Dürr Develops Human-Robot Collaboration for Vehicle Assembly

Dürr is introducing the first complete robotic unit in vehicle manufacturing that uses human-robot collaboration (HRC). In this production design, humans and robots work hand in hand during final assembly without safety barriers between them. The innovative HRC method improves seam quality in fuel tanks while accelerating the production process and reducing costs. Robots are increasingly taking center stage in different areas of vehicle manufacturing. Automation is advancing not only in body shops and paint facilities but also in final assembly operations. For example, robotic units separated by protective barriers perform repetitive tasks at the highest level of repeatability. However, since fully automatic processes are difficult to achieve in final assembly, they are carried out by workers performing complex tasks. Workers must be able to respond to new situations that may arise and be flexible when needed. Yet collaboration between humans and robots opens new possibilities for this area.

High Production Efficiency

For this reason, workers and robots work together, complementing each other in performing various tasks. Dürr provides this flexibility in vehicle manufacturing. Human-robot collaboration simplifies the installation of tanks into vehicles. "We continually receive requests from the industry to integrate robot applications in assembly operations and thereby increase productivity," says Dr. Hans Schumacher, Head of Application Technology at Dürr, explaining this new step. Experts are developing complex assembly processes required for flexible applications based on human-robot collaboration. Robot systems are deployed in situations where humans face significant physical strain or must work under ergonomically unfavorable conditions. They are quite satisfactory in situations where the same movements are repeated many times with consistent rhythm and high reliability. For this reason, creating an HRC system requires leveraging robot workforce while also utilizing human flexibility in accelerating the production process, reducing costs and improving quality.

Come On Robot Partner, Apply Adhesive!

In the new system model, workers in the assembly facility first bring tanks to the shared work area with the help of an operating device (manipulator). Parts are cleaned by workers and other processes are transferred to the machine. Upon receiving the start signal, robots place adhesive beads evenly along the tank edges. Sensors on the application head monitor whether seam heights are appropriate. Once the mechanical production assistance completes its work, the assigned specialist mounts the tank in its designated location on the body. Individual skills and abilities specific to humans are of great importance in performing this complex operation. For ergonomically unfavorable movements, the operating device (manipulator) provides support. Dürr supplies complete facility equipment for the new human-robot collaboration from a single source. In addition to the design concept, this includes a complete material supply system, electrically controlled metering equipment for speed-dependent adhesive flow, as well as an upper control unit with operator panel for controlling, applying adhesive, and screwing. Dürr has also developed application heads that are designed very light and can rotate 360 degrees for safety purposes. The entire process of mounting the tank to the vehicle body via manipulator technology is part of Dürr's supply scope. Additionally, planning of HRC robots is also performed by Dürr.

High Safety Standard

Although there are no barriers or railings, safety conditions applied in human-robot collaboration are significantly stricter when compared with independent robot units. The safety concept, depending on risk assessment, foresees the implementation of strict conditions and standards. In the safety package, among other points, an important consideration is minimizing the risk of the robot coming into contact with humans. However, it must also be taken into account that human movements are not always predictable. For this reason, robots must move extremely carefully and must shut down in milliseconds upon contact with humans. In Dürr's adhesive unit design, the robot operates below the human head and chest area. At the same time, the application technology and robot are designed to be light, broad and rounded, such that only low forces are involved in the robot's contact.

High Potential

HRC systems typically excel in operations such as adhesive application that require consistently high quality. The new robotic units have high potential in reducing physical exertion on humans and lowering production costs. Zafer Tok / Application Technologies Manager - Dürr Systems Turkey