Increasing cost pressure in industrial productions, shorter lifecycles and high product diversity call for flexible cost-effective assembly systems that can be easily adapted to changing requirements. The ability to freely program robots makes them extremely adaptable but they do not possess either sensors or intelligence. Therefore, to meet market demands, sensors and analysis algorithms need to be incorporated into robots. Experts at Fraunhofer IPA develop sensor-controlled assembly processes to replace expensive devices, thus improving flexibility and cost-efficiency in assembly.
Do you have manual assembly processes in your company which cannot be automated due to tolerances and inaccurate positioning? Or are your automated assembly processes not running as smoothly as they should because of tolerances and inaccurate positioning? Then get in touch with us. In a personal meeting, we can discuss the possibilities of integrating sensors into your company’s assembly processes.
Fraunhofer IPA adapted the lightweight robot KUKA LBR iiwa to enable it to screw a coupling onto the crankshaft of a chain saw. The couplings to be assembled are placed in the robot’s work space without the use of special equipment. The robot uses a fixed 3D camera mounted overhead to locate the approximate position of the coupling; it then approaches this position and identifies the exact position of the coupling with the aid of a stereo camera integrated into the robot tool. The assembly position, i.e. the crankshaft, is located in the same way, thus enabling the motor block to be flexibly positioned in the working area. Force control is used to fit the coupling onto the crankshaft and screw it on. This allows other tolerances to be compensated for. Errors occurring during the screwing process, e.g. canting, are also recognized and remedied directly.