DLR and KUKA demonstrate simple and flexible automa-tion solutions for the assembly of metal structures us-ing the KUKA LBR iiwa lightweight robot. The shop-floor worker can instruct the assembly process on the shop floor by just showing the desired arrangement without the need for complex manual robot programming. The assembly process is automatically planned and convert-ed into a robot program for execution. Dexterous skills based on the robot's capabilities allow the uncertainties of a real SME environment to be addressed.

Still today many assembly tasks are performed manually because of the human's unmatched flexibility. Assembly automation solutions often prove to be too complex and only worth the engineering and installation efforts for large series production. When assembly is automated, in general several assembly stations are needed instead of one manual workplace. Changing the assembly line from one product to the next is time-consuming and usually requires careful re-engineering and reprogramming. This is costly and, therefore, leads to shifting assembly production into low-wage countries.

Taking a closer look at manufacturing processes in SMEs, they often have a product portfolio that is assembled from a limited pool of parts. Thus, it is possible to cus-tomise a basic concept and provide individual solutions to the customers. The assembly task for every product however is different.

It is the aim of the exhibit to demonstrate that the as-sembly of customised products can easily be automated using advanced planning methods and intelligent, com-

pliant robot systems. Thus, a robotic assembly station can be re-configured in short time without extensive downtimes and complex manual programming by ex-perts.

As an example for industrial applications, the exhibit shows the automatic assembly of aluminium profiles from the well-known ITEM system using a KUKA LBR iiwa lightweight robot with a two-finger gripper. In order to show flexibility, the user only has to demonstrate the arrangement. Starting from the resulting CAD model, the assembly sequence is automatically planned and transformed into a robot program. The transformation incorporates grasp and motion planning skills as well as force-controlled alignment and peg-in-hole skills. As an example for the integration of joining technologies into the assembly process, an automatic screwdriver is used to connect the profiles. Therewith fast and efficient adaptation of assembly workcells is possible and can be demonstrated with inherent flexibility of ITEM profiles.

The SMErobotics project not only supports the develop-ment of advanced methods for planning and handling of robots, but also aims for the integration of components, towards a flexible and easy-to-use system. The exhibit gives a first glance on how robots can aid a worker at assembly tasks. It demonstrates how the definition of robotic assembly tasks can be transferred to the domain of non-experts, combining object recognition as well as assembly, motion and grasp planning with automatic program generation and compliant robot skills.

The combination of the integrated technologies reveals

Easy automation of assembly tasks by automatic planning and program generation using the KUKA LBR iiwa lightweight robot

a large innovation potential for utilising robotic co-work-ers in SMEs and small lot-size production settings. The demonstrated system might be used by SMEs to support the usage of robots for small lot-sizes without spending a large amount of money for installation and configura-tion of new robot workcells and tasks. The flexibility which is supported by planning algorithm and code generation can be used at SMEs even without employing robot pro-gramming experts. The exhibit shows the application and usage by a job-floor worker who might only change parts of the program in an easy and intuitive manner. All the remaining complex programming steps are transferred to a powerful software system.

The long-term goal of the DLR Institute for Robotics and Mechatronics is based on the idea of relieving man from inhuman and dangerous tasks and of enabling access to hitherto non-reachable places. Three vision-ary space scenarios are the starting point for research: the development of orbital service satellites capable of performing maintenance work in space autonomously

or telecontrolled, the robonaut as robotic assistant of astronauts for establishing infrastructures in space as well as autonomously flying, driving, and walking robot systems for the exploration of far-off planets.

The institute has also a long history in the development and usage of compliant lightweight robots for industrial and service applications. It was always a goal of DLR to develop new robotic concepts that enable an easy and safe cooperation between human and robot.

Within the SMErobotics consortium, the institute in-troduces its expertise in assembly and grasp planning, automatic program generation, and in the handling of force-controlled, compliant robots.

The mission to establish the robot as an intelligent help-er, able to support humans by virtue of its high-quality work, is something that KUKA has been fulfilling for a long time with its industrial robots. In the field of service robotics, we are now pursuing a new, far-reaching vi-

sion. As a bringer of the latest technologies from KUKA's research, the LBR iiwa is now a trailblazer for totally new forms of cooperation between humans and machines. LBR stands for “Leichtbauroboter” (German for light-weight robot), iiwa for “intelligent industrial work assis-tant”. The robotic innovation with sensory capabilities for safety, fast teaching and simple operator control, opens up new areas of application in the vicinity of humans that were previously off-limits for robots.

These features make the LBR iiwa especially interesting for the use cases in SMErobotics. In this exact area the robots will be able to work no longer as a machine, but as a co-worker to the human in production. Teaching the robot directly in its own workspace and even collabora-tion with the robot during manufacturing processes is made possible by utilising the sensors and the software features of LBR iiwa. KUKA is striving to remove the need for external safety systems and the separation of hu-mans and robots.

New ideas as those in the SMErobotics project can only be developed by those who dare to push back the bound-aries. To realise visions, these ideas must also be imple-mented with skilled partners. That's why KUKA is particu-larly proud of its longstanding partnerships in industry and research in order to implement ground-breaking ideas – working ideas. In addition, KUKA plays a major role in actively shaping the future of robotics through its membership of the European robotics association, eu-Robotics AISBL. Furthermore, competitions such as the KUKA Innovation Award aim to motivate young scientists and enterprises in the field of service robotics to make their contribution to the robotics of tomorrow.

Together, DLR and KUKA have the goal to bring safe and compliant robots to the shop-floor of SMEs, towards a smart robot assistant that aid the worker at his work sta-tion.

About DLR Institute of Robotics and MechatronicsThe Institute of Robotics and Mechatronics of the German Aerospace Center (DLR) is located in Oberpfaffenhofen, near Munich. Mechatronics is the closest integration of mechanics, electronics and information technology for the realization of “intelligent mechanisms” which in-

teract with their environment. The core competence of the institute is the development of complex mechatronic systems and human-machine interfaces. In the robot-ics community, the institute is considered as one of the world leading institutions. The application of technology and systems developed in the institute are focusing pri-marily on the programmatic tasks in the research area space. The developed technologies have direct impact and applications in other societal areas such as medi-cal robotics, factory of the future, and personal robot assistance. Technology transfer is a major goal of the institute, with its 200 employees it is the largest entity within the DLR Robotics and Mechatronics Center (RMC).

About KUKA Laboratories GmbHKUKA Laboratories GmbH, based in Augsburg, is a glob-ally active subsidiary of the KUKA Group. The core com-petences of the company are the development and sale of service and medical robotics products. KUKA is already one of Europe's leading providers of professional ser-vice robotics and robotics for the key players of medical device manufacturers. KUKA Laboratories is engaged in research and development cooperation with renowned customers, institutes and universities around the world. The subsidiary develops basic technologies for the KUKA Group as a whole.

Facts about SMEroboticsThe SMErobotics initiative, www.smerobotics.org, con-sisting of major European robot manufacturers and leading research institutes, is developing and maturing technical foundations for productive and intelligent ro-bot solutions that are feasible in small-to-medium-scale production settings and will showcase some of these at AUTOMATICA 2014 on booth 131 in hall A4. We strive to bring cognitive robotics to the shop-floor, facilitating the use of automation and robot technology to improve the competitiveness of small and medium-sized enterprises (SMEs) in assembly, woodworking and welding scenarios.

Project full title: “The European Robotics Initiative for Strengthening the Competitiveness of SMEs in Manufac-turing by integrating aspects of cognitive systems”

Grant Agreement Number: FP7 – IP 287787

SMErobotics partners:

Fraunhofer-Institut für Produktionstechnik und Au-tomatisierung (IPA)

COMAU S.p.A.

DLR – Deutsches Zentrum für Luft- und Raumfahrt e.V.

DTI – Danish Technological Institute

GPS Gesellschaft für Produktionssysteme GmbH

GÜDEL AG

KUKA Laboratories GmbH

Reis GmbH & Co KG Maschinenfabrik

fortiss – An-Institut der Technischen Universität München

Lund University – ULUND

For specific questions related to SMErobotics do not hesitate to contact us:

SMErobotics Project Secretariat Thilo Zimmermann and Björn Kahl GPS Gesellschaft für Produktionssysteme GmbH

Nobelstr. 12 70569 Stuttgart Germany

Phone: +49 711 687031-42 secretariat@smerobotics.org

www.smerobotics.org www.twitter.com/SMEroboticsEU www.facebook.com/SMEroboticsEU www.youtube.com/user/SMEroboticsEU

The European Robotics Initiative for Strengthening the Competitiveness of SMEs in Manufacturing by integrating aspects of cognitive systems