Tailor-made innovations for demanding assembly tasks

The IPA software »pitasc« enables sensitive, automated assembly processes for robots of all manufacturers. (Source: Fraunhofer IPA, Photo: Rainer Bez)

With "drag&bot," robot programs can be created in an easy and intuitive way. (Source: ARENA2036, Photo: Rainer Bez)

The intelligent workpiece carrier »IPA.smartWT« collects quality-relevant logistics and process data and transmits it wirelessly outward. (Source: Fraunhofer IPA)

Intelligent tools can actively support the worker in the assembly of small and very small parts. (Source: Fraunhofer IPA)

Fully automated with intelligently programmed robots and tools, cooperatively working with humans and robots in a team, or entirely manual for assembly tasks requiring high precision and small batch sizes: Fraunhofer IPA will showcase technologies at this year's international trade fair for production and assembly automation, Motek, from October 10 to 13 in Stuttgart, that enable companies to perform their assembly tasks optimally. The experts will present their innovations at the IPA main booth and at other exhibition stands.

Whether in automated or manual execution of assembly tasks, many requirements must be considered, as the joining processes themselves and the workpieces are diverse. Therefore, task- and product-specific solutions are necessary. Fraunhofer IPA will present innovative technologies and applications at Motek that offer companies a qualitative and economic added value for their assembly tasks—even when the level of automation is high or when a worker performs the task manually with active and ergonomic support.

Intelligent Robotics Solutions

Among the solutions for fully automated assembly is the new software »pitasc«. It enables, for the first time, the economical automation of force-controlled processes that were previously performed manually. Example applications include the assembly of control cabinets, sensitive insertion of car door handles, or screwing processes. The software is innovative because the once-modeled task can be transferred to new workpiece variants, different robot types, and robots from other manufacturers. Additionally, it is structured similarly to a modular system: it contains a variety of ready-to-use and reusable program modules that system integrators can assemble and deploy individually depending on the task. This provides companies with a flexible, efficient, and cost-effective automation solution.

Furthermore, experts will demonstrate at Motek how robot programs can be created quickly and intuitively using the software »drag&bot« with a graphical user interface. The goal of this efficient approach is to significantly simplify programming efforts and make robotic applications particularly attractive for small and medium-sized enterprises. These companies need to act very flexibly and often have to adapt programs, which has previously been very labor-intensive. This improves with the new IPA software: it defines the program flow by selecting and combining individual, already existing program modules. The advantage: these modules are compatible across robot manufacturers, reusable, and hide the complexity of the robot program from the user. User interfaces and input aids support the operator in entering task-specific parameters.

Monitoring and Ensuring Process Requirements

For many assembly tasks, it is important to precisely adhere to certain process parameters. For example, during joining, the temperature of a workpiece can be critical because a high temperature may cause it to be too large and unfit for assembly. The »IPA.smartWT«, an intelligent workpiece carrier with integrated sensors, allows continuous monitoring of the workpiece condition: using an embedded miniaturized signal processing unit with wireless communication interface, it can centrally provide quality-relevant logistics and process data or transmit them to the cloud in Industry 4.0 scenarios. The user always has current data at hand and can intervene if necessary. This can increase both the quality and throughput of production.

Cleanliness is also a criterion for precise assembly processes. Due to the increasing miniaturization of products and rising quality requirements, cleanliness in the production environment is becoming increasingly important, requiring certain purity standards. Fraunhofer IPA will inform interested companies at Motek about its services, which have been successfully offered in this field for many years. The experts advise on all questions regarding cleanliness, certify systems, devices, and consumables in the purest cleanroom in the world, identify improvement opportunities, document results in test reports, and award the »Tested Device®« certificate.

Active Support for Workers in Micro-Assembly

Despite the high demands in assembly, many processes can at least be semi-automated. However, especially in micro-assembly, there are tasks that cannot be automated due to typically low batch sizes or the small dimensions of the workpieces. An example is gear assembly in watch manufacturing. For these tasks, Fraunhofer IPA presents the »IPA.PreciTool«, tools that actively support the worker and thus physically relieve them. Additionally, product quality and precision improve, and waste decreases. The relief begins with active parts provision: the worker no longer has to search through an unordered mass of tiny parts but can pick them individually from a supportive workpiece carrier or magazine. For the assembly itself, there is the active assembly aid—a personalized tool that stabilizes the worker’s hand and helps with highly precise positioning and guiding of the tool. This process can also be supported by an integrated positioning unit in the worktable, which moves the workpiece relative to the tool during processing. This allows the worker to hold the tool steadily and work more precisely than if they had to guide the tool themselves. Companies can learn more about micro-assembly and other topics, development work, and services of Fraunhofer IPA at the trade fair booth.