’s jobs,” comments Junji Tsuda, president of the International Federation of Robotics. “Companies and governments must collaborate to ensure workers have the skills that the technological change requires.”
Singapore invests in SkillsFuture initiative
As far as training is concerned, Singapore is one of the most advanced countries with its SkillsFuture initiative. Employers in the city-state are asked to spell out the changes, industry by industry, that they expect to happen over the next three to five years, and to identify the skills they will need. Their answers are used to create “industry transformation maps” designed to guide individuals on where to head.
Since January 2016 every Singaporean above the age of 25 has been given $345 credit that can be freely used to pay for any training courses provided by 500 approved providers, including universities and MOOCs.
These are exciting times in robotics. Robot adoption has grown at a rapid pace over the past three years and we expect this to continue. The IFR forecasts 15% average annual growth in industrial robots and up to 25% growth in professional service robots by 2020.
We see a number of trends that will fuel a broader adoption of robots across new geographies, industries and applications. For example, collaborative robots that can work alongside humans will start to make their mark in a wide range of industries such as manufacturing and logistics. The application of collaborative and service robots in healthcare holds great promise for enabling advanced economies to provide quality care to rapidly growing ageing populations, supporting healthcare workers in tedious, back-breaking tasks and enabling them to focus on patient care.
Many of the recent developments in robotics are driven by advances in artificial intelligence (AI). For example, AI enables robots to sense and respond to their environment. This increases the range of functions they can perform, from navigating their way around warehouse floors, to sorting and handling objects that are uneven, fragile or jumbled together. Picking up a strawberry is an easy task for humans, but a remarkably difficult one for a robot. Most collaborative robots today work in sequence with humans, each performing separate tasks. Developments in AI mean we can expect robots to perform increasingly effectively as human assistants, not only understanding and answering questions as they do today, but also acting on voice commands and gestures, and even anticipating a worker’s next move in order to remove an obstacle from her path.
In all of these applications, human safety is paramount, which means many of these AI innovations will take longer to bring to market than AI software applications which can be tested and adapted in a ‘live’ setting. Meanwhile, governments, educational institutes and companies must work to ensure that today’s and tomorrow’s workers are equipped with the knowledge and skills to benefit from advances in AI and robotics.
Our new positioning paper, ‘Robots and the Workplace of the Future’ gives more detail on how robots and automation are changing the nature of work in manufacturing, logistics and healthcare.
The Robotic Industries Association (RIA) announced the winners of the 2018 Engelberger Robotics Awards, the world's most prestigious robotics honor. The 2018 awards will be presented to Gudrun Litzenberger, the General Secretary of the International Federation of Robotics (IFR), and Esben Østergaard, CTO and Cofounder of Universal Robots.
Litzenberger and Østergaard will be honored at a special ceremony on June 20 in conjunction with Automatica and the International Symposium on Robotics, held June 19-22 in Munich, Germany. The award is named for Joseph F. Engelberger, known throughout the world as the ”father of robotics.” Engelberger was founder and president of Unimation, Inc., the world’s first industrial robot manufacturer. The Engelberger Robotics awards are presented to individuals for excellence in technology development, application, education and leadership in the robotics industry. Each winner receives a $5,000 honorarium and commemorative medallion with the inscription, “Contributing to the advancement of the science of robotics in the service of mankind.”
The awards recognize outstanding individuals from all over the world. Since the award’s inception in 1977, it has been bestowed upon 126 robotics leaders from 17 different nations. This year the awards will be presented in the categories of leadership and technology.
The Engelberger Robotics Award for Leadership is awarded to Gudrun Litzenberger.
“Gudrun Litzenberger has spent much of her career helping our industry better understand the size and scope of the global robotics market,” said Jeff Burnstein, RIA president. “Her work has established the IFR as the leading source of global robotics statistics during an era when the interest in robotics is growing exponentially. Furthermore, Gudrun has been a tireless advocate for our industry throughout the world.”
The Engelberger Robotics Award for Technology is awarded to Esben Østergaard.
“Esben Østergaard’s work in the field of collaborative robot applications has allowed robots to enter previously unthinkable sectors in just about every industry,” added Burnstein. “His emphasis on robots that work side by side with people has created enormous interest among many small and medium sized companies who never even considered robots before. In a world that is increasingly characterized by people and robots working together, Esben’s pioneering technology advances play a pivotal role.”
2018 Engelberger Award Winners
Gudrun Litzenberger joined the German Mechanical Engineering Industry Association (VDMA) in 1986. In 2002 she transitioned to the VDMA Robotics+Automation Association where she took responsibility for statistics in the fields of robotics, assembly technology and machine vision. After the foundation of the IFR Statistical Department in 2003, Litzenberger assumed responsibility for the World Robotics Statistics from the United Nations Economic Commission for Europe (UNECE) and compiled the annual study World Robotics from 2005. Over the years, World Robotics has developed into the international benchmark for global robot statistics covering all relevant market related activities of industrial and service robots. In 2008, Litzenberger was appointed General Secretary of the IFR. The IFR connects the world of robotics around the globe and now represents over fifty members from more than twenty countries.
Esben H. Østergaard is Chief Technology Officer at Universal Robots, one of the inventors behind the UR cobots, and is responsible for the enhancement of existing UR cobots and the development of new products. During his years as researcher and assistant professor in robotics and user interfaces at University of Southern Denmark, he created the foundation for a reinvention of the industrial robot. In 2005, this led him to found Universal Robots together with two of his research colleagues. Besides his work as CTO Østergaard is participating in national research projects and he is also an external examiner at several universities in Denmark. Earlier in his career, he worked as a research scientist at USC Robotics Labs in Southern California and also at AIST in Tokyo as a visiting researcher.
2018 Joseph F. Engelberger Robotics Award Dinner
The Engelberger Awards Ceremony will be held at 6:30pm on Wednesday, June 20, 2018 at the Hofbräuhaus in Munich, Germany as part of the International Symposium on Robotics. Tickets can be purchased for the event by visiting the RIA website’s Engelberger section.
At 309 units per 10,000 employees, robot density in German manufacturing industry is the third highest worldwide. At the same time, the number of people employed in Germany reached 44 million in 2017, the highest figure since reunification. The rapid spread of industrial robots hasn’t made a dent in employment figures: today, new tasks have been created for the workforce alongside once performed by machines.
These are the results of the latest study by the Centre for European Economic Research (ZEW) on behalf of the German Federal Ministry for Education and Research (BMBF). “The results of the ZEW study on the labour market confirm what we’re observing in leading industrial nations across the world,” comments Junji Tsuda, president of the International Federation of Robotics. “The modernisation of production shifts hazardous, unhealthy and monotonous work to the machines. In the vast majority of cases, only certain activities of a job are automated and not the entire spectrum of an employee´s work.” However, if jobs are cut – the ZEW reports that 5% of employees were replaced within five years – these losses are compensated for by new jobs overall.
In Germany, the rise in the use of machines has allowed employment to grow by 1%. This development looks set to continue in future: based on details from companies surveyed, the ZEW estimates that further automation and digitalisation in industry will generate a 1.8% rise in employment by 2021.
This development tallies with experience from the 1990s onwards with the computer boom. The large-scale use of IT in companies did render traditional processing jobs superfluous. But according to calculations by the ZEW, from 1995 to 2011 employment rose by just under 0.2% per year.
The London School of Economics (LSE) recently published a study entitled Robots at Work on the use of industrial robots in 17 developed economies between 1993 and 2007. LSE head of research, Guy Michaels, summarised the key results at a Messe Muenchen press conference on automatica 2018: “Productivity has improved by around 15% due to industrial robots. At the same time, the proportion of low-skilled labour dropped and pay increased slightly. Industrial robots don’t have any significant impact on the number of employees overall,” commented Guy Michaels.
About the Impact of Robots on Productivity, Employment and Jobs
With the help of robots from WITTMANN BATTENFELD, INC., the US branch of the WITTMANN Group, Intertech Medical wins first place for MAPP Innovations Award 2017.
In August 2017, MAPP, the Manufacturers Association for Plastic Processors, awarded Intertech Medical first place for their 2017 Innovations Award for their work cell automating quality inspection, degating, and packaging. Intertech Medical, located in Denver, Colorado, is the region’s premier full service injection molder and contract manufacturer, specializing in medical devices.
The changes began after Intertech had been molding a medical part with complex geometry and features that was difficult to trace defects on using conventional inspection methods and sampling. With the part’s critical application and an expectation of zero defects, this was particularly problematic. After three customer complaints within six months, it was clear to both Intertech and their customer that a solution was needed.
To solve the problem, Intertech designed and built a machine-side, automated work-cell that utilized integrated process control and quality control to get to zero defects. The solution primarily centered on integrated process control, automated quality inspection, and the reduction of bioburden from part handling and packaging. Rather than just adding more operators and increasing the number of times quality inspections, Intertech took a leap forward in their automation and inspection technology and were able to achieve the best results possible.
Successful WITTMANN automation
Intertech already had robots, but the supplier they had been using was limiting their ability to program and customize their process. Knowing that WITTMANN robots had a reputation for open architecture and flexibility, they reached out to see what they could do. WITTMANN BATTENFELD, INC., USA, initially setup a few complete automation cells, including robots, EOAT, downstream part orientation stations, and tray filling conveyor systems, to demonstrate their capabilities. The WITTMANN BATTENFELD employees stayed on site for a couple weeks, allowing them to provide extensive training on their systems. Intertech was then off and running, taking the reins from WITTMANN BATTENFELD. Their in-house engineering, automation, mold shop, and maintenance department used the programmability they had lacked before to create a new process and system that could exceed their customer’s needs.
“We love what we are able to do with the WITTMANN robots,” said Kevin Clements, Director of Engineering at Intertech Medical. “The capabilities far exceed anything else we see in the market, from their SmartRemoval technology to the training and support that’s available when needed. With this automation in place, our company achieved ROI on the complete automation system in less than 9 months.”
Since the completion of this work cell, Intertech has had zero returns from their customer, and was ranked by their customer as a preferred supplier. The design was so successful that they have replicated the technology to three additional work cells, and they now have nine WITTMANN robots in their plant.
The automation of production is accelerating around the world: 74 robot units per 10,000 employees is the new average of global robot density in the manufacturing industries (2015: 66 units). By regions, the average robot density in Europe is 99 units, in the Americas 84 and in Asia 63 units.
The top 10 most automated countries in the world are: South Korea, Singapore, Germany, Japan, Sweden, Denmark, USA, Italy, Belgium and Taiwan. This is according to the 2017 World Robot Statistics, issued by the International Federation of Robotics (IFR).
“Robot density is an excellent standard for comparison in order to take into account the differences in the automation degree of the manufacturing industry in various countries,” says Junji Tsuda, President of the International Federation of Robotics. “As a result of the high volume of robot installations in Asia in recent years, the region has the highest growth rate. Between 2010 and 2016, the average annual growth rate of robot density in Asia was 9 percent, in the Americas 7 percent and in Europe 5 percent.”
The development of robot density in China was the most dynamic in the world. Due to the significant growth of robot installations, particularly between 2013 and 2016, the density rate rose from 25 units in 2013 to 68 units in 2016. Today, China’s robot density ranks 23rd worldwide. And the government intends to forge ahead and make it into the world’s top 10 most intensively automated nations by 2020. By then, its robot density is targeted to rise to 150 units. Furthermore, the aim is to sell a total of 100,000 domestically produced industrial robots by 2020 (2017: 27,000 units from Chinese robot suppliers, 60,000 from foreign robot suppliers).
Worldwide, the Republic of Korea has by far the highest robot density in the manufacturing industry – a position the country has held since 2010. The country’s robot density exceeds the global average by a good eight-fold (631 units). This high growth rate is the result of continued installations of a high volume of robots particularly in the electrical/electronics industry and in the automotive industry.
Singapore follows in second place with a rate of 488 robots per 10,000 employees in 2016. About 90 percent of robots are installed in the electronics industry in Singapore.
Japan ranked fourth in the world: In 2016, 303 robots were installed per 10,000 employees in the manufacturing industry – following Germany ranking 3rd (309 units). Japan is the world´s predominant industrial robot manufacturer: The production capacity of Japanese suppliers reached 153,000 units in 2016 – the highest level ever recorded. Today, Japan´s manufacturers deliver 52 percent of the global supply.
Robot density in the United States increased significantly to 189 robots in 2016 – the country ranks seventh in the world. Since 2010, the necessary modernization of domestic production facilities has boosted robot sales in the United States. The main driver of this growth was the ongoing trend to automate production in order to strengthen American industries on the global market and to keep manufacturing at home, and in some cases, to bring back manufacturing that had previously been sent overseas. The automotive industry still leads as the main customer of industrial robots with about 52 percent of total sales in 2016. Robot sales in the United States will continue to increase between 2017 and 2020 by at least 15 percent on average per year.
Robot density in Canada has been on the rise and reached 145 units in 2016 (ranking 13th worldwide). Growth was mainly driven by installations in the automotive industry.
Mexico is predominantly a production hub for car manufacturers and automotive parts suppliers that export to the United States and increasingly to South America. The automotive industry in Mexico is by far the main robot customer with a share of 81 percent in 2016. Robot density is at 33 units, which is still far below the world average of 74 units, ranking 31st on the global scale.
Europe´s most automated country is Germany - ranking 3rd worldwide with 309 units. The annual supply and the operational stock of industrial robots in 2016 had a share of 36 percent and 41 percent respectively of total robot sales in Europe. Between 2018 and 2020, the annual supply in Germany will continue to grow by at least 5 percent on average per year due to the increasing demand for robots in the general industry and in the automotive industry.
France has a robot density of 132 units (ranking 18th in the world), which is well above the global average of 74 robots – but relatively weak compared to other EU countries. EU members like Sweden (223 units), Denmark (211 units), Italy (185 units) and Spain (160 units) enjoy a much higher degree of automation using industrial robots in the manufacturing segment. But under the new government, France is in the process of regaining competitiveness in its manufacturing sectors. This may, to a certain extent, promote installations of new robots in the next few years. In 2017, the number of robot installations in France is expected to increase by about 10 percent. Between 2018 and 2020, an average annual growth rate between 5 and 10 percent is likely.
As the only G7 country – the UK has a robot density below the world average of 74 units with 71 units, ranking 22nd. The general industry is highly in need of necessary investment in order to modernize and increase productivity. The low robot density rate is indicative of this fact. Despite the decision to leave the EU, there are currently many suggested investment plans for capacity expansion and modernization of foreign and local automotive companies. It is not evident though whether companies will hold back investments due to uncertainties concerning customs duties.
The eastern European countries Slovenia (137 units, ranking 16th in the world) and Slovakia (135 units, ranking 17th worldwide), both have a robot density that is above Switzerland’s (128 units, ranking 19th in the world). The Czech Republic is ranking 20th on the global scale with 101 units. Robot supplies in the Czech Republic and Slovakia mainly depend on the automotive industry’s demand. Slovenia is the most successful among the Balkan countries with 60 percent of the total robot supply used mainly for the automotive industry (387 units, 33 percent more than in 2015).
I just returned from the iREX in Tokyo. The record number of more than 130,000 visitors and more than 600 exhibitors has demonstrated the high interest in robotics. The global success story of industrial robots continued in 2017 for the 8th year in a row. Prospects for 2018 and beyond are promising.
A few days ago, I was elected as President of the IFR. I succeeded Joe Gemma. He successfully followed the mission, to deliver a better understanding about what drives the rapidly changing world of robotics. As new President together with the new Vice President, Steven Wyatt, I will carry his mission forward - for the International Federation of Robotics. Robots increase productivity and competitiveness. Robots have been enablers for the industry development for automobile, semiconductor, distribution and so on. The quality of work has improved. Dangerous, tedious and dirty work is being transferred from human to machine.
2018 looks to continue the energy and excitement with multiple events that will have IFR or IFR member associations participation.
Major events in 2018
automatica 2018 (19-22 June 2018), Munich
IFR CEO Round Table at automatica, 20 June 2018
ISR 2018 (20-21 June 2018)
Joseph Engelberger Award presentation (20 June 2018)
International Robot Exhibition 2017 (iREX 2017), which was the largest scale ever, was a great success with 130,480 visitors from various countries during the four-day exhibition period from November 29 through December 2, 2017.
Held once every two years, the world biggest robot exhibition marked its 22nd exhibition this year and it attracted 612 exhibitors and 2,775 booths including 88 overseas exhibitors from 14 countries. It was held under the theme of “The Robot Revolution Has begun – Toward Heartwarming Society”, featuring the largest-size-ever industrial robot zone; service robot zone ranging widely from disaster reactions, nursing cares, and agriculture to education; and an array of international symposiums/forums held throughout the exhibition term. Reflecting the current trends in the robotics industry, many collaborative robots including newly developed ones were exhibited, and also more exhibits in logistics robot systems were shown at the Exhibition.
The North American automation market set new records through the first nine months of 2017, according to the Association for Advancing Automation (A3), the leading global advocate for the benefits of automating. Results found records set in the areas of robotics, machine vision, motion control, and motor technology.
Here is a look at the latest findings:
For the first nine months of 2017, 27,294 orders of robots valued at approximately $1.473 billion were sold in North America, which is the highest level ever recorded in any other year during the same time period. These figures represent growth of 14% in units and 10% in dollars over the first nine months of 2016. Automotive-related orders are up 11% in units and 10% in dollars, while non-automotive orders are up 20% and 11%, respectively.
For shipments, 25,936 robots valued at $1.496 billion were shipped in North America during the first nine months. These record high quantities represent growth of 18% in units and 13% in dollars over what sold in 2016. Automotive-related shipments also grew 12% in units and 9% in dollars during that time, with non-automotive shipments increasing by 32% and 22% for units and dollars, respectively.
The hottest industries were Metals (54%), Automotive Components (42%), and Food and Consumer Goods (21%).
Motion Control & Motors
Total motion control shipments increased by 10% to $2.6 billion, marking the industry’s best nine month mark since these figures began being tracked. The largest product category is Motors (38% of shipments), followed by Actuators and Mechanical Systems (18% of shipments), and Electronic Drives (17% of shipments).
The fastest growing categories in the first nine months of 2017 were Motion Controllers (24% to $147m), Sensors & Feedback Devices (20% to $116m), AC Drives (15% to $295m), Actuators & Mechanical Systems (13% to $479m), and Motors (11% to $1b).
The majority of suppliers believe that order and shipment volumes will increase in the next six months, with most distributors feeling that orders and shipments will be flat in the same time period.
Vision & Imaging
The North American Machine Vision Market continued its best start to a year ever in 2017, with growth of 14% overall to $1.937b, 14% in systems to $1.657b, and 14% in components to $271m. Each of those three categories set new records in the first nine months of this year, and every individual product category experienced positive year-over-year growth for the same period last year. Some notable growth rates were Smart Cameras (21% to $295m), Lighting (20% to $54m), Software (16% to $15m), and Component Cameras (14% to $143m).
Experts believe lighting, optics, imaging boards, and software will trend up, while camera sales will remain flat in the next six months. Additionally, expectations are for Application Specific Machine Vision (ASMV) systems to increase and smart cameras to remain flat over the same time period. The U.S. manufacturing sector expanded in the second quarter (avg. PMI of 53.0) and is expected to remain strong through the end of the year.
Interaction between rigid robotic devices and soft materials imposes significant challenges and largely unresolved problems to current practice in robotics. Therefore, a collaboration between the University of Stuttgart (Germany) and the University of Auckland (New Zealand) has been established, developing simulation-driven concepts and design for control and automation of robotic devices interacting with soft tissues.
The International Research Training Group (IRTG) consists of 8 institutes from Stuttgart and 5 institutes from Auckland, providing a wide range of research expertise ranging from simulation technology, through cyber-physical engineering and robotic device technology, to biomedical engineering and technologies. The project is led by Prof. Oliver Röhrle (Institute of Applied Mechanics) and Prof. Alexander Verl (Institute for Control Engineering of Machine Tools and Manufacturing Units) from the University of Stuttgart and Professor Peter Xu (Faculty of Engineering) and Associate Professor Leo Cheng (Auckland Bioengineering Institute) from the University of Auckland.
The research group aims to develop novel approaches to interact safely and adequately with soft tissues. Therefore novel concepts are going to be examined, covering the lack of information and knowledge on how soft materials deform and how signals can effectively be recorded and interpreted accordingly to provide appropriate feedback to the control. To achieve these goals, research will be advanced in detailed simulations of soft tissue on high performance computers, model order reduction and also in practical fields as developing new concepts for sensors and actuators as well as biomedical and industrial applications such as exoskeletons, meat cutting systems or surgical devices.
However, the main focus of the IRTG does not lie solely on new technical developments but as well on the education of a new generation of young researchers. Thus, 20 PhD students (10 from Stuttgart and 10 from Auckland) will be provided with unique education on the highest academic level. Combining the interdisciplinary skills and in-depth expertise in developing and applying novel simulation techniques, modelling approaches as well as sensing and control methods, the young researchers will be very well prepared to face the future challenges of soft tissue robotics.
The IRTG is funded by the German Research Foundation (DFG) within grant GRK 2198, starting with 2017.
The Executive Board of the IFR has elected Japanese Junji Tsuda (Yaskawa Electric Corporation) as its new President. Mr. Tsuda succeeds Joe Gemma (KUKA, USA), who is leaving the rotating post as head of the global federation of robot manufacturers, having served his two-year term. Steven Wyatt (ABB, Switzerland) has been appointed as IFR´s new Vice President.
The 66 year old Junji Tsuda is one of the most senior experts in the robotics industry. He serves as the Representative Director Chairman of the Board of the Japanese robot manufacturer Yaskawa Electric Corporation. Tsuda began working for Yaskawa in 1976, after obtaining his university degree (B.S.) in mechanical engineering at the renowned Tokyo Institute of Technology. Since the 1990s, Tsuda has headed various America-related business units and has been active in the parent company since 2003. Before being elected President of IFR, Mr. Tsuda assisted his predecessor, Joe Gemma, as Vice-President, a role he held for two years.
The new elected Vice President, Steven Wyatt, is the global Head of Marketing & Sales for ABB’s Robotics Business Unit. Prior to joining ABB in 2010, Mr. Wyatt held a series of executive marketing & sales roles within the plastics industry globally. He holds a degree in Chemical Engineering from the University of Edinburgh in his native Scotland. Steven Wyatt and Junji Tsuda were both elected by the IFR Executive Board which is composed of representatives of national robotics associations from all over the world, the IFR president and delegates of robot manufacturers and research institutes.
Junji Tsuda thanked the previous IFR President, Joe Gemma, for his successful work: “The presidency of Joe Gemma followed the mission, to deliver a better understanding about what drives the rapidly changing world of robotics. He did a great job by communicating with our many stakeholders around the Globe. As its new President it is my pleasure to proceed with his work. Together with the new Vice President, Steven Wyatt, I will carry his mission forward - for the International Federation of Robotics.
The production capacity of the Japanese suppliers has reached 153,000 units in 2016 – the highest level ever recorded. Today, Japan´s manufacturers deliver 52 percent of the global supply. These are results published by the International Federation of Robotics (IFR) ahead of the International Robot Exhibition (iREX) in Tokyo - November 29th - December 2nd 2017.
“Japan is a highly robotized country where even robots are assembled by robots”, said Joe Gemma, President of the International Federation of Robotics (IFR). “The statistics show that automation strongly boosts exports and domestic investments as well – robot sales in Japan increased by 10 percent to about 39,000 units in 2016 - reaching the highest level in the last ten years.”
Japan´s high export rate
Japan exported a total of nearly 115,000 industrial robots in 2016 with a value of 309 billion yen (about US$ 2.7 billion). This is by far the highest export volume for one year. The export rate increased from 72 percent to 75 percent (2011-2016). North America, China, the Republic of Korea and Europe were target export destinations. The Japanese imports of robots were extremely low, only about 1 percent of installations. Thus, foreign robot suppliers did not achieve a high sales volume in Japan. The home market has strongly recovered since the financial crisis in 2009 and reached 39,000 units, the highest level since 2006 (37,000 units).
Car- and electrical/electronics industry dominate
The automotive industry is the largest destination market for industrial robots in Japan with a share of 36 percent of the total supply. Car manufacturers bought 48 percent more industrial robots than in 2015 (2016: 5,711 units). Japanese car suppliers are leading in the production of hybrid cars and will increase investments in automated driving technologies. The development of new materials which reduce weight and save energy will also foster investments in robot automation. However, the ongoing reduction of production capacities in Japan will impact domestic demand for robots. Investments abroad, on the other hand, will continue to increase. The Japanese car companies have been increasingly expanding production facilities overseas, particularly in China, as well as other Asian countries and in the United States and Mexico.
After the strong growth of robots in the electrical/electronics industry in 2015 (11,659 units), a decrease of 7 percent followed in 2016. However, the electrical/electronics industry has preferred to invest in production facilities abroad. Furthermore, continued investments in robots can be expected in this sector with the increasing demand for chips, displays, sensors, batteries and other technologies around electro mobility, and industry 4.0 (connected industries).
The two most important customer groups of industrial robots in Japan - automotive and electrical/electronics - had jointly, a share of 64 percent of the total supply in 2016. Robot sales to both sectors increased by 8 percent in 2016. In all other branches, as a whole, the market increased by 14 percent.
Japan outlook 2020
In Japan, the economy benefits from increased foreign demand, especially from China, the expansive monetary policy of the Bank of Japan and the weaker yen. Based on estimates provided by the Japanese Robot Association (JARA), the IFR expects an increase of around 10 percent in 2017 in domestic installations. Between 2018 and 2020 a further average annual increase of about 5 percent is likely, provided the economic recovery in Japan continues.
IFR Japan data overview
Please find below an overview of the new IFR data about industrial robots in Japan:
Japan – new peak in 2016
38,586 new robots installed (new record), 10% higher than in 2015
CAGR 2011-2016: +7%
Global ranking 2016: No. 3
Shares of total supply: Handling operations 36%, welding 22%; Automotive industry 36%, electrical/electronics industry 28%
Stock of operational robots
About 287,300 units, slight increase over 2015 (286,600)
CAGR 2011-2016: -1%
Global ranking 2016: No. 2
Shares of total stock: Handling operations 36%, welding 23%; Automotive industry 35%, electrical/electronics industry 31%, metal and machinery industry 10%
“There are a variety of educational opportunities as well as many networking situations where I have broadened my industry contacts with suppliers, partners and end users. The IFR has been a strong advocate for our industry bringing awareness to crucial areas to insure visibility and awareness of the benefits of automation and service robots in various markets. The IFR offers the opportunity to exchange information and create alliances or partnerships.”
“The industry is experiencing technical breakthroughs in many areas like human robot collaboration, mobility, and artificial intelligence. The IFR is the globally central point to stay informed about these and other trends. The key advantages of our involvement with the IFR have been and continue to be, education, networking, research and advocacy.”
Innovative Apps Significantly Improve Manufacturing Capabilities, Efficiencies, and Financials for Both End Users and Systems Integrators
OptoForce, a robotics technology provider of multi-axis force and torque sensors, announced that it has developed three new applications for KUKA industrial robots.
The new applications are hand guiding, presence detection, and center pointing and will be utilized by both end users and systems integrators. Each application, listed below, is also supported by new videos to demonstrate how they work.
With OptoForce’s Hand Guiding application, KUKA robots can easily and smoothly move in an assigned direction and selected route. This video shows specifically how to program the robot for hand guiding.
This application allows KUKA robots to detect the presence of a specific object and to find the object even if it has moved. Visit here to learn more about presence detection.
With this application, the OptoForce sensor helps the KUKA robot find the center point of an object by providing the robot with a sense of touch. This solution also works with glossy metal objects where a vision system would not be able to define its position. This video shows in detail how the center pointing application works.
“OptoForce’s new applications for KUKA robots pave the way for substantial improvements in industrial automation for both end users and systems integrators,” said Ákos Dömötör, CEO of OptoForce. “Our 6-axis force/torque sensors are combined with highly functional hardware and a comprehensive software package, which include the pre-programmed industrial applications. Essentially, we’re adding a ‘sense of touch’ to KUKA robot arms, enabling these robots to have abilities similar to a human hand, and opening up numerous new capabilities in industrial automation.”
End users and systems integrators will recognize two major business benefits from these new applications:
Performing New Automation Tasks in Manufacturing
For end users, this development provides new automation capabilities for the KUKA robots when using these applications - saving inspection and rework resources, and decreasing manufacturing costs. Automating precision-oriented tasks not previously possible will translate to higher quality and greater efficiency in production, therefore helping companies become more competitive in global markets.
For systems integrators, this means implementing applications with OptoForce sensors that will enable them to automate complex/precise tasks, accept more orders, and acquire more customers. Customers are more satisfied as well with the substantial rise in quality.
Providing Simpler and Quicker Integration Due to Software Package
Another major benefit is that the software package is a catalyst for the robot system integration, as the pre-programmed applications simplify the process, accelerating it approximately twenty percent. Simplified integration leads to less programming and documentation, enabling systems integrators to offer a quicker, more cost-efficient service to their customers.
Sales in service robots for professional use will increase 12 percent by the end of 2017 to a new record of 5.2 billion U.S. dollars. And the long-term forecast is positive too, with an expected average growth rate of 20 to 25 percent in the period 2018 - 2020.
“In terms of value, the sales forecast 2018-2020 indicates a cumulative volume of around 27 billion U.S. dollars for the professional service segment”, says Gudrun Litzenberger,
General Secretary of the IFR. “Robots for medical, logistics and field services are the most significant contributors.”
At the same time, the market for personal service robots which assist humans in their everyday lives is also progressingrapidly; it is projected that sales of all types of robots for domestic tasks –e.g. vacuum cleaning, lawn mowing or window cleaning - could reach an estimatedvalue of around 11 billion U.S. dollars (2018-2020).
“Robots are clearly on the rise, in manufacturing and increasingly in everyday environments”, says Martin Hägele, IFR Service Robot Group.” The growinginterest in service robotics is partly due to the variety and number of new start-ups which currently account for 29 percent of all robot companies. Furthermore, large companies are increasingly investing in robotics, often through the acquisition of start-ups.”
Service robot manufacturers and start-ups by regions
European service robot manufacturers play an important role in the global market: about 290 out of the 700 registered companies supplying service robots come from Europe.North America ranks second with about 240 manufacturers and Asia third with about 130.
Further progress will rely on entrepreneurs taking up disruptive technologies and deploying them for new applications and markets. In the US, about 200 start-up companies are working on new service robots. The European Union plus Switzerland count 170 companies that are creating a new entrepreneurial culture for the service robotics industry - followed by Asia with 135 start-ups. Virtually all economies are attempting to foster a vibrant entrepreneurial environment and the service robotics industry has become one of the focus areas of their public policies.
Service robotics market overview
Robotics in professional applications has already had a significant impact in areas such as agriculture, surgery, logistics or public relations and is growing in economic importance. There is a growing demand to monitor our everyday surroundings which results in increased and difficult-to-manage workloads and data flows. To meet this demand, robots will play an even greater role in the maintenance, security and rescue markets.
Robotics in personal and domestic applications has experienced strong global growth with a limited number of mass-market products: floor cleaning robots, robo-mowers and
robots for edutainment. Future product visions point to domestic robots of higher sophistication, capability and value, such as assistive robots for supporting the elderly, for helping with household chores and for entertainment.
About World Robotics Reports by IFR
The IFR Statistical Department publishes two robotics studies each year:
World Robotics - Service Robots: This unique report provides global statistics on service robots, market analyses, case studies and international research strategies on service robots. The study is jointly prepared with our partner Fraunhofer IPA, Stuttgart.
World Robotics - Industrial Robots: This unique report provides global statistics on industrial robots in standardizedtables and enables national comparisons to be made. It contains statisticaldata from around 40 countries broken down into areas of application, industrialsectors, types of robots and other technical and economic aspects. Production,
export and import data is listed for selected countries. It also describes thetrends in relation to robotic density, e.g. the number of robots per 10,000 employees in relevant sectors.
Europe and North America home of most service robotics manufacturers
Today, the strongest growth in the robotics industry is in Asia – lead by China as the world´s number one marketplace. In 2017 robot installations are estimated to increase by 21 percent in the Asia-Australia region. Robot supplies in the Americas will surge by 16 percent and in Europe by 8 percent.
Important drivers of this development: robot adoption is a response to faster business cycles and the requirement to produce with greater flexibility tailored to customer demand in all manufacturing sectors. A new generation of industrial robots will pave the way for ever more flexible automation. “Robots offer high levels of precision and their connectivity will play a key role in new digital manufacturing environments,” says Joe Gemma, President of the International Federation of Robotics. “Increasing availability enables more and more manufacturers from companies of all sizes to automate.”
Industrial robots in operation
In terms of units, it is estimated that by 2020 the worldwide stock of operational industrial robots will increase from about 1,828,000 units at the end of 2016 to 3,053,000 units. This represents an average annual growth rate of 14 percent between 2018 and 2020. In Australasia the operational stock of robots is estimated to increase by 16 percent in 2017, by 9 percent in the Americas and by 7 percent in Europe. Since 2016, the largest number of industrial robots in operation has been in China. In 2020, this will amount to about 950,300 units, considerably more than in Europe (611,700 units). The Japanese robot stock will slightly increase in the period between 2018 and 2020. About 1.9 million robots will be in operation across Asia in 2020. This is almost equal to the global stock of robots in 2016.
TOP five markets in the world
There are five major markets representing 74 percent of the total sales volume in 2016: China, South Korea, Japan, the United States and Germany. China has significantly expanded its leading position as the largest market with a share of 30 percent of the total supply in 2016. With sales of about 87,000 industrial robots China came close to the total sales volume of Europe and the Americas combined (97,300 units). Chinese robot suppliers continued to expand their home market share to 31 percent in 2016.
South Korea is the second biggest market in the world. Due to major investments by the electrical and electronics industry in robots, annual sales increased considerably. About 41,400 units were sold in 2016. This is a rise of 8 percent compared to 2015. South Korea has the highest level of robot density in the world, about 630 robots installed per 10,000 employees in the manufacturing industry in 2016. Korea is a market leader in LCD and memory chip manufacturing.
In Japan robot sales increased by 10 percent to about 38,600 units (2016), reaching the highest level since 2006 (37,400 units). Japan is the predominant robot manufacturing country. Since 2010, the production capacity of Japanese robot suppliers has increased in order to meet the growing demand for industrial robots: production more than doubled from 73,900 units in 2010 to 152,600 units in 2016 (52 percent of the global supply in 2016).
In the United States robot installations increased by 14 percent to a peak of 31,400 units (2016). The driver for this continued growth since 2010 was the ongoing trend to automate production in order to strengthen the competitiveness of American industries in overseas markets. Investments have been made to keep manufacturing at home, and in some cases, to bring back manufacturing that had previously been relocated overseas. Due to this dynamic development, the robot density in the United States increased considerably – in particular in the automotive industry. With a density of 1,261 installed robots per 10,000 employees the United States ranked second in 2016 after the Republic of Korea. Most of the robots in the USA are imported from Japan, Korea and Europe.
Germany is the fifth largest robot market in the world and by far the largest in Europe. The annual supply and operational stock of industrial robots in 2016 had a share of 36 percent and 41 percent respectively of total robot sales in Europe. In 2016, the number of robots sold increased slightly to 20,039 units compared to 2015 (19,945 units).
Future trend: smart factory
Industry 4.0 - linking the real-life factory with virtual reality - will play an increasingly important role in global manufacturing. As obstacles like system complexities and data incompatibility are overcome, manufacturers will integrate robots into factory-wide networks of machines and systems. Robot manufacturers are already developing and commercializing new service models: these are based on real-time data collected by sensors which are attached to robots. Analysts predict a rapidly growing market for cloud robotics in which data from one robot is compared to data from other robots in the same or different locations. The cloud network allows these connected robots to perform the same activities. This will be used to optimize parameters of the robot’s movement such as speed, angle or force. Ultimately, the advent of big data in manufacturing could redefine the industry boundaries between equipment makers and manufacturers.
Future trend: small-to-medium-sized manufacturers to automate
Some robot manufacturers are also considering leasing models, particularly in order to accelerate adoption by small-to-medium-sized manufacturers. Simplification is a key trend for this market segment. The ongoing need for robots which are easier to use and to program and the increasing need for ever more flexible automation initiated the development of smarter solutions. This is especially useful for industries with a lack of specialized production engineers in-house. Thus, it is important to provide easy-to-use robots that can easily be integrated into and operated in standard production processes. Robots that are uncomplicated to use will enable the deployment of industrial robots in many industries to sustain efficient and flexible manufacturing.
IFR World Robotics 2017 Industrial Robots is published and it shows bright prospects for the robotics industry. Since 2010, the demand for industrial robots has accelerated at an increasing rate. By 2020 more than 1.7 million new industrial robots will be installed in factories around the world. What are the reasons for this successful development?
Faster business cycles, a requirement to respond to greater variety in customer demand, market pressure and the challenge of reducing emissions are issues common to all manufacturing sectors. Robot adoption is a response to these and other challenges, enabling companies to improve productivity of labor and capital by improving output per worker. Additionally, this allows for increasing production efficiency while cutting waste and increasing energy efficiency. Robots can work around the clock, offer high levels of precision and improve worker health and safety by performing dangerous and unergonomic tasks. Robots products continue to broaden including becoming smaller, more affordable and easier to program. This more easily accommodates for high-mix, low-volume models that are increasingly the norm in all manufacturing sectors. Robots now are more viable for small-to-medium-sized manufacturers for whom the capital investment cost of industrial robots and programming complexity have so far presented obstacles. The increasing availability and competitive pricing of collaborative robots - small, mobile, dexterous and easily programmable robots that work outside of cages and generally together with a human worker – enables manufacturers to automate short or mixed production runs that require high levels of precision and sophisticated vision and handling capabilities.
Creating high paying and skilled jobs has been a wonderful side benefit of automation. In fact, there is no evidence to support the notion of robots as job killers. The robots might be coming - but they are not coming for our jobs. Instead, there is clear evidence that humans will remain central to effective automation strategies which are key to improving productivity and economic growth. As in the past, this wave of technological change will alter job profiles. The evidence points to this mostly being in the direction of higher-skilled, higher-paid work force. We need more robots, not less of them, and our focus must be on ensuring current and future workers are equipped to work with them.
Established in 1987, IFR has brought together the international robotics players in more than 20 countries. It is a unique platform for sharing information and exchanging ideas, thus contributing to the dynamic development of the robotics around the world. The role of IFR is becoming more and more important for further global development of robotics in the future. CRIA is proud to be part of this international robotics family.
"The International Federation of Robotics is here to provide a reliable and highly trained professional network for the robotics community. By sponsoring the International Symposium on Robotics (ISR), the IFR stands as a major driver for researchers and engineers from around the globe, allowing them to present their pioneering works in service and industrial robotics."
China has rapidly become a global leader in automation. From 2018 to 2020, a sales increase between 15 and 20 percent on average per year is possible for industrial robots. Annual sales volume has currently reached the highest level ever recorded for a single country: Within a year, sales in China surged by 27 percent to 87,000 units (2016).
The operational stock of industrial robots marks the highest level in the world. At the same time, Chinese robot manufacturers expand the market share in their home country. “China is by far the biggest robot market in the world regarding annual sales and regarding the operational stock,” said Joe Gemma, President of the International Federation of Robotics (IFR). “It is the fastest growing market worldwide. There has never been such a dynamic rise in such a short period of time in any other market.”
Electrical and electronics industry are the main drivers
The main drivers of the latest growth in China are the electrical and electronics industry. Sales increased by 75 percent to almost 30,000 units (2016). About one third of the robots were produced by Chinese robot suppliers, who more than doubled sales by almost 120 percent. All international robot suppliers also increased sales considerably to the electrical and electronics industry (+59 percent). This remarkable demand will further grow in the future. Major contract manufacturers of electronic devices have already started to automate production. The semiconductor and the chip industries, for example, have strongly invested in automation. Large battery production facilities are being installed to meet the increasing demand for electric and hybrid cars.
Car industry lost its pole position
The automotive industry lost its pole position to the electrical and electronics industry, but is still a powerful driver for industrial robot sales. China has become both the world’s largest car market and the world’s largest production site for cars – including electric cars - with much growth potential. Sales to China made up 25 percent of the global supply of industrial robots to the automotive industry in 2016. Between 2011 and 2016, a total of 108,000 units were installed, representing an average increase of 18 percent per year. The market share of Chinese robot suppliers in the automotive industry is still on a rather low level but has increased from 10 to 13 percent. China is the largest growing consumer market with increasing demands for all kinds of consumer goods. Consequently, various other industries have also started to expand capacities and automate production.
Some international robot suppliers have already launched production plants in China and in all likelihood more will follow suit in the coming years. Most industrial robots in China are imported from Japan, Korea, Europe, and North America.
China outlook 2020
The Chinese government wants to transform China from a manufacturing giant into a world manufacturing power according to the ten-year national plan “Made in China 2025”. The plan includes strengthening Chinese robot suppliers and further increasing their market shares in China and abroad. China intends to forge ahead and make it into the world’s top 10 most intensively automated nations by 2020. By then, its robot density is targeted to rise to 150 units – this being the number of industrial robots per 10,000 employees. Today, Asia is the leader regarding robot density is South Korea, with 531 robot units. In the Americas, it is the USA with 176 robot units and in Europe, it is Germany with 301 robot units.
IFR China data overview
Please find below an overview of the new IFR preliminary data about industrial robots in China:
China – new peak in 2016
87,000 new robots installed (thereof, about 27,000 from Chinese suppliers), 27% more than in 2015
CAGR 2011-2016: +31%
Global ranking 2016: No. 1
Shares of total supply:
Handling operations 45%, welding 26%
Electrical/electronics industry 35%, automotive industry 30%
Stock of operational robots
About 340,000 units, 33% higher than 2015
CAGR 2011-2016: +36%
Global ranking 2016: No. 1
These are results published by the International Federation of Robotics (IFR) ahead of the World Robotics Report 2017 to be released on September 27th.
OptoForce, a robotics technology provider of multi-axis force and torque sensors, today announced that its HEX-70-XE-200N and HEX-70-XH-200N are both being renamed and have been enhanced with several new product developments in July. Although several new features are being added, the price point for the sensors will remain the same.
The HEX-70-XE-200N will now be branded as HEX-E and the HEX-70-XH-200N will be branded as HEX-H. Both models are part of OptoForce’s 6 axis F/T sensor family, which provides measurement in 6 axes. HEX-E offers higher precision while HEX-H provides lower deformation.
In addition, the following product enhancements have been made:
Each sensor will get increased overload protection - instead of having an overload capacity of two times, the sensors will now be strengthened to five times overload.
New integrated (built-in) sensor mounting plates are being added now making the product compatible with ABB. (The sensors have been and are fully compatible for Universal Robots and KUKA robots).
In addition, OptoForce is introducing a new compute box. This new platform allows for full compatibility with all robot types. The compute box provides a new interface that eliminates the need for an Ethernet or EtherCat. Also, with the compute box capability, computing capacity will be higher.
A new stronger cable clamp (90 degrees) has been added to improve the durability of the cable, further decreasing the chance of it breaking
Calibration was developed to advance sensor precision.
The hardware design was modified so that during sensor mounting, the axes of the sensor and the axes of the robot overlaps.
The 13th Innovation and Entrepreneurship in Robotics and Automation Award (IERA) was presented to the Relay butler robot. Made by Savioke, an American company, the little robot completes deliveries all on its own, for example in hotels, hospitals or logistics centers.
Thanks to artificial intelligence and sensor technology, Relay can move safely through public spaces and navigate around people and obstacles as necessary.
“The IERA Award is one of the most important distinctions in the world of robotics today,” said Joe Gemma, President of the International Federation of Robotics (IFR). “This year’s award winner, Relay, perfectly exemplifies how research and development can successfully work hand in hand with industry.” The International Federation of Robotics (IFR) and the IEEE Robotics and Automation Society (IEEE/RAS) jointly sponsor the annual IERA award.
“This year once again, we received a large number of truly exceptional applications,” said Erwin Prassler, Vice President of the IEEE-RAS. “In the end, the jury was unanimous in its decision. This award is a testament to the excellent work by California-based Savioke led by its CEO, Steve Cousins. Steve Cousins and Savioke have developed the core technology in professional service robotics to a readiness level which enables a 24/7 operation in public, human inhabited environments.”
“Relay is the first fully autonomous delivery robot worldwide that is able to navigate safely through human-occupied spaces,” said Steve Cousins, CEO of Savioke. “Up until now, similar technologies have been limited to fixed routes, or deployed only in closely defined spaces. Our highest aim is always to create robots that can help people. The interaction should be as friendly and pleasant as possible.”
The Relay robot is barely three feet tall, with a slender 18-inch torso. It communicates with its surroundings via touchscreen, smart phone and sounds. Additionally, the robot is equipped with friendly, easy to understand facial expressions. A transport compartment is located at the top of the robot. The Relay robot can activate elevators on its own while delivering, making it well suited for performing deliveries in building complexes such as offices, hospitals or hotels. The ‘botler’ can deliver drinks, medication or towels, just like a human butler. When the job is done, Relay returns automatically to its docking station.
The first Relay models were deployed three years ago in the hotel industry. The second stage of deployment was in apartment and industrial buildings. Savioke robots have already completed over 100,000 deliveries in the United States, Asia and the Middle East. Relay is slated to come to Germany and France in the near future.
The IERA Award 2017 winners were selected by a jury comprised of high-ranking IFR and IEEE-RAS members. A total of four finalists were recognized this year for their innovative solutions. The other three finalists were:
Marco Hutter, ANYbotics AG, ANYdrive: A modular joint actuator for advanced interacting robots
Jody Saglia, Movendo Technology s.r.l.: Hunova - an easy to use and intuitive medical device
György Cserey, OptoForce Ltd: Sensing flexibility - 3D force and 6-axis force/torque sensors for industrial robotic applications
Chicken or egg? - By going digital of assembly systems, this famous question will soon be cleared up. SCHUNK is beginning to digitalize its entire gripper range and thus paves the way for virtual commissioning and simulation of complete handling solutions.
With the aid of the mechatronics concept designer from Siemens PLM Software and the Digital Twins from SCHUNK, designers and systems planners will soon be in a position to simulate complete assembly systems in 3D and virtually depict the entire engineering process from the concept to mechanics, electronics and software, right up to commissioning. Instead of the classical CAD cover model, a detailed digital image of the individual components appears, including their full functionality. The Digital Twin comprises the CAD volume model with all geometric data for modeling in Siemens NX, CAE data (EPLAN), and a kinematic behavior model in which the stroke, extension and retraction speed, acceleration, jerk, nominal force and mass are stored. In addition, SCHUNK seeks to extend its Digital Twins in a second step in the future with a range of PLC components for virtual commissioning (software/hardware in the loop).
Clear shortening of project duration
The integrated engineering with the aid of virtual simulation enables systems constructors and users a significant shortening of project duration, faster commissioning and clear efficiency effects for repeated implementation of similar systems. All relevant planning steps from calculation of the cycle times to designing the components with respect to traverse path and stroke as well as collision calculations can be completely virtually covered by the engineering software. Besides savings of 30% on pure engineering time, systems constructors and users also benefit from a significantly reduced project duration. Instead of only beginning programming after physically assembling the system, as had normally been the case until now, all individual processes can be systematically coordinated, programmed and optimized in the form of relative conditional rules using the virtual model. Furthermore, the virtual model forms the basis for follow-up and realtime control in ongoing production. In the first step, SCHUNK digitalizes its 24V mechatronics range for high-performance assembly. It comprises the parallel grippers SCHUNK EGP and EGL, the linear modules SCHUNK ELP, the rotary gripping modules EGS and the rotary modules ERS. The data can be requested from SCHUNK directly.
For over 15 years HK-CON Maschinenbau GmbH has been designing and building high-tech metal cutting machines at its Fulda site. HK-CON recently realised a complete installation for Georg Fischer Fittings GmbH, manufacturer of cast iron fittings.
Besides replacing three previous installations, it satisfies the high customer expectations with regard to productivity and achieves exemplary cycle times despite its extremely complex design. Four Yaskawa handling robots are responsible for feeding: two Motoman MH12 and two Motoman MH5 robots, each of them operated with a DX 200 high-performance control.
At HK-CON Maschinenbau GmbH over 60 employees design and construct turning centres at a production plant of almost 4,000 m². Its product range comprises one- to two-spindle turning and milling centres which can be used, among other things, for turning, grinding or milling. About 99% of customers call for complete systems that can be integrated into their processes. In addition, the Fulda-based high-tech company offers professional services for the design and maintenance of machines. Customers from the automotive industry also employ HK-CON solutions. As David Reinmold, Head of Sales, assures: “Our solutions enable reductions of over 50% in unit costs, particularly in large-scale manufacturing, resulting in a drastic cut in overall production costs.” That also has an economic component: the lower unit costs once again make it profitable to produce in central Europe.
For Georg Fischer Fittings GmbH, based in Traisen/Austria, HK-CON has designed and constructed a complete machining centre for manufacturing malleable cast iron fittings. The challenge presented by the project: the installation was to be capable of manufacturing a total of 35 different final products – with an extremely low cycle time of five seconds per unit for the part with the shortest cycle time. Furthermore, it was critical that only absolutely immaculate parts be delivered to the cutting machine. That is the task assigned to the four Yaskawa Motoman robots – two MH 12 and two MH5 models – working in concert with the DX200 high-performance controls. They are supported by a camera system with a total of 6 cameras. The control software employed here is the MotoPlus SDK. As an interface it is responsible for communication with the cameras and regulates cooperation with them.
35 possible final products
In simplified terms, the facility has two turning centres located opposite to one another. Upstream of each of these are two Motoman robots. The robots are arranged cross-wise: the same models are situated bottom left and top right, and vice versa. This configuration has proved to be effective in achieving the necessary working range for loading – the machines could not be located closer together for work safety reasons.
The facility has a bunker for bulk material and a feeding bench for special parts, which are inserted in the correct orientation via pallets. The system can be operated either double-sided by mass feeding or one-sided for special parts, and the parts are delivered already sorted. Georg Fischer GmbH produces a total of nine different cast iron fitting components with this facility. The different sizes result in a total of 35 different final products. Hitherto, three of their own systems were required for their manufacture. Retooling times are only incurred in the new HK-CON system when a different component has to be machined. For the most part, varying sizes can be inserted without further conversion.
Robots and cameras work together
Three cameras are situated on each side, close to the robots. The first of these tell the Motoman robots where and how the parts are delivered and whether they are the desired components. Unwanted parts can already be eliminated at this point. If it is a required component, the camera inspects it for major defects and communicates the exact orientation and position to the robot. The robot now has all the information needed to pick it up. Once it has completed this step, it scans the part for casting defects, and in the case of doubt deposits it in a crate. If the part is free of defects, the handling robot moves to the next camera and rotates it three to four times, so that it can check all six to eight sides. At this point the camera checks whether sprue remains on the component. Here again, the robot has an opportunity to reject it. In addition, the camera recognises the orientation of the parts, enabling the robot to deposit them either in a subsequent turning station or directly on a belt conveying them to the next robot.
Correct parts which are flawless and lie in the right position are conveyed to the next robot. The third camera checks the position and angle of rotation. Finally, the second robot picks up the part from the outside and transfers it to the turning centre. Each of the two machines at the turning centre is two-spindle. This enables each of the two cutting machines to work two parts simultaneously and eject four finished parts, i.e. parts with the shortest cycle time, every 20 seconds. The machine runs 690 shifts per year. In this time it must produce a predetermined number of cast iron fittings.
If a different component is to be worked, a fitter may need to replace the robot jaws or adjust the delivery system. The different programs were taught, i.e. programmed, by HK-CON. The fitter only needs to select them. Every second counts in mass production. The system can be retooled in only one hour per side. Only half an operator is needed to operate the system.
Fast, precise, stable
“Because cast iron is difficult to handle, designing the system was also a challenge for us. However, with Yaskawa’s Motoman robots MH12 and MH5, the respective DX200 controls and the MotoPlus SDK software to coordinate the camera, we succeeded in designing the feed system so that at the end only high-quality parts arrive at the turning centres for machining,” explains David Reinmold. “We built a highly flexible system with higher productivity. It operates very fast, with highest precision and stability, and requires less operating personnel.”
At the time of placing the order, the customer specified that the system should be equipped with Yaskawa handling robots. One of the reasons for this was the good price-performance relationship of Yaskawa products; the other was that exclusively Yaskawa robots had hitherto been used throughout the plant, and the employees had already been trained to use them.
Thanks to HK-CON’s complete installation for metal cutting, Austrian malleable cast fittings manufacturer Georg Fischer GmbH was able to replace three old machines. For smooth running production it is important that only absolutely immaculate components be delivered to the turning centres. With the Yaskawa Motoman robots (two MH12 and two MH5 models) the DX200 controller and the MotoPlus interface for coordination of the cameras, the installation achieves precise results with extremely short cycle times. In addition, the system is highly flexible: a total of 35 different final products can be manufactured.
The manufacturer of collaborative robots has developed online training modules to further lower the automation barrier. The hands-on modules are offered free of charge, open to all, and built to deliver hands-on learning via interactive simulations to maximize user engagement.
Learning how to set up and program a collaborative robot – or cobot – no longer depends on real life access to a robot or a training class. Now everybody with a desire to learn the concepts of cobots can log in to the Universal Robots Academy and get the introduction necessary to master basic programming skills.
CTO and founder of Universal Robots, Esben Østergaard, explains that it is unusual in the industry to make a robot training curriculum of this kind available for free. “But this is a long-term investment for us. We want to raise the robot literacy and the reason for speeding up the entry of cobots is not only to optimize production here and now,” says Østergaard. “We are facing a looming skills gap in the manufacturing industry that we need to bridge by all means possible. Facilitating knowledge creation and access to our robots is an important step in that direction.”
The online training modules are available in English, Spanish, German, French and Chinese and consist of six e-learning modules that make up the basic programming training for UR robots. This includes configuring end-effectors, connecting I/Os, creating basic programs in addition to applying safety features to an application.
One of the early adopters of the Universal Robots Academy is the Whirlpool Corporation where the online training modules now provide the basic foundation for all UR robot training at the company’s plant in Ohio, USA. Tim Hossler, Controls Engineer at Whirlpool, emphasizes the great convenience of being able to offer this resource to employees in-house: “Now we don’t have to wait and send them out for basic training elsewhere. The modules can be completed at our own pace and we can even pick and choose which modules we offer different personnel depending on skill sets and their level of interaction with the robots,” says Hossler. “I really like the interactive approach, it makes learning very hands-on and transferable to what we would actually be doing here at our plant. I was also pleasantly surprised that the modules were free of charge for anyone to use. It definitely increases the accessibility of the UR robots.”
Stefan Stubgaard, Global Product Manager at Universal Robots, says that the academy modules have received positive feedback from users around the world: “This learning resource is now also reaching small and medium-sized manufacturers that up until now regarded robotics as costly and complex, says Stubgaard. “By simply logging into the Academy they experience first-hand how simple the setup can be and they can easily envision what production tasks could be automated with the cobots. We will definitely be adding more modules to complement our basic offering going forward.”
MRK-Systeme GmbH, Augsburg, Germany, specializes in industrial solutions that are based on human-robot collaboration. The company enables direct human-robot collaboration – without the need for safety fencing. The 16 employees of the company, which was founded in 2004, work primarily for customers in the field of mechanical engineering, with a particular focus on the automotive industry.
The factory of the BMW Group in Landshut has one of the most modern light-metal foundries in the world. The crankshaft housings for the entire BMW fleet are manufactured in Landshut, irrespective of whether the engines have three, four or six cylinders. BMW wished to automate the process at the factory in Landshut in order to safeguard the quality of the crankshaft housings. This quality assurance process cannot, however, be automated in its entirety. Skilled personnel are still required to keep a watchful eye on proceedings. For this very reason, the assignment issued to MRK-Systeme GmbH was to develop a system in which humans and robots cooperate directly. This safeguards the well-being of the employees, who no longer need to move heavy components. “Human-robot collaboration ensures that the employees at BMW are relieved of ergonomically unfavorable tasks,” explains Michael Mohre, Head of Operations at MRK-Systeme GmbH, who plays a decisive role in the installation of automation systems. For 18 months now, two identical applications have been in operation at the BMW production line in Landshut, Bavaria. Each application includes one KUKA robot of type KR 210 R2900 prime K from the KR QUANTEC series, specializing in high payloads. The K indicates the shelf-mounted variant of the robot. In this application, an employee controls the movement of one robot by means of a joystick in order to maneuver the components into a position that allows them to be inspected for faults without the need for the employee to deviate from a natural posture.
Every crankshaft housing is inspected
Each crankshaft housing that is manufactured is delivered into the workspace by a conveyor. Depending on the design (three, four or six-cylinder engine), the higher-level controller selects the appropriate program to control the movement of the robot. Once the crankshaft housing reaches the robot’s workspace, the worker controls the movement of the robot using the joystick. This sees the robot move towards the housing along a defined path, close the gripper and bring the component to the operator. The worker then inspects the component for faults using a cold light lamp. All the while, the robot securely holds the component weighing roughly 30 kg at the optimum height for the employee. Once the operator has completed the inspection process, he moves the robot with the housing back to the conveyor belt and sets the housing down. The interactive inspection process is then ended by pressing a button. In doing so, the employee documents whether the part is “OK” or “not OK”.
The requirement: to be as safe and as user-friendly as possible
In the case of direct cooperation between human and machine, the safety of the employees is always the main priority. Three mutually independent safety devices ensure maximum safety at the work station. The safety system consists of a programmable logic controller (safe PLC), which also controls the gripper in a safe manner, a safe robot controller, which limits the robot to certain speeds within workspaces, and an enabling switch. The robot cannot move at all unless the employee holds down the enabling switch. If the employee lets go of the switch, the robot stops immediately. Straightforward operator control is also crucial for ensuring that human-robot collaboration (HRC) is practical. The system is implemented in such a way that it is easy for both right-handed and left-handed employees to control the robot. Furthermore, the operator can master the robot control functions intuitively. If the employee pushes or pulls the joystick handle forwards/backwards, the robot moves in a parameterized direction. If the joystick is moved to the left or right, the robot realigns itself accordingly. The height of the crankshaft housing in relation to the worker can also be adjusted using a thumbwheel.
Ergonomics: a decisive factor
Up to now, the quality inspection was carried out using an “aero wheel”. The crankshaft housing was rotated using an aero wheel and brute strength so that it could be inspected for faults from all sides. The inherent problem: the aero wheel is heavy. Moreover, tall workers in particular had to stoop over during every inspection which could result in back injuries. The objective was to come up with an application that relieved the employees of ergonomically unfavorable tasks, was easy to control and adhered to the short cycle times required. “Our robots are predestined for the specific requirements put forth by BMW because they can be deployed flexibly. In addition, it is easy to reprogram the robots if changes are made to components. What’s more, they offer good value for money,” explains Mohre, whose company works exclusively with KUKA products. Both of the KUKA KR QUANTEC series robots that are used in the application have a payload capacity of 210 kg. The KUKA KR QUANTEC series, which forms part of the company’s high payload segment, specializes in quick cycle times and the highest level of path accuracy.
Plans to expand the existing system
Both systems have been in operation since 2015. Time to sum up the results: “We have been able to meet all of the customer’s expectations. The cycle time requirements have been met and the employee’ tasks are now far more enjoyable,” says Mohre. Mohre and his colleagues are now working on plans to expand the system. There are plans to install another two quality assurance test stands in order to keep up with the increase in production. “The new applications will be identical to the existing applications with the sole exception that some new features will be incorporated,” Mohre reveals. In addition to the success achieved with this application, the system also demonstrates that collaboration between humans and robots is both useful and safe.
The Dutch supplier Korte Friesland does precision welding in a quality which in some cases is barely achievable manually.
Despite the many modifications, they were unable to achieve the required precision with their previous welding robot. For that reason a Valk Welding robot system with offline programming had been at the top of their wish list for some time. The supplier now has a universally usable welding robot system that both positions the components and welds them with the required level of precision.
Top quality welding and the precise machining of large parts are what the professionals at Korte Friesland do best. As well as tooling for Aerospace the supplier also works for OEMs in the agricultural sector, machinery manufacturers and the simulator industry. They confidentially leave the production of their frames and critical parts for their machines to this Frisian supplier. “With a reliability of supply above 95% and a maximum of 0.4% rejection we are now supplying 3-metre rotors for grass mowers with a tolerance within 1 mm. It is only because of our investment in this Valk Welding robot system that we are able to achieve this precision and quality”, says owner Henk Korte.
Korte Friesland has shown with its quality assurance certificate ISO 3834-2 that it is able to meet the strictest welding requirements. “Our experienced welders are happy to take on complex orders. The internal training plan and the certification of our welders result in consistently high welding quality, says company manager Samuel Oberman. Oberman is an International Welding Specialist and is responsible both for the welding process and the quality assurance aspect. “All of the welders and materials are certified and registered in the manufacturing manual. This makes it possible for us to trace who made the weld. The next step is to also certify the welding robot. Registrating the settings and the conditions makes it possible to predict the quality of the weld. Getting this data in correct format makes it possible to attract new business”, explains Oberman.
Universally deployable welding robot system
Although the welding robot system is now used mainly for the production of the rotors, the system is suitable for a wide range of products with a length up to 9m. For this purpose Korte Friesland has made its own mobile welding fume extraction system and the fixed screen. The Panasonic TL- 2000WG3 on a track now serves 2 separate jig supports with a length of 4 metres. “Removing the middle section and relocating the positioners makes it possible for us to weld longer components. We also have 2 jig supports at the back for small products. This makes the system very flexible, which places it perfectly in line with our machinery for metalworking”, says Samuel Oberman.
Offline was an important requirement
Henk Korte: “We started by looking into how a number of colleague companies tackled welding robotisation. Valk Welding’s robots with offline programme appealed to us the most. DTPS is more than just a programming system: we also use it to design our welding jigs and to plan the welding jobs. With our other welding robot we often had to spend a couple of days on programming a complex product online. The welding robot had to be taken out of operation during that time. With the Valk Welding robot system we not only achieve the required precision, but also gain a lot of time.”
Korte Friesland uses the welding robot for several rotor types. For one of them 128 mounting brackets have to be welded around a 3m tube. Valk Welding has developed a gripper system that is situated next to the welding torch. Each bracket is taken off a shelf and held at the pre-programmed position on the shaft so that the robot can attach it. Samuel Oberman: “Because of the heat distribution aspect, the welding order is very important to remaining within the runout. The sequence is laid down in DTPS, for which we have divided the rotor into small sections that are welded alternately. It is only barely possible to organise that division manually.”
For another type of rotor corner lines are welded to the tube with 345 small welds. As well as the welding order, finding the welding position of the corner lines is a vital aspect of the welding process with the welding robot. For this purpose use is made of the Quick Touch wire search system that Valk Welding has integrated in DTPS. The robot relocates the 3 to 4 corner lines. Wire searching is based on the gas nozzle searching system, but uses the welding wire rather than the gas nozzle as the ‘sensor’. The big advantage of this wire search method is that it is not only possible to detect all weld forms: access is improved to areas that are difficult to reach and the detection works with both thin and thick plates.
By investing in the welding robot system Korte Friesland has secured an important part of its turnover. “The products are now in line with the requested specifications and we have also been able to substantially step up our productivity. We used to weld 5 to 6 rotors a day, but this has now risen to 8 a day. And the next orders for the welding robot are already in the pipeline”, concludes Henk Korte. www.kortefriesland.nl
The number of robots installed by the French car industry rose 22 percent to 1,400 units – compared with 700 units in the UK (+ 7 percent). The automotive sector is one of the main driving forces modernizing the French economy: with a robot density of 940 units per 10,000 workers, France currently ranks 2nd within the European Union - the UK ranks 10th with 606 units.
French investments in machinery accelerate
In France, investment in machinery and equipment are accelerating at a faster pace than the overall economy. The frontrunners here are the dynamic showcase industries, such as automotive: annual robot sales to the automotive industry as a whole increased by an average of 7 percent per year between 2010 and 2015. During the same period, the motor vehicle sector ordered on average 6 percent more robots per year and the demand from automotive parts suppliers increased by 9 percent. Since 2010, governmental initiatives to strengthen production in France have resulted in significant investments by the automotive industry. The two French automotive suppliers, PSA and Renault, will further invest in new car models, energy efficient cars, common platforms and also modernize their factories. Both companies have already successfully restructured to insure their position for increased productivity to meet the demand. Automotive parts suppliers will benefit from investments by the automotive industry in France as well as from the improving car market in Europe.
Automotive companies face up to Brexit
It is not unfair to assume that the decision to leave the EU will influence investment decisions by foreign car companies on production sites in the UK. For example, Japanese auto makers such as Toyota, Nissan and Honda export more than three quarters of their vehicles built in Britain, and most of these exports go to other European countries. Were they to have to pay duty on the shipments of goods, they might decide to move out of the UK. We assume, however, that the UK government will develop regulations and supporting measures to avoid this. In any case, there are currently frequent announcements on investment plans concerning capacity expansions and modernization by foreign and local automotive companies. Investments in the general industry sector should also gain momentum. The development of robot installations in the next few years depends on the question “if and when” these planned projects will actually be implemented in the country. This said, it can be assumed that investments planned by domestic manufacturers will most likely go ahead and that and that modernization, as well as a strengthening of their overall competitiveness, will continue unabated.
Robots support competitiveness and employment in Europe
“The positive impact of robots on European competitiveness and employment can be seen in Germany,” said Joe Gemma, President of the International Federation of Robotics. “The country´s automotive sector, for instance, holds the top position for robot density in Europe - with about 1,150 industrial robots per 10,000 employees. As a result of the ongoing trend to automate production, employment in the German car industry rose by about 93,000 jobs to 813,000 during the period 2010 to 2015.” In France, modernization and digitalization of production systems is increasingly likely to involve small and medium enterprises over the coming years. The country´s main strength lies in industrial software and networking objects which could positively impact the implementation of new production concepts and create scope for employing innovative machinery and equipment and likely create new opportunities for skilled labor.
This paper provides the IFR’s opinion on the impact of automation - specifically of robots - on productivity, competitiveness and employment. IFR is not a policy institute. However, this report includes the main conclusions from a variety of experts on appropriate policy responses to ensure ongoing positive outcomes from automation and the ongoing development and uptake of robots, with which we concur.
Driving the increase in public interest in robotics and automation is both a fascination with the potential of these technologies to change our lives, and a fear of the impact of automation – including robotics – on jobs. These fears are tied into broader geo-political and social shifts driven by issues such as trade policy and immigration that, overall, contribute to a sense of insecurity about the employment prospects of current and future generations. Consequently, many headlines focus on the potential negative outcomes of automation. This risks overshadowing the very real positive contributions of automation and robotics to productivity, competitiveness and job creation. In addition, it could undermine discussion and action on the measures that should be taken to enable countries, organizations, and individuals to reap the benefits of automation.
The Association for Advancing Automation (A3) announced that the Automate 2017 show and conference broke all previous attendance records with show attendance of 12,960 people, which is a 37 percent increase over 2015. With the collocated ProMat and ProFood Tech attendees taking advantage of free entry, well over 20,000 people visited Automate.
The show is North America’s premier biennial event devoted to leading-edge automation technology and business innovation. Automate featured more than 400 exhibitors displaying their latest technologies and services, including global suppliers of robotics, motion control, motors, vision systems, metrology, software and system integration services for enterprises large and small. In addition, over 1,000 attendees participated in the 120+ Automate conference sessions, which were held in conjunction with the International Symposium on Robotics – Americas, a greater than 90 percent increase over 2015.
“Automate has firmly established itself as the leading automation show in North America,” said Jeff Burnstein, president of A3. “This year’s record attendance demonstrates the growing global demand for the entire ecosystem of automation technologies and services.”
Automate features key automation industry business leaders and has become the primary event for breaking automation news. The show opened with a jobs forum titled “Working in the Automation Age,” featuring speakers from A3, Amazon, Advanced Robotics for Manufacturing (ARM) Institute, RAMTEC Ohio, and FANUC. In conjunction, A3 released a white paper exploring how companies like General Motors and Amazon continue to grow their workforce even as they add automation technologies.
First-Ever Chinese Participation
Automate 2017 also garnered increased international participation. For the first time, 13 Chinese automation companies exhibited, reflecting China’s dramatic growth in robotics implementation and development. A first-ever joint US-China Robotics Forum brought together leaders from the Robotic Industries Association (RIA) and its counterpart, the China Robot Industry Alliance (CRIA).
Launch Pad Startup Competition
A3 announces Apellix as the winner of the Automate Launch Pad Startup Competition. Sponsored by GE, the competition provided eight innovative startup companies with an opportunity to generate awareness of their technology and find new sources of funding. Apellix offers a Platform-as-a-Service for industrial workers performing critical but dangerous tasks. The patent-pending Apellix Worker Bee robotics system physically interacts with and modifies its environment to move workers out of harm’s way. The $10,000 prize will allow Apellix to bring their product to market sooner.
Automate 2017 Reflections
Automate brings together business leaders from every facet of the automation industry providing opportunities to meet customers, network and showcase solutions.
“Automate was a great show,” said Staubli robotics division manager, Sebastien Schmitt. “Staubli couldn’t hope for a better event to meet new prospects. The customer traffic in our booth the entire show was excellent!”
Date Set for Automate 2019
A3 has also announced the date and location for Automate 2019. It takes place April 8-11 at Chicago’s McCormick Place.
“A3 anticipates that demand for exhibition space for Automate 2019 will be even higher than prior years,” added Burnstein. “We expect to run out of space well before the event.”
Participants and exhibitors can find more information about Automate 2019 at the event website: www.automateshow.com.