presentazione standard di powerpoint - hkstp · • a network of 29 operative centers located in 17...

COMAU OVERVIEW

1 Team

29 Locations

40 Years experience

4 Innovation centers

15 Manufacturing plants

17 Countries

127 PMI® certified

project managers

14,500 Employees worldwide

FACTS & FIGURES

Czech Republic

Poland

U.S.A.

Mexico

Argentina

Brazil

Romania

U.K.

France

Germany

Spain

Italy

China

Russia

India

Thailand

Industrial operation Engineering Innovation Center

COMAU IN THE WORLD

ROBOTICS OVERVIEW

• A major player in the manufacturing of High Quality Industrial Robots

• Wide range of Standard Products and fully Integrated Solutions

• >40 years experience in Automation

Manufacturing Plants

• Kunshan – China

• Turin – Italy

R&D Center

• Turin – Italy

• Kunshan – China

• Pune – India )

ROBOTICS: WHAT WE CAN OFFER

Our Offer tailored to Your needs:

• “Naked” robots

• Peripherals

• Application packages

• Ready To Use cells

• Turn Key Solutions

• After Sales Service

ROBOTS FOR GENERAL & SPECIAL PURPOSE

With a strong history in the AUTOMOTIVE

INDUSTRY, we have continued to grow,

and today we offer our skills and

know-how to a wide range of INDUSTRIES

and APPLICATIONS

COMAU is a leading GLOBAL provider of advanced

manufacturing systems, INNOVATIVE sustainable

automation and service SOLUTIONS

COMAU VISION

• A network of 29 OPERATIVE

CENTERS located in 17

COUNTRIES, led by global

processes

• 70% resources in BRIC countries

• GLOBAL PROJECT

MANAGEMENT based on PMI®

standards, customized for local

market needs and cultures

• THE BEST AUTOMATION COMPETENCE

across a wide range of key technologies

• PLUG & PLAY SOLUTIONS PROVIDER

• FULLY INTEGRATED CAPABILITY in product,

process and service solutions

• HIGH DENSITY AUTOMATION cells

to hone and optimize investments

• ENERGY SAVING products and

service solutions

• LEAN PRODUCTION APPROACH

Global Solution oriented

Innovative

OUR DISTINCTIVE STRATEGY

AUTOMATION MEGA TRENDS

Ageing society Sustainability

Near shoring

Internet of things

Increasing wage levels in emerging

countries

Growth by Robot - based automation

July

2013 Property of Comau - Duplication prohibited

Grassi 02/04/2014

Comau Robotics :

industrial robots for flexible

production and not structured

environments

July


Examples of Comau R&D

Projects for industry 4.0

• AUTORECON (completed in September 2014): AUTOnoumous co-

operative machine for highly RECONfigurable assembly operations of the

future

• SME Robotics: the European Robotic initiative for strengthening the

Competitiveness of SMEs in manufacturing integrating aspects of cognitive

systems

• X-act : Automatic and flexible mechanical assembly

July


AUTORECON

July


AUTORECON: project

overview

The increasing need for High Mix and Low Volume (HMLV) production pushes the

industry to investigate new solutions for increasing flexibility [4] [7]. Technologies that

need to be developed and integrated to do this involves

• Reconfigurable tools to enable autonomous and flexible assembly

equipment to adapt production process to process/market variations.

• Intelligent, Control and Monitoring systems enabling enhanced performance

and high level reconfigurability of production processes

• Open integration and communication architectures to allow easier integration

and networking of the control systems utilizing agent-based, web-services

and ontology technologies.

July


Project AUTORECON:

scenario definition

The demo scenario was created in order to prove the feasibility of an autonomous and

flexible production line which will be able to reconfigure dynamically according to the

current situation.

The demonstrator took place at TOFAS (Bursa, Turkey).

Two different zones have been setup: a loading area and a welding area.

Into the loading area a mobile robot (composed by and industrial antropomorphic robot

and a mobile platform designed by TECNALIA use a dexterous gripper to collect all the

components of the assembly and prepare it for the welding procedure.

Into the welding area a fixed robot perform the welding operation. In the demo scenario

a fault situation has been simulated: when this happens the mobile robot can move to

the welding area and substitute the ”‘faulty”’ robot, so the welding procedure is not

interrupted.

July


Project AUTORECON: final

test video

July


SME

ROBOTICS

July


D1 work-cell flow for gear box assembly

Assembly planner (WP5) – task level

Interaction manager (WP1)

Skill execution engine (WP2)

Sensor based control (WP2)

Skill DB

C5G open (robot drive)

Mapping task to skill (WP1)

(XML_task_file)

(CAD, config_file, Assembly_file)

Situation

assessm

ent

and

exception h

andle

r (W

P1/W

P2)

(XML_file)

Process model (WP3) (CAD,

workcell)

Knowledge integration services (WP4)

July


D1 Semantic-level integration implementation

Definition of task should be intuitive allowing the user to define the process and subtask in a semantic way

This is an example of the approach used on D1:

'Put the bearing on the mechanical pipe’

Definition of subtask in the GUI by worker

Definition of process in the GUI by worker ‘Assembly gear box’

Motion planner (Program execution)

Skill execution engine (State machine)

Skill DB (XML files)

July


D1 Workcell

Hardware setup

• Smart dual arm robot

• C5G and C5G open controller

(LPC)

• Vision system

• F/T sensor

• Safety eyes device

• Kinect camera

• Automatic screwdriver

• Tool changer

• Handling system (gripper,

fingers, tray)

• Projector

• Leap motion

https://youtu.be/mdD7Z_nwUuA

https://youtu.be/mdD7Z_nwUuA

July


Implementation: Uncertainty handling/reuse of

knowledge

Sensor based approach is the main resource in D1 to face the uncertainties of the process (workpiece tolerances, object detection, etc). The information gathering is based on IT chain that for D1 foresees the use of C5G open, eORL an COMAU ROS node.

Sensor Uncertainty Task

Vision system Object position Detection on working area

Force torque sensor Object position, workpiece tolerance

Contact task (Peg in hole)

Grippers encoders Object presence/grasping Object and grasping detection

Screwdriver encoders workpiece tolerance Screwing task

rml_itasc_force_reduct.mp4

July


D1– Time-line for this year

Activity Partners involved

Result Time-line

Complete integration of cognitive functionalities

COMAU, RTD partners

Complete integration and testing on real process of several SW module (IM, SA, Skill engine, SOAD)

M46

Deployment COMAU, TOFAS

Complete deployment on COMAU site of real process of gear box and ABS unit assembling

M47

Assessment COMAU, TOFAS

Comparison between current manual assembling and new implementation

M48

Anticipated risk Likelihood Contingency

Difficulties on adapting an automatized solution to a mechanical part designed for a manual assembling.

40% Robust testing phase. Adjustment of mechanical part for a robotics solution

Hardware and software failure (vision system, force control, grippers)

30% Robust and redundant implementation

July


X-ACT

July


X-Act: project Goal

Starting from a manual user case the target of WP2 Hydraulic pump assembly

is focused on hybrid operation that foresees an interaction between robot and

human: with a new fenceless approach permits to share the same working

space in a safe environments.

A sensor based platform as well the presence of several tool and devices

allows to accomplish delicate tasks also for automatic case.

July


X-Act: cell design

36

Cell layout

Cell

implementation

and integration

July


Handling devices

37

Grippers

• Schunk PG70

• Recommended workpiece weight: 1kg

• Max gripping force: 200N

• Min gripping force: 30N

• One per each arm

• Profibus communication

• Position, Velocity, and force gripping

Fingers

Customized fingers have been designed and

built in order to grasp all the parts. The two

arms present two different fingers: this dual

approach allows the execution of different

tasks with dedicated features.

July

2013 Property of Comau - Duplication prohibited 38

In order to explore and discover new solutions a new

gripper, called VERSABALL has been tested, applying it

on pick place mounting tasks of the hydraulic pump.

The core principle behind VERSABALL is the jamming

phase transition of granular materials. The green ball is

filled with a sand like material. When air is pumped into

the ball, the ball softens. The ball is then pushed against

the target object. Pulling air out of the ball jams the

sand like material together, causing the ball to harden.

This transition from soft to hard creates the gripping

forces.

Gripping Forces

Different object shapes have very different gripping

dynamics and as a result very different grip strengths.

Friction from pinching, entrapment or capture, and

vacuum suction are all possible grip forces.

Handling devices

IMG_0498.MOV

July


In order to reach a high flexibility, has been

integrated on the system a pneumatic tool

change device controlled by a bi-stable electro

valve (placed on the axis 4 of the robot) and

managed by I/Os

RSP TC20-4

Tools: tool changer

July


Tray and table

A tray has been designed and built in order to

hold the base of pump permitting the stacking of

several assembling parts.

Tools: tray and table

DUAL_DEF_14.m4v

July


Screwing is a very challenging task for robotized system. The

solution adopted in Hydraulic pump assembling foresees an

industrial servo nut-runner

with a dedicated controller that permits to have a wide range of

screwing application as well as the possibility to adopt and change

the tools for several type of screws or bolt. The communication

between C5G and nut-runner controller is managed by I/Os. The

arm 1 takes charge of the screwing process (using the tool

changer for the specific task).

ESTIC ENRZ-TU003

Tools: screwing system

July


Further improvements and device integration are carried out on Smart

dual arm for the executing of assembling tasks of Hydraulic pump;

Basically the vision system is used in the process for two main tasks:

• Robot guidance for components recognition

• Detection of anomaly and recovery on the process

A camera CORSIGHT NET has been evaluated and selected for the

scenario

The new advantage of this solution is the ease of use and the

integration of the vision application directly into the C5G system with a

dedicated page an GUI (HTML) in the TP.

Vision system

July


Taking advantage from the Open C5G controller (LPC), a new architecture for force control has

been developed, in order to accomplish assembling tasks in which contact between robot and

other components of the process is requested.

The Hardware of this architecture foresees:

• LPC (open controller)

• Powerlink connection

• F/T sensor ATI FTN-GAMMA-SI 32-2.5 and controller

• Mechanical flange

In the tests carried out has been used

the modality 5 and 7 of Open

controller and a loop of 400ms (same

of the internal one in C5G controller).

Force Control Sensor

July


The Safe camera system by PILZ, allows to define and manage safety zones around the

robot. It allows creating danger zones around the robot (which stop directly the robot) as well

as warning areas (that can be used for example to modify the robot behaviour).

Safety System: Safety Eyes

July


Several configurations have been tested. The one chosen for the demo project foresees 3

different zone arrangement: each zone is used for a specific task in the process sequence.

The switching from one zone to another is managed by a algorithm written in PDL2 that runs

into the C5G controller. The signals $DIN[15], $DIN[16], $DIN[17] and $DIN[18] are used to

trigger the several steps of the process activating or deactivating the different zones

arrangement.

Safety System: Safety Eyes

July


Kinect has been integrated in order to create a

redundant system with safety eyes that allows the

worker to cooperate with the robot in a safe way.

In particular the Kinect device is able to monitoring

the presence of the worker limiting the robot speed

according to 3 different thresholds (distance from

operator and robot). The Kinect is used when

cooperation mode is active (zone arrangement 2

of safety eyes).

The control algorithm, called safe_area are

developed using OpenCV and OpenNI library and

are managed inside the LPC of controller using

Linux OS. The information between LPC and APC

area managed with a TCP/IP protocol.

Flow chart of safe area algorithm:

Safety System: Kynect

July


The final architecture for safety chain is showed below: Safety eyes and Kinect are

used in parallel in order make more robust and flexible the cooperation between human

and robot enhancing the functionality of safety system.

Safety approach

Safety System: use

ComauSafetyVision_LAST.mp4

July


• All parts are on the working table

• Vision system detects all parts

• The Arm 1 grasps the first object (pump base) putting it into the tray

• Vision system detects the screw holes on the triangle of pump base orienting it in a

appropriate way

• The Arm 1 grasps the second object (steel cover)

Assembly task

July

2013 Property of Comau - Duplication prohibited 49 49

• Vision system detects the screw holes on steel cover and Arm 1 orient it in order to

align the holes with pump base

• Arm 2 Pick screws from the the customized support and fastens them

• Arm 1 grasps the third object (aluminum circle)

• Vision system detects the screw holes on the aluminum circle

Assembly task

July


• Arm 1 corrects it orientation alligning the holes with triangle base taking advantage of

F/T sensor to execute the task

• Arm 2 Pick screws from the the customized support and fastens them

https://youtu.be/YvGSyVdiBtk

Assembly task

https://youtu.be/YvGSyVdiBtk

July


COMAU S.p.A. Via Rivalta, 30

10095 GRUGLIASCO (TO)

ITALY

www.comau.com

Property of Comau - Duplication prohibited

Via Rivalta, 30

10095 GRUGLIASCO (TO)

ITALY

COMAU S.p.A.

presentazione standard di powerpoint - hkstp · • a network of 29 operative centers located in 17...

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