Variable assembly

The trend is clear: the batch sizes are becoming smaller and smaller and more and more manufacturers are looking for ways to economically produce the quantity. ActiveAssist is the solution for a wide range of applications. The intelligent assistance system identifies the next order, retrieves the corresponding work plan and guides the employees through the assembly. For this purpose, it projects work instructions onto the work surface and monitors their execution. In case of errors, ActiveAssist provides immediate help to correct them and in the next step, it will continue to support the assembly process. From that point, the connection to artificial intelligence in assembly is not far away.

ActiveAssist

My friend, the robot

Safe collaboration between human and machine – without additional safety cages – is an elementary component in the Factory of the Future. Our automatic production assistants are specially developed for this application. Thanks to the unique capacitive sensor skin, the APAS assistant stops automatically and without contact if an employee gets too close. Once the employee has left the immediate vicinity, the robot independently resumes its work.

Without additional protective surroundings, human and robot can work together instead of side by side to handle work processes efficiently. As a result, our production assistants are already able to gradually take over monotonous or ergonomically challenging tasks. This enables the employee to concentrate on the more complex tasks in the Smart Factory.

APAS

Everything flows

In the Factory of the Future, only the building is fixed in place, while all machines and systems are fully mobile. The first steps in this direction are control cabinet-less drives with integrated controls. The IndraDrive Mi servo drives reduce cabling costs by up to 90 percent and drive forward the modularization of mechanical engineering. Modules and stations can thus be easily combined and only synchronized via software. With the introduction of the new 5G mobile radio standard, sufficient bandwidth is available for wireless communication. In the future, power will be supplied inductively from charging stations in the ground. As a result, machines can be pushed together to form new production cells which further simplifies the multi-variant production.

IndraDrive Mi

ActiveAssist

The ActiveAssist assistance system makes varied assembly tasks significantly easier thanks to an interactive step-by-step tutorial. Intuitive to use and completely connected, you increase process reliability, minimize defects and final inspections and increase quality. It brings people, equipment and processing together through decentralized intelligence.

Now: The web-based software makes right information available to the right employees at the right time. Depending on the customer order, ActiveAssist will guide the worker, prevent for failures and guaranty a high flexibility. This is how “One-Piece-Flow” works. As a networked solution, orders can be routed to different ActiveAssist.

Next: In a next step, it will be possible to connect further systems with ActiveAssist, such as intelligent nutrunner systems or test benches. With the one layer teaching, you configure one system instead of programming specific solution.

Beyond: What can you imagine it can do in the future?

APAS

APAS – the automatic production assistants – support employees in simple, monotonous or ergonomically challenging tasks. The globally unique, contact-free machine safety enables completely new forms of human-machine collaboration.

Now: More than 100 APAS systems are already in use at production plants throughout the world. Although APAS assistant robots have fully collaborative safety, they can move with high speed if no humans are close to them. The APAS inline versions are fully compatible with standard industrial robots.

Next: APAS assistant of the next generation will use a modular platform independent software for all APAS robots. It will come with an enhanced machine vision capability. The mobile solutions are suited for flexible usage in different locations.

Beyond: Digital twins of APAS in the future will fit into fully digitized value stream design. It will support advanced interaction with human co-workers based on digital safety sensors. Additionally it will identify parts and their pick positions based on CAD-datasets. It will be ready to deep-learning and AI-algorithms for automated part handling without extensive engineering.

IndraDrive Mi

The IndraDrive Mi enables machine manufactures to integrate all electrical drive components directly into the machine. The results are entirely cabinet-free modular machines with minimized required space.

Now: Thanks to the system design, IndraDrive Mi contributes to cost reduction not only in terms of the components. It reduces control cabinet space and energy consumption for cabinet cooling up to 100%. Additionally the wiring effort can be cut up to 90%.

Next: The extended motor encoder functionality for health-index measurement can be used for predictive maintenance and thus increases the machine availability.

Beyond: What can you imagine it can do in the future?