A Methodology for Flexible Implementation of Collaborative Robots in Smart Manufacturing Systems

Small-scale production is relying more and more on personalization and flexibility as an innovation key for success in response to market needs such as diversification of consumer preferences and/or greater regulatory pressure. This can be possible thanks to assembly lines dynamically adaptable to new production requirements, easily reconfigurable and reprogrammable to any change in the production line. In such new automated production lines, where traditional automation is not applicable, human and robot collaboration can be established, giving birth to a kind of industrial craftsmanship. The idea at the base of this work is to take advantage of collaborative robotics by using the robots as other generic industrial tools. To overcome the need of complex programming, identified in the literature as one of the main issues preventing cobot diffusion into industrial environments, the paper proposes an approach for simplifying the programming process while still maintaining high flexibility through a pyramidal parametrized approach exploiting cobot collaborative features. An Interactive Refinement Programming procedure is described and validated through a real test case performed as a pilot in the Building Automation department of ABB in Vittuone (Milan, Italy). The key novel ingredients in this approach are a first translation phase, carried out by engineers of production processes who convert the sequence of assembly operations into a preliminary code built as a sequence of robot operations, followed by an on-line correction carried out by non-expert users who can interact with the machine to define the input parameters to make the robotic code runnable. The users in this second step do not need any competence in programming robotic code. Moreover, from an economic point of view, a standardized way of assessing the convenience of the robotic investment is proposed. Both economic and technical results highlight improvements in comparison to the traditional automation approach, demonstrating the possibility to open new further opportunities for collaborative robots when small/medium batch sizes are involved.

Analysing Factory Workers’ Acceptance of Collaborative Robots: A Web-Based Tool for Company Representatives

Collaborative robots are a new type of lightweight robots that are especially suitable for small and medium-sized enterprises. They offer new interaction opportunities and thereby pose new challenges with regard to technology acceptance. Despite acknowledging the importance of acceptance issues, small and medium-sized enterprises often lack coherent strategies to identify barriers and foster acceptance. Therefore, in this article, we present a collection of crucial acceptance factors with regard to collaborative robot use at the industrial workplace. Based on these factors, we present a web-based tool to estimate employee acceptance, to provide company representatives with practical recommendations and to stimulate reflection on acceptance issues. An evaluation with three German small and medium-sized enterprises reveals that the tool’s concept meets the demands of small and medium-sized enterprises and is perceived as beneficial as it raises awareness and deepens knowledge on this topic. In order to realise economic potentials, further low-threshold usable tools are needed to transfer research findings into the daily practice of small and medium-sized enterprises.

A Human-Following Motion Planning and Control Scheme for Collaborative Robots Based on Human Motion Prediction

Human–Robot Interaction (HRI) for collaborative robots has become an active research topic recently. Collaborative robots assist human workers in their tasks and improve their efficiency. However, the worker should also feel safe and comfortable while interacting with the robot. In this paper, we propose a human-following motion planning and control scheme for a collaborative robot which supplies the necessary parts and tools to a worker in an assembly process in a factory. In our proposed scheme, a 3-D sensing system is employed to measure the skeletal data of the worker. At each sampling time of the sensing system, an optimal delivery position is estimated using the real-time worker data. At the same time, the future positions of the worker are predicted as probabilistic distributions. A Model Predictive Control (MPC)-based trajectory planner is used to calculate a robot trajectory that supplies the required parts and tools to the worker and follows the predicted future positions of the worker. We have installed our proposed scheme in a collaborative robot system with a 2-DOF planar manipulator. Experimental results show that the proposed scheme enables the robot to provide anytime assistance to a worker who is moving around in the workspace while ensuring the safety and comfort of the worker.

Egocentric Gesture Recognition Using 3D Convolutional Neural Networks for the Spatiotemporal Adaptation of Collaborative Robots

Collaborative robots are currently deployed in professional environments, in collaboration with professional human operators, helping to strike the right balance between mechanization and manual intervention in manufacturing processes required by Industry 4.0. In this paper, the contribution of gesture recognition and pose estimation to the smooth introduction of cobots into an industrial assembly line is described, with a view to performing actions in parallel with the human operators and enabling interaction between them. The proposed active vision system uses two RGB-D cameras that record different points of view of gestures and poses of the operator, to build an external perception layer for the robot that facilitates spatiotemporal adaptation, in accordance with the human's behavior. The use-case of this work is concerned with LCD TV assembly of an appliance manufacturer, comprising of two parts. The first part of the above-mentioned operation is assigned to a robot, strengthening the assembly line. The second part is assigned to a human operator. Gesture recognition, pose estimation, physical interaction, and sonic notification, create a multimodal human-robot interaction system. Five experiments are performed, to test if gesture recognition and pose estimation can reduce the cycle time and range of motion of the operator, respectively. Physical interaction is achieved using the force sensor of the cobot. Pose estimation through a skeleton-tracking algorithm provides the cobot with human pose information and makes it spatially adjustable. Sonic notification is added for the case of unexpected incidents. A real-time gesture recognition module is implemented through a Deep Learning architecture consisting of Convolutional layers, trained in an egocentric view and reducing the cycle time of the routine by almost 20%. This constitutes an added value in this work, as it affords the potential of recognizing gestures independently of the anthropometric characteristics and the background. Common metrics derived from the literature are used for the evaluation of the proposed system. The percentage of spatial adaptation of the cobot is proposed as a new KPI for a collaborative system and the opinion of the human operator is measured through a questionnaire that concerns the various affective states of the operator during the collaboration.

Human-Following Motion Planning and Control Scheme for Collaborative Robots Based on Human Motion Prediction

Human-Robot Interaction (HRI) for collaborative robots has become an active research topic recently. Collaborative robots assist the human workers in their tasks and improve their efficiency. But the worker should also feel safe and comfortable while interacting with the robot. In this paper, we propose a human-following motion planning and control scheme for a collaborative robot which supplies the necessary parts and tools to a worker in an assembly process in a factory. In our proposed scheme, a 3-D sensing system is employed to measure the skeletal data of the worker. At each sampling time of the sensing system, an optimal delivery position is estimated using the real-time worker data. At the same time, the future positions of the worker are predicted as probabilistic distributions. A Model Predictive Control (MPC) based trajectory planner is used to calculate a robot trajectory that supplies the required parts and tools to the worker and follows the predicted future positions of the worker. We have installed our proposed scheme in a collaborative robot system with a 2-DOF planar manipulator. Experimental results show that the proposed scheme enables the robot to provide anytime assistance to a worker who is moving around in the workspace while ensuring the safety and comfort of the worker.