Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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Mobile Machine Tending with ROS2: Evaluation of system capabilities

2023 , Heimann, Oliver , Niemann, Sönke Christoph , Vick, Axel , Schorn, Carolina Sophie , Krüger, Jörg

Automating machine tending for high mix - low volume environment provides additional engineering challenges. Current machine tending systems are usually fixed in place and preprogrammed by a human operator. Available mobile robots are limited in their machine tending capabilities as they cannot provide the required accuracy that is necessary for the precise insertion of work pieces into a fixture. This paper presents a mobile machine tending system that uses computer vision and ROS2 to address these limitations and to enable autonomous machine tending. After a brief introduction to the system architecture, the article provides first insights into the systems capabilities based on experimental evaluation. The first experiment addresses the accuracy of the end effector, showing reasonable improvements using low cost sensors. The second experiment evaluates the network load of the distributed control system and discusses the requirements for the operation of a fleet of such robots.

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Roboterprogrammierung vereinfachen

2020 , Guhl, J. , Heimann, Oliver , Krüger, Jörg

Roboterprogrammierung ist trotz allen Weiterentwicklungen in der Steuerungstechnik und Mensch-Maschine-Interaktion immer noch ein kompliziertes Problem und dementsprechend kostspielig. Gerade in kleinen und mittelständischen Unternehmen stehen daher dem Robotereinsatz hohe Hürden gegenüber. Dieser Artikel befasst sich mit Möglichkeiten die Roboterprogrammierung - unter Zuhilfenahme von verschiedenen erweiterten Realitäten - zu vereinfachen und zu beschleunigen.

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Combining the Advantages of On- and Offline Industrial Robot Programming

2019 , Guhl, Jan , Nikoleizig, Sylvio , Heimann, Oliver , Hügle, Johannes , Krüger, Jörg

Classic off- and online programming approaches offer different advantages but cannot provide intuitive programming as it would be needed for frequent reconfiguration of industrial robotic cells and their programs. While a simulation and therewith a collision control can be used offline, highest precision can be achieved by using online teach-in. We propose a system that combines the advantages of both offline and online programming. By creating a programming framework that is independent of in- and output devices we allow the use of augmented as well as virtual reality. Thus, enabling the user to choose for a programming technique that best suits his needs during different stages of programming. Bringing together both methods allows us to not only drastically reduce programming time but simultaneously increase intuitiveness of human robot interaction.

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Präzise gestenbasierte Roboterprogrammierung

2018 , Heimann, Oliver , Hügle, Johannes , Krüger, Jörg

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Production environment of tomorrow (ProMo)

2021 , Kuschan, Jan , Müller, Vinzenz , Monchinger, Stephan , Heimann, Oliver , Niebuhr, Carsten , Kabha, Oday

Small defects in the grain or major damage to a moulded part or tool can bring production to a standstill. SMEs in particular have neither the personnel nor the equipment to repair such damage on their own, so they send it to specialised contractors. The repair process is carried out manually, depending on the accuracy requirements, and is usually completed by a finishing process. This work requires qualified personnel and, at the same time, requires a lot of time in case of larger damages. In this paper we present a way to map the Maintenance, Repair and Operations (MRO) process chain in a partially automated manner. The symbiosis of individual technologies results in a significantly increased efficiency of the MRO process chain, which continues to focus on people and their process knowledge. While Directed Energy Deposition (DED) for the MRO of moulded parts is used widely, usually a high manual effort in measuring the component geometries and teaching of the machine tool paths is necessary. However, there are clear advantages compared to the manufacture of new parts or manual laser welding repair. At the same time, the resource and energy requirements can often be significantly reduced compared to new part production. ProMo focuses on automating the time-consuming machine programming by reducing the number of necessary work steps in CAD/CAM-based program creation. Based on a subsequent robot-guided scan, a digital actual 3D model is generated. Due to intelligent path planning algorithms, no manual programming of the robot is necessary and at the same time it is possible to detect components of different sizes, shapes and covers in this system with a minimum of effort. In addition, the operator passes on elementary information, such as the approach path of the milling head, to the subsequent processes by means of finger gestures and can thus significantly reduce tedious CAM programming steps. Now, the scanned component is transferred to a 3D-CAD model and a target/actual comparison is created for the damaged areas. Those are milled out in a defined manner and then restored using DED.

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Information requirements and interfaces for the programming of robots in flexible manufacturing

2020 , Bastidas Cruz, Arturo , Heimann, Oliver , Haninger, Kevin , Krüger, Jörg

Flexible automation limits what information is known during robot commissioning, requiring new robot programming methodologies. To adapt robot behavior to product variation, an operator can supply missing information, controlling predefined robot behaviors via a user interface. This operator interface can abstract domain expertise (in robotic programming, assembly planning), allowing the efficient specification of changes to a robot program by a wide range of potential users. Towards designing such interfaces, this paper analyzes the requirements of flexible manufacturing, the required changes to the robot program, and the information needed to make those changes. Two user interfaces are presented, a drag and drop and a gesture interface, implemented on a robotic flexible manufacturing testbed.

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Reale Daten für Simulationen im digitalen Zwilling - Untersuchung zur Aufnahme von Profinet-Daten und deren Wiedergabe in komplexen Simulationsumgebungen

2019 , Chemnitz, Philipp Axel Moritz , Heimann, Oliver , Vick, Axel

Powerful engineering tools are required to keep modern production systems manageable. Siemens DI FA and the Fraunhofer IPK present a novel tool for root cause analysis within complex manufacturing systems. The solution combines a CAx plant model with control data recorded from the field bus. This creates a comprehensive digital twin, allowing to analyse past machine behavior with bus clock resolution.

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Industrial Robot Programming Methods: A Scoping Review

2020 , Heimann, Oliver , Guhl, Jan

Easy-to-use programming methods for robotic manufacturing systems are a key element in enabling a wider audience to benefit from increasing automation. This paper provides an overview of current programming methods for industrial mating operations. More specifically, the review focuses on programming methods for welding and assembly tasks. While welding is mainly concerned with the exact definition of the free space trajectories, assembly tasks revolve around the contact with the environment. Thus, the two tasks at hand not only represent two of the most common robotic applications, but also two distinct groups of operations that place very different demands on the programming interface.

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Framework for energy efficiency optimization of industrial systems based on the Control Layer Model

2019 , Thiele, Gregor , Heimann, Oliver , Grabowski, Knut , Küger, Jörg

In the context of sustainable manufacturing, the energy efficient operation of industrial systems is of major interest. This paper presents a modular framework for practical research about energy efficiency optimization of complex technical systems. Whereas many approaches focus on stand-alone machines or processes, this approach is concerned with energy-related coupling of several entities. Using a method for energy-related key performance indicators, the overall efficiency is deduced from all subsystems. A given topology is modeled in an XML-based format, inspired by AutomationML. The framework gives the opportunity to analyze and compare optimization algorithms. First experiments with two optimization algorithms were applied to a simulated cooling system.

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Reale Daten für Simulationen im digitalen Zwilling

2019 , Chemnitz, Moritz , Heimann, Oliver , Vick, A.

Die hohen Anforderungen an moderne Fertigungssysteme erfordern leistungsfähige Engineering-Lösungen. Wie man die Identifikation von Fehlerursachen in komplexen Anlagen erleichtert, wurde in einer Machbarkeitsstudie des Fraunhofer IPK im Auftrag von Siemens DI FA untersucht. In der vorgestellten Lösung werden die Daten der Anlage auf Feldbusebene erfasst und in den digitalen Zwilling eingespeist. So kann das Verhalten der Komponenten taktgenau nachvollzogen werden. Dies erlaubt einen tiefen Einblick in das System und unterstützt so bei der Fehlerbehebung.

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