Future Trends in Robotics - Cloud Object StorageSingh+Rathee+-+Kuka+Robotics.pdf · Future Trends...

Future Trends in

Robotics

Commercial Vehicle Megatrends India 2012

Raj Singh Rathee

KUKA Robotics (India) Pvt. Ltd.

[email protected]

www.kuka.in

mailto:[email protected]

http://www.kuka.in

www.kuka-robotics.com

Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 3

Introduction

Automotive Industry faces right now the

largest period of growth in history:

REE’s (Rapidly Emerging Markets):

• China

• India

• Brazil

• Russia

• Malaysia

• Mexico

• Indonesia

China has already replaced the US as largest

automotive market in the world

In the “Rapidly Emerging Markets” the

sales volume will be six times larger in

2018

370 Mio. new cars up to 2013

715 Mio. New cars up to 2018

Increasing industrialization and per-capital-

income will dramatically increase the car

sales volume in general

http://www.kuka.biz/



Introduction

Actual production in India

0

100,000

200,000

300,000

400,000

500,000

600,000

700,000

800,000

2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11

Commercial Vehicles




Introduction

To meet the requirements of a cost-effective mass-

production the automotive industry worldwide will

have to develop new body shop and production line

concepts:

shorter production lines with higher robot density to

minimize the required floor space

shorter cycle time and faster cell-to-cell transport to

increase the required through-put

higher availability to guarantee the daily output of the

body shop

cost-efficient and multi-functional equipment to reduce the

overall investment costs

cost-efficient solutions for standard processes and

integration of new processes for light weight bodies

lower life time costs specially in respect to energy

consumption




Content

Compact Production Lines

New Robot Generation for Future Body Shops

Lean and Cost Effective Cell Concepts

Multi-Functional Robot Controller

Energy-Efficient Production Lines

Sustainable and Energy-Efficient Robot Systems

Reduction of Floor Space, Cycle Time and Enhanced Safety

Safe Robot Technology




Compact Production

QUANTEC – The New Robot Generation




Compact Production: QUANTEC - Compact, Fast and Accurate Robots

The KUKA QUANTEC Series was especially designed

for the future requirements of a compact body shop

with highest output and shortest cycle time:

extremely compact design with 25 % less volume

intelligent material selection and latest casting technology

12 % weight reduction

30% reduced energy consumption

minimized interference contours for enhanced accessibility

very small foot print for maximum robot density

reduced weight, highest stiffness of the structural elements

and new control algorithms guarantee:

maximum dynamic and speed 25 % faster

highest repeatability ± 0.06 mm

highest path accuracy ± 0.15 mm




Compact Production: QUANTEC - Minimized Life Cycle Costs

The intelligent design and highly reliable components

used for the KUKA robot system reduce the operating

costs and the maintenance requirements drastically:

up to 30% less energy consumption during production

and stand-by

robust and wear free drive chain in axis 3 with straight

shafts and without belts

well proven durable SIEMENS motors and sophisticated

drive technology

oil change after 20.000 hours of operating time within 30

minutes

exchange of buffer batteries after 4 years

self-explanatory electronic mastering of all six robot

axes within 10 minutes

easily accessible mechanical interfaces for wrist

exchange within 30 minutes

very fast exchange of media supply without removing

the connectors through the 150mm hollow shaft




Compact Spot Robot – Increasing Robot Density

A significant reduction of the production area inside

a body-in-white requires an increased robot density

that can only be achieved with new robot concepts:

a new generation of extremely compact spot-welding

robots with a low overall height

these robots will be installed in front and between

standard or shelf-mounted robots

the reduction of the production area leads to:

increased energy-efficiency regarding the building

increased number of process jobs per m2 and

shorter throughput-time

reduction of non-value-adding transportation time

the KUKA CSR family

Reach approx. 1800mm

Height approx. 1300mm

Weight approx. 800kg

Payloads 180kg, 150kg, 120kg, 90kg




Compact Production: QUANTEC - Productivity Benchmark

0 200 400 600 800 1000 1200 1400 1600

Productivity / Cycles per hour

Po

wer

Co

nsu

mp

tio

n [

Wh

]

1000

2000

3000

4000

5000

6000

7000

Competitor

QUANTEC Productivity is a measure of the efficiency of a

production process and is measured as a ratio

of output per hour and costs per part:

the energy-efficient design of the KUKA robot

reduces the required energy per production cycle

compared to our competitors significantly

Reduction of costs per part at the

same production volume

Significant increase of production

volume without effects on the part

costs

Lower investment costs for a

cost-effective production

the unmatched speed and acceleration of the KUKA

robot allow shorter cycle times without a significant

increase in power consumption

0 200 400 600 800 1000 1200 1400 1600

Productivity / Cycles per hour

Part

Co

sts

/ E

nerg

y p

er

Part

[W

]

1

2

3

4

5

6

7

Competitor

QUANTEC

15%

20%




Compact Production: QUANTEC - Productivity Benchmark

Due to fluctuation in demand the production

volume often has to be adapted to meet the

market requirement immediately:

installing the new KUKA robot system guarantees

shorter cycle times and higher part throughput in

comparison to our competitors

Scalable productivity buffer due

to different robot models

Increased production capacities

for the same investment costs

Highest volume flexibility to react

on market fluctuations

flexible adaptation of the production volume

without adding additional robots and almost no

adverse effects on the part costs

Production Benchmark Program Automotive

45 55 65 75 85 95 105

Productivity / Parts per hour

Po

wer

Co

nsu

mp

tio

n [

Wh

]

500

1000

1500

2000

2500

3000

3500

Competitor

QUANTEC

QUANTEC

PRIME

+ 32%QUANTEC

EXTRA

+ 18%Competitors




Lean and Cost-Effective Production Concepts

Multi-Functional Robot Controller




SW-based

Closed Loop ControlDSE

SW-based

Safety PLC ESCSRDW

SW-based

ProfiNet / ProfiSafe CP1616 ET200S/F

KR C4 Controller: Software Replaces Hardware-Components

SW-based

Master-Stack MFC

SW-based

Main Contactor K1/2SW-based

Visualization VGA


http://www.google.com/imgres?imgurl=http://www.elektroradar.de/WebRoot/Store/Shops/ElektroRadar/Products/Images/82/0708682/671217_0708006.jpg&imgrefurl=https://www.preisroboter.de/ergebnis7501064.html&sortmode=1&usg=__KoaVxJ0amtXFOVyYBUEPsAlZevQ=&h=711&w=600&sz=40&hl=de&start=1&um=1&itbs=1&tbnid=vqO_qUIaUl4QTM:&tbnh=140&tbnw=118&prev=/images?q=sch%25C3%25BCtz&um=1&hl=de&tbs=isch:1

http://www.google.com/imgres?imgurl=http://www.der-pc-shop.net/catalog/images/VGA-KarteG9700pro.jpg&imgrefurl=http://www.der-pc-shop.net/catalog/default.php?cPath=56&usg=__O3OgTTDzXFZ04mfeZ9CIuM0bFSY=&h=243&w=300&sz=59&hl=de&start=1&um=1&itbs=1&tbnid=oNbz86AtcDyCNM:&tbnh=94&tbnw=116&prev=/images?q=vgakarte&um=1&hl=de&tbs=isch:1



KR C4 Controller: Software Replaces Hardware-Components

SW-based

Closed Loop ControlSW-based


SW-based

Safety PLC SW-based

Safety PLC ESCSRDW

SW-based

ProfiNet / ProfiSafeSW-based


SW-based

Master-Stack SW-based

Master-Stack MFC

SW-based

Main ContactorSW-based

Main Contactor K1/2

SW-based

VisualizationSW-based

Visualization VGA

SW-based



SW-based


Closed Loop ControlDSEDSE

SW-based

Safety PLC SW-based

Safety PLC ESCSRDW

SW-based

Safety PLC SW-based

Safety PLC ESCESCSRDWSRDW

SW-based



SW-based


ProfiNet / ProfiSafe CP1616CP1616 ET200S/FET200S/F

SW-based


Master-Stack MFC

SW-based


Master-Stack MFCMFC

SW-based


Main Contactor K1/2

SW-based


Main Contactor K1/2K1/2

SW-based


Visualization VGA

SW-based


Visualization VGAVGA

A powerful multi-core processor allows

the general replacement of formerly

hardware-based functionalities with

software-based tasks:

increase of system availability

smaller spare part stock

higher adaptability to customer’s requirements

30% more compact controller

35% reduction of controller hardware

components

50% reduction of controller cables and

connectors

The reduction of controller hardware

components results in a significant




Energy-efficient production

Sustainable and energy-efficient robot systems




Energy Efficiency: Development of energy prices

Development of Energy Prices (approx. 6% Inflation)

End Customer

Stock Exchange Price

Development of Energy Prices (approx. 6% Inflation)

End Customer

Stock Exchange Price

Source:

www.stromvergleich.de

Energy prices will definitely rise during the

coming years – it is only the exact magnitude

of this increase that cannot be predicted:

Within the service life of a robot system, the

energy price for the automotive industry will more

than double from €0.10 to €0.20 for 1 kWh.

As natural resources become scarcer, this will

affect energy prices. This is because the

development of competitive renewable energy

sources has only just begun.

Saving energy by installing energy-efficient robot

systems will be one new “source of energy”.

Incalculable energy costs as a corporate risk




Requirements for an energy management system that will

allow companies to reduce their energy consumption

systematically and continuously:

Reduced costs – Up to 10% of energy costs could be saved in

the first few years after implementation of an energy

management system.

Environmental protection – Efficient energy management is an

important element, as it can make a major contribution to the

reduction of greenhouse gas emissions.

Sustainable industry – New energy concepts and innovative

energy technologies are the key to operating successfully in the

market in the coming years.

Improved image – Ecological requirements are tending to play

a greater role in public image.

Energy Efficiency: Energy management systems in acc. with DIN EN 16001:2009

Energy-intensive companies can benefit

from legislative relief




Sustainable Product Development

Energy Efficiency: The Consequences

The Energy-Efficient Robot System

Involves all steps during planning, engineering and final design of the

robot system including materials and production processes

Supports the energy-efficient use of the robot system during the

complete life span by online condition monitoring

Considers the possibilities of recycling parts of the robot system or

the reuse of the complete system

Reduced power consumption during motion

Reduced power consumption during stand-by

Online monitoring of energy consumption during production

Report of energy consumption data to energy management

Strategies for an energy-efficient programming

Recuperation of brake energy


http://www.kukait.net/c0/Bilder/Bilder/Forms/DispForm.aspx?ID=3162



Engineering and design

12% weight reduction

30% reduction of volume

Sustainable materials

Supply chain logistics:

Innovative logistics concept

60% reduction of CO2 emissions

Robust robot systems:

Service life of more than 15 years

Repurchase of used systems

Energy efficiency: Sustainability throughout the entire life cycle

Energy efficiency on the shop floor

Up to 30% less energy consumption

in motion

Up to 80% less energy consumption

in standby mode







Energy Efficiency: Energy consumption in a car plant

Energy Consumption Plant

Paint Shop

Body Shop

Final Assembly

Press Shop

Components

Air Conditioning

Light

Water-cooling

Energy Consumption Body Shop

With an average share of 22 % less than one third

of the energy required in an automotive plant is

consumed in the body shop:

in the body shop approx. 50% of the energy is

consumed by the building including light, air

conditioning and water cooling

the other 50 % are consumed by robot

systems, process equipment, transportation systems

etc.

at an average only 5% of the plant-wide energy

demand is consumed by the robot systems

next to the possible energy savings that are possible

with the new generation robot systems the building

itself has the biggest potential for energy conservation

concepts

shorter and more compact production lines with

significantly increased robot density




In a typical tree-shift-production with a production

stop over the weekend the robot systems show

different levels of energy consumption:

Robot in Motion

19 % robot system is moving with an average

energy consumption of 2,5 kW to 3,5 kW

Robot is stopped 2sec to 20sec

10 % brakes are not activated with an average

energy consumption of 650 W to 800 W

Robot is stopped 20sec to 10min

26 % brakes are activated with an average energy

consumption of 220 W

Robot is stopped 10min to 3h



Robot is stopped over the weekend



Energy Efficiency: Energetic States of a Robot in Production

Energy consumption states of a robot

system in a three-shift-production

19%

10%

26%

17%

28%

Robot in Motion

Wait 2sec - 20sec

Wait 20sec - 10min

Wait 10min - 3h

Wait Weekend




- 80 %- 30 %- 15 %- 60 %- 30 %

Robot in

Motion

Wait

20sec – 10minWait

2sec – 20sec

Wait

10min – 3h

Ble

nd

ed

Bre

akin

g

Tem

pera

tur

Co

ntr

olled

Fan

Wait

Weekend

KR

C4 a

nd

QU

AN

TE

C

Sta

nd

by-M

od

e 2

Sta

nd

by-M

od

e 3

Energy Efficiency: KUKA Energy-Efficiency Functions

19 %26 %

10 %

17 %

28 %




Energy consumption of a robot system in a three-

shift-production with production break over the

weekend:

Assumption:

Energy consumption in motion 3.0 kW

5.000.000 brake cycles

32 h Robot in Motion

16,8 h Wait 2sec – 20 sec

43,7 h Wait 20sec – 10min

28,5 h Wait 10min – 3h

47 h Wait Weekend

168 h per Week

Energetic State Energy Consumption Energy Consumption

96 kWh → 9,60 €

11,8 kWh → 1,18 €

9,6 kWh → 0,96 €

6,3 kWh → 0,63 €

10,6 kWh → 1,06 €

134,3 kWh → 13,43 €

67,2 kWh → 6,72 €

4,7 kWh → 0,47 €

8,1 kWh → 0,81 €

4,4 kWh → 0,44 €

2.2 kWh → 0,22 €

86,6 kWh → 8,66 €

KR C4 and

QUANTEC

- 30%

- 60%

- 15%

- 30%

- 80%

- 36%

- 2480 kWh per Year

- 1426 kg CO2 per Year

- 248 € per Year

CO2 – Emission related to Energy 2009: 575 g CO2 / kWh

Energy Efficiency: KUKA Sustainability in Numbers




Energy

consumption

The KR C4 and QUANTEC series are market

leaders in terms of speed and energy efficiency

Energy efficiency – Reduced energy consumption in the production motion

– 30% 15% reduction in weld gun weight by means of

robot-based gun compensation

12% reduction in weight of robot structure

Optimized gear units with minimized friction

Energy-efficient motor and drive technology

Model-based closed loop control for energy-efficient

motion and positioning

Intelligent brake control system

Temperature-controlled cabinet fan




KR C4 supports the PROFIenergy profile for reducing

energy consumption in standby mode and for efficient

energy management

The standard was defined by the German automotive

industry together with SIEMENS and KUKA

During breaks in production, the robot controller

automatically reduces energy consumption

The breaks in production are initiated by the line PLC using

standardized PROFInet services

The KR C4 supports two different standby modes which are

activated according to the length of the break

The KR C4 supports, by means of configurable

measurement points, all necessary information for a future

plant-wide energy management system.

Standby 2

Standby 3

– 30%

– 80%

Energy efficiency – Virtual main switch in standby mode




Robot

simulation

Model-based

energy

consumption

forecast

Analysis

Checking

Settings

Payload category of the robot

Tooling – Weight – Center of gravity

Adaptation of velocity and acceleration

Energy-optimized motion profiles

Energy-optimized robot paths

Optimized robot selection

Cycle time and energy-optimized paths

Energy efficiency must be taken into consideration

as early as the planning phase:

The expected energy consumption of the application must

be forecast on the basis of a robot path programmed

offline.

The energy efficiency is improved by adapting the payload

category, the tool parameters and the velocity.

Optimization of robot and tool selection, as well as the path and

velocity, ensures maximum energy efficiency.

Energy efficiency – Consumption forecasts during planning


UP11%20Energy%20Efficient%20Fast.wmv

http://i.msdn.microsoft.com/cc163497.fig12(de-de).gif



Reduction of Floor Space, Cycle Time and Enhanced Safety

Safe Robot Technology




In the case of manual loading/unloading stations, additional

measures must be taken to protect the operator:

• separation of operator and robot and intermediate supports

(additional tools and increased space requirements)

• if parts are loaded directly into the gripper, the robot drives

must be safely deactivated (cycle time losses due to restarting)

Safe Robot Technology: Simplification of Manual Loading Station

Safe Robot Technology:

the safe operational stop greatly simplifies direct loading of

parts into the robot gripper

the velocity of the robot moving in and out the loading area is

safely monitored and the drives remain activated during loading

• Reduced space and shorter cycle times

• No costs for additional positioning systems

• Lower costs for additional safety components




Until now, the workspaces of the operator and the robot were

strictly separated – assembly tasks were either fully manual or fully

automated:

complex sensor systems are required for automation

cost-optimized partial automation was not possible

Safe Robot Technology: Partial Automation of Manual Tasks


robot tasks are optimally broken down into autonomous and

operator-guided sequences

utilizes the high-availability sensory capabilities of the operator

Reduces costs by means of scalable

automation

Implements cost-effective intermediate

steps on the way to full automation




Until now, the workspaces of the operator and the robot were

strictly separated – robots were always surrounded by safety

fences that hampered production flow and the flow of materials:

safety fences increase the space requirements and make an

unobstructed production flow more difficult

very low degree of automation in final assembly

100%60%40%20%20%40%60%80% 80%100%

sicherer Betriebshalt

Arbeitsbereich 1 mit 20% Geschwindigkeit




100%60%40%20%20%40%60%80% 80%100%

sicherer Betriebshalt





Sensor unit

Space

with restricted

detection capability

6.4 x 4.8 m

9.8 x 7.4 m

(maximum

field of vision)

1.5

m

5.0

m

7.5

m r

ea

ch

Safe Robot Technology: Cooperation of Robot and Worker


robot and operator work next to one another without physical

safeguards

if the operator gets closer to the robot, the velocity of the robot

is gradually reduced and failsafe monitored

Reduction of costs for access control and

access protection (roll doors, light curtains

and laser scanners)

Unimpeded flow of materials and production

flow combined with low space requirements




KUKA Robots in CV production in India

Ashok Leyland

Bharat Benz

M&M

TATA




Thank You


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