The Value of Teaming Humans with Robots and Automation in ...
Transcript of The Value of Teaming Humans with Robots and Automation in ...
The Value of Teaming Humans with Robots and Automation in
the Connected FactoryPaul Santi
General Manager – Powertrain Systems Group
FANUC America Corporation
• Achieving the Operational Requirements
• Including the Support Needs
• Awareness of the Environment
• Familiarity with the Connected Factory
• Mindful of the Human Factors
• Traditional and Collaborative Robotic Automation
• Collaborative Robotics Impact on Manufacturing Methodology
• Safety & Safeguarding related to Human & Robot Interaction
So, You’ve Decided to Automate…Now What?
Things to Consider when Automating
Operational – Design – Revenue Impacting
• Part Quality
• Production Schedule
• Talent
• Reliability
• Safety
• Ease of Use
Supporting – Implementation - Investment
• Maintainability
• Personal Training
• Launch Duration
• Spare Parts
• Utilities
• Plant To-Do’s
Awareness of the Environment
• Air
• Floor
• Ceiling / Roof
• External Openings
• Lighting
• Traffic
Familiarity with the Connected Factory
Data
Collection
Cyber
Security
Shared
Learning
Network
Protocol
Plant
IT
Edge
Fog
Cloud Systems able to interact with one another,
analyze data, self configure, and adapt to
changes within the manufacturing process itself
Voltage, Kwh, Running Time,Temperature, Safety
Real-time Data
ANALYTICSPredict component failure
Knowledge Optimize
SMARTMachines & Equipment
CONTEXTUALIZATIONEnergy/Product, OEE, Safety
InformationACTION
More efficient process workflows
Familiarity with the Impact of the Connected Factory
Mindful of the Human Factors
• Safety
• Ergonomics
• Interaction
• HMI Communication
• Emotional
• Human Response
HRI – Human Robot Interaction
Not Just a Machine
• “On the one hand, these robots are just another modern machine to enter the factory. However, new research shows that people don’t treat them that way; rather, they treat them as living things.”
Commands: Human Self Doubt
• “Companies should be aware of the persuasive power of directions when coming from a social robot, and create policies and procedures for identifying situations where there is a human-robot disagreement and what to do when there is.”
Source: WSJ June 02, 2015
HRI – Human Robot Interaction
Empathy toward Robots: Protection from Damage / Harm.
• “People feel bad when bad things happen to robots.”
• “…Companies might want to separate robots that do collaborative tasks (thus building rapport) from those that do dangerous ones (and be at risk). That would minimize opportunities for workers to directly observe robots being mangled or disassembled.”
Source: WSJ June 02, 2015
What Does Collaborative Mean to You?
• Cohabitating?
• Nearby?
• Helping each other?
• Working together?
Assisting
Enhancing
• Home Service
• Humanoid
• Driverless Car
• Telepresence
• Exoskeleton
• Terminator
• Optimus Prime
• AGV / Mobile Platform
• Same as any other robot?
Your View of “Collaborative Robotics”?
Both of these are ‘Collaborative Ready’
What Features Do You Think Are Built-In?
• Safe? With NO additional Safeguarding? ………… Unlikely.
• Simple & Easy to Program? ……………………….. Depends.
• Direct Replacement for an Operator? ……………. Rarely.
• Industry accepted (they must be, right?) …………. Please Confirm!
• No engineering needed? …………………………… Yeah, Right!
• Accepted by co-workers? ………………………….. Can Be!
Do you know the Truth vs. Myth?
Why is Your Company Going Collaborative?
• Everyone else is doing it.
• My boss says we have to.
• Ergonomic lost-time issues.
• No floor space for ‘traditional’ robot.
• Easier to deploy than an operator?
• No time to engineer a new system.
Ideally:
The application is optimized by combining the values
of Robotic Automation with Human Skill & Intelligence.
Education: Become familiar with the types of Collaborative Operation
Proper Application Requires Knowledge
Analyze: Which is the best type for your application?
5.10.2Safety-rated monitored
stop
5.10.3Hand
Guiding
Collaborative Operation Types
5.10.4Speed and separation monitoring
Analyze: Or is one of these better for your application?
5.10.5Power & Force Limited
Collaborative Operation Types
Education: Become Familiar with industry accepted Guidance.
With Knowledge Comes Ability
ISO/TS15066:2016
Source: RIA Editorial POSTED 07/05/2016
Robots, Jobs and Productivity in the Manufacturing Industry
As robot shipments increase, so has nonfarm employment.
More Robots = More Employment
Robot shipments are also linked with the
growth in manufacturing labor productivity.
Source: RIA Editorial POSTED 07/05/2016
Robots, Jobs and Productivity in the Manufacturing Industry
More Robots = More Productive Labor Force
Source: RIA
More Robots … Year over Year
• Ordered Units Increased.
• Ordered $$$ Increased…but at lower rate.
“American Industrial Automation Growth to Stay Strong”, says RIA.
33
25
24
22
22
21
21
20
18
18
16
14
13
9 9 9
8 8 8
7 7 7
6
3
0 0
LABOR-COST SAVINGS FROM ADOPTION OF ADVANCED INDUSTRIAL ROBOTS (% 2025 PROJECTED)
Total Cost of Robotic Automation is Decreasing
Source: Boston Consulting Group (via The Fiscal Times)
Why This Matters to Collaborative Robotics?
• Applications are expanding.
• Robot Costs are Declining while Performance (Speed, Capability) is Expanding = More Opportunities.
• Robots are increasingly replacing fixed automation.
• Robots are replacing many manual tasks.
• Technology has reached point where research has resulted in capability that is now commercially available.
More Collaborative is on the way.
Risk Assessment is Still Needed
• ANSI/RIA R15.06-2012
• Functional Safety
• TS15066 Guidance• Forces & Pressures
• Safety Rated Axis Limits
Forces and Pressures – ISO/TS 15066:2016
Body Region Specific Body Area
Quasi-Static Contact Transient Contact
Maximum
Allowable
Pressure
[N/cm2 ]
Maximum
Allowable
Force
[N]
Maximum
Allowable
Pressure
Multiplier
Maximum
Allowable
Force
Multiplier
Skull and forehead
Middle of forehead 130
130
N/A
N/ATemple 110 N/A
Face Masticatory muscle 110 65 N/A N/A
Neck Neck muscle 140150
22
Seventh neck muscle 210 2
Back and shoulders
Shoulder joint 160210
2 2
Fifth lumbar vertebra 210 2 2
Chest Sternum 120140
22
Pectoral muscle 170 2
Abdomen Abdominal muscle 140 110 2 2
Pelvis Pelvic bone 210 180 2 2
Upper arms and elbow joints
Deltoid muscle 190
150
2
2Humerus 220 2
Lower arms and wrist joints
Radial bone 190
160
2
2Forearm muscle 180 2
Arm nerve 180 2
Hands and fingers
Forefinger pad D 300
140
2
2
Forefinger pad ND 270 2
Forefinger end joint D 280 2
Forefinger end joint ND 220 2
Thenar eminence 200 2
Palm D 260 2
Palm ND 260 2
Back of the hand D 200 2
Back of the hand ND 190 2
Thighs and knees
Thigh muscle 250220
22
Kneecap 220 2
Lower legs Middle of shin 220130
22
Calf muscle 210 2
You don’t need to be a Medical
Doctor but need to consider contact.
• Forces & Pressures
Features required by the application still need to be used with a collaborative application.
Force Sensing Vision High Accuracy
Collaborative Operation Safety was Addressed
What Next?It’s All About the Process…..
• Still need to achieve Production and Quality levels.
• Still Need to Control the Process
• Communicate with External Equipment
New Applications but Same Challenges
• Integrate into Larger Manufacturing Systems
Technology Acceptance by “The Next Generation”
• The rules for robotics in manufacturing have taken 30+ years to be understood; people are separated from robots.
• With new technology, the rules have been rewritten.
• Clear indications of robots using “new rules” is needed especially with Power and Force limited robots.
Step Into Tomorrow – Today!
• Collaborative Operation Capabilities are opening new opportunities for Robotics.
• Advances in Machine Vision, Machine
Intelligence, Smart Devices, and the
Connected Enterprise will further
enable the opportunities.
It’s best to be prepared
What Matters Today Will Matter Tomorrow
• Safety
• Productivity
• Interoperability
• Capability
• Durability
• Flexibility
• Reliability
Contact
Paul SantiGeneral Manager – Powertrain Systems Group
FANUC America Corporation
3900 W. Hamlin Rd.
Rochester Hills, Michigan 48309
U.S.A.
Telephone: 248-377-7383
Email: [email protected]
www.fanucamerica.com
Booth #1625