The arrival of digitalization and the resulting networking are changing the markets and the working world. They have become faster. Product lifecycles have become shorter. Customers demand individualized products with a larger variety at constantly changing volumes, while competition is increasing.
These challenges put the spot on flexible and connected production and intralogistics solutions as well as on mobile assistance systems, which are no longer limited to a single production process. They can be adapted quickly according to requirements and contribute significantly to process optimization, enabling the cost-efficient production even of small batches starting with lot size 1. Working together safely with humans and machines without the need for a safety enclosure makes APAS break former boundaries within the production and material flow.
Mobile assistance systems which are no longer limited to a single production process but can be flexibly used for different purposes, are at the heart of the intelligent factory. They help to optimize processes and increase efficiency. Moreover, they can not only handle small batches starting with lot size 1, they can also handle peak loads flexibly and economically. Accordingly, they fulfill customer demands for individualized products and thus shape the Factory of the Future.
The forth industrial revolution poses new challenges to working conditions. Production processes are more varied and more complex. Moreover, the demographic change will lead to a lack of workers and specialists, and impose completely new requirements on workplace layouts. Companies have the task of making working conditions more attractive and of enabling employees to take part in working life for a longer time. While technology is asked to support and offer adaptation possibilities, humans with their changing requirements are at the center of the Industry 4.0 Factory. Changes in work organization and the adaptation of workplace layouts should not only advantage and motivate younger employees. Experienced, older employees should also have the chance to participate in the active working life for a longer time. This is why we concentrate our development activities on human requirements right from the beginning.
Sensors make intelligent automation possible in the first place. Our powerful solutions benefit from years of experience in that technology field, which also made the Automated Production Assistant APAS ready to sense its environment.
The unique sensor skin empowers APAS assistant to detect humans. This allows the robot to stop automatically and thus to avoid contact completely if an employee comes too close.
Optical sensors enable APAS not only to detect parts but also to inspect them. This enables APAS assistant to adapt its movements to the specific environment and also pick and place very precisely. With the APAS inspector increased quality can be achieved as even smallest defects in surfaces can be found.
Collaborative robots, so-called cobots, support humans without replacing them. Our cobots based on full-industrial robots help to optimize quality and output, since they are able to work constantly at high speeds and precisely even while performing monotonous tasks. They complement the unique human skills and assist employees in dealing with their work. While the robot is especially precise and enduring, humans have problem solving competencies, which machines cannot offer, despite their access to large amounts of data. Knowledge and experience enable humans to assess even unforeseeable and highly complex situations and to find creative solutions.
Experience how APAS robots ensure efficient quality inspection for an intelligent material flow in a Bosch production. The end-of-line inspection is performed here by an APAS inspector in interaction with two APAS assistant mobile. This makes the collaborative robots fit seamlessly into the industry 4.0 environment.
How can an APAS assistant support severely disabled employees in press-in operations for plastic sieves in water nozzles? This is shown at a workplace for human-robot collaboration, where the robot compensates individually impaired performance.
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The APAS assistant is being tested for usage in canteen kitchens, for instance to place food and tableware on serving trays. During peak periods, the production assistant can support staff and reduce queues.
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Two APAS assistants have been integrated into an existing line, where they are responsible for joining and welding of magnetic cores and tubes. The integration of the robots was performed without line downtime and only minor modifications.
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Used in flexible combinations, four mobile APAS assistants provide support with testing control units' temperature resistance - and free employees from tasks that are not only monotonous, but also potentially dangerous.
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The APAS assistant mobile is a collaborative mobile robot for flexible use in the Smart Factory. It can be used independently of location and can adapt to different tasks. The intelligent robot system is primarily intended for end users, who require a fast and budget-priced realization of new operations, as well as a highly robust, easy-to-handle and intuitively controllable system without programming knowledge.
The 3D image processing system and integrated lighting allow the APAS assistant to identify objects and determine their position. Further, the assistant’s ability to precisely grasp and position components simplifies parts feeding. Thanks to its sensitive three-finger gripper, it can flexibly and reliably grasp and hold components and products. The repetitive accuracy of the APAS assistant mobile is +/- 0.03 mm, whereby force and position control of the gripper fingers allow both gentle and safe gripping. In the event of collision, the gripper fingers automatically retract, helping to avoid pinching and jamming. The APAS assistant can also be equipped with individual, proprietary grippers while adhering to all relevant safety standards.
Before a collision occurs, the APAS assistant mobile stops. Unlike other robots on the market, our APAS assistant mobile stops automatically and completely contactless. Once the employee has left the immediate vicinity, the robot independently resumes its work exactly where it stopped before. This is possible thanks to our unique capacitive sensor skin, which enables the robot to identify its human colleagues before they get too close. Equipped with more than 120 sensors, the skin enables the robot to stop automatically and without contact at a safe speed of 0.5 m/s or even more. Hence we enable the safe identification of humans by our solutions at performance level d (category 3, two-channel safety). All our systems are also certified by the German employers' liability insurance association for the direct and safe human-robot collaboration.
So-called work plans make the robot’s configuration an intuitive task. The APAS assistant mobile can be trained for new tasks via step-by-step instructions. Robot, camera and gripper are applied from the same software, hence no programming knowledge is necessary. Work plans can be saved and retrieved at any time, thus leading to fast availability and cost savings, even when conditions change.
The APAS assistant mobile can be employed anywhere you might need it within your production facility without the need of additional safety enclosures. Thanks to its quick-fixation casters the assistant is independent of the location. The system’s slim design allows it to be positioned at existing production lines or machines, even if very little room is available. The integrated camera calibration enables the robot to automatically compensate its own position deviation after being moved.
The APAS assistant inline is a robot designed for human-robot collaboration without safety fence. Thus the APAS assistant inline requires only small space. Since expensive safety enclosures are no longer needed, additional costs can be saved. It is ideally suited for expansion of production lines. As automation component it is primarily designed for system integrators who wish to extend their scope of solutions through collaborative robotics without having to forgo the familiar construction and programming environment. Transitions between individual production steps can be accelerated, process flows optimized and production times reduced.
The compact design of the integrated robot safety allows space-saving automation even in existing systems. This opens up a whole new world of collaboration between humans, machines and robots without the need for a safety fence.
As the APAS assistant inline can be quickly and easily integrated even into existing systems, even older production environments can be supplemented or expanded efficiently. With APAS, Bosch Rexroth is securing the way towards the factory of the future in a familiar robot environment.
With the APAS inspector, we offer a comprehensive construction kit of hardware and software for the realization of individual solutions in visual inspection and quality control. Whether used as complete system or integrated into existing machines and lines – innovative technologies and 3D imaging methods guarantee reliable results, even in rough production environments.
As a complete system, the APAS inspector can be operated via a mobile touchpad intuitively. The mobile, cable-bound operator panel always gives you the best view and access to the machine: setup is easier, errors can quickly be located and eliminated. Pictures of the objects being tested are acquired by high-performance 2D and 3D imaging technologies. The evaluation of the resulting images is based on HALCON and can be supplemented by our learning image processing.
Thanks to the learning image processing, an operator who is untrained in dealing with industrial image processing can intuitively teach the vision system.
The basic idea of supporting humans in their daily work is applied to surface, completeness, micro-crack and dimensional inspection. Training images are used to separate test items into “good” and “faulty” parts. The operator uses the APAS inspector to take pictures of several test items, and marks the “good” and “reject” areas of the sample.
The system then analyzes and records this information for future inspections. The inspection system can be retrained at any time using additional images. This enables the operator to continually improve the recognition abilities of the APAS inspector, or to adapt it to new conditions, without the need for programming expertise.
There are different, manually exchangeable test modules available. They are characterized by particularly robust 3D-imaging processes. During development, emphasis was placed on the simple exchangeability of the test modules. At the same time, new tests can easily be integrated. Additionally, the know-how from the implementation within Bosch production sites has been integrated. Our experts can compile 2D and 3D imaging techniques and intelligent processing for your individual test requirements. Benefit from our many years of experience in the field of visual inspection.
The planar table makes the APAS inspector versatile. One or two independent workpiece carriers are loaded manually or automatically with the test objects and transported via the highly flexible planar table to one or more image recording positions. There they can be scanned step by step or rotated under the camera. Therefore, many different motion sequences of the test objects can be realized only by parameterizing the software and without mechanical retooling.
Whether mobile, firmly integrated into your own systems, retrofitted or in the course of machine and plant construction - our test technologies can be used flexibly and as needed. As a mobile system, the APAS inspector can be located anywhere in the production process. In addition to an integrated, PC-based control system and a standardized operating concept, the platform also includes standardized networking options that allow communication to external periphery. The slim design makes it possible to integrate the system even under difficult spatial conditions.
Our systems are designed to fit seamlessly into your overall concept. Robots leave their safety enclosures and support their human colleagues in their direct working environment.
Image processing is not only the core technology for reliable quality inspection but also for part and position recognition, optical calibration of the robot as well as part identification and code reading.
Application and Usage
Surface testing
The APAS inspector checks surfaces with robust 3D technology, which can even test parts with dirt. Different test modules are available for matt and high-gloss surfaces. With both modules, the surface can be reconstructed in 3D in order to make even small damages such as quirks, spikes and scratches visible. The system is insensitive to foreign influences and is thus particularly suitable for industrial applications.
Micro crack detection
Detecting hairline cracks in ceramic components is a major challenge for the human eye. With this module, the APAS inspector is able to reliably detect such microcracks in ceramic components, which are often overlooked by humans.
Color inspection
With this module, robust color tests can be implemented. The test module determines the color spectrum for each point and can thus reliably distinguish even between colors that are very similar.
Environment recognition & quality inspection
Image processing is not only the core technology for reliable quality inspection but also for part and position recognition, optical calibration of the robot as well as part identification and code reading.
Our high-quality 3D imaging processes make you benefit from our many years of experience in the field of optical visual inspection. Here, the findings from the practical implementation of the company's own production sites have been incorporated.
Deflectometry
Suitable for the automatic recognition and inspection of reflective surfaces. With this technique, even smallest flaws like surface blemishes, deformations and scratches can be detected. Cylindrical forms can also be scanned by an extremely fast, patented imaging capturing process.
Photometric stereo
Suitable for the automatic recognition and inspection of matte surfaces. In addition to smallest flaws like surface blemishes, deformations and scratches, even microfractures in ceramic components can be reliably detected.
Spectroscopy
Suitable for robust color testing. The testing module measures the color spectrum at each point, allowing it to reliably recognize even hardly visible color deviations