Norbert Bargmann, Business Manager of the Munich Fair: "The encounter of the leading heads from research and development in ICM on the one hand and the industryf at the AUTOMATICA on the other, makes Munich one of the most important meeting points for the international robotics branch in 2010.“ Photo: Messe München

The "ISR/ROBOTIK 2010" conference will be held for the second time within the scope of the AUTOMATICA. The participants at the conference consisting of the International Symposium on Robotics 2010 (ISR) and ROBOTIK 2010, will convene from 7th through 9th June, 2010 at the International Congress Center (ICM) on the new fairgrounds in Munich. The Robotics World Organization. International Federation of Robotics (IFR) approved this supplement to the AUTOMATICA. This means that everyone of distinction on the international robotic scene will be present in Munich. On the one hand, to exchange practical results at the conference and, on the other, to participate in and visit the world's largest robotics event, the AUTOMATICA 2010. Congress participation includes tickets for AUTOMATICA 2010 The contributors will present results and new products from the areas of service and industrial robotics, components and accessories. During the symposium, participants will have an opportunity to discuss research and development with colleagues and chat with experts from the robotics industry on automation of their production. The congress ticket includes a visit to the AUTOMATICA 2010. Approximately 80 contributors and 200 participants from around the world are expected. For Prof. Rolf Dieter Schraft, Institute Director Emer., of the Fraunhofer Institute for Automation and Production Technology (IPA) and Director of the Organizing Committee for ISR/ROBOTIK 2010, the Congress is "far more than the leading event in robotics research and science. It is distinguished by its high popularity and participation by the industry. All leading robot manufacturers will be present in Munich in June 2010. It is a branch meeting par excellence for the robotics industry worldwide." Interested parties from research and production can already investigate the symposium themes online at www.ifr.org. The exact date for submitting theme recommendations, the "Call for Papers" will be announced later.

Engelberger Robotics Award to be conferred
Within the scope of the 41st International Symposium of Robotics 2010 the famous Engelberger Robotics Award will be conferred. The award ceremony will take place on 8th June, 2010 during a formal dinner. Internationally, the award is considered to be the highest commendation in the branch. It is granted annually to individual persons for their exceptional work in technological research, development or application. The nomination phase for the Engelberger Robotics Award has already began. The US Robotic Industries Association (RIA) provides information on how to submit documents at www.robotics.org.

Dr.-Ing. Michael Wenzel, Reis Robotics: „Photovoltaics has experience a boom during the past few years. There are numerous applications for robots in the area of automation of photovoltaic production. In one sentence: The perspectives are very good.“ Photo: Wagner

Robotics is looking for new challenges, applications and markets. On the occasion of the 2nd VDMA Convention 'Intelligent Production (Mannheim, 22nd and 23rd June, 2009) we spoke with Dr. Michael Wenzel, Business Manager of the robot producer Reis, regarding current trends such as human/robot interaction and use of robot technology in the photovoltaic sector. The robot technology field is looking for new applications. What perspectives do you see for use of robots in the photovoltaic field? Dr. Wenzel: Photovoltaics has experienced a boom during the past few years. There are numerous applications for robots in the area of automation of photovoltaic production. In one sentence: The perspectives are very good. We anticipate manifold applications, which we cannot even start to mention here at this time. But these potentials can certainly still be utilized. Interaction between humans and robots has become an important aspect of robot engineering. What do you think about this? Dr. Wenzel: In contrast to previous situations, interaction between humans and robots opens up the possibility of employees working directly with, so to say, hand-in-hand with robots. Where protective fences, safety guards and separating railings were required between workers and robots previously for safety reasons, they are no longer necessary today thanks to new safety concepts - while still providing complete protection for the workers, of course. To date, the focal point of human/machine interaction was in the automotive industry. Do you also see applications for this in other industrial sectors? Dr. Wenzel: We do not only anticipate applications, we have already realized them. We have numerous installations, i.e. actual customer projects, where these technologies are in use. However, these technologies also open up other fields. That is why we are confident that human/robot interaction will be used on an even wider basis in the future.

Where do such semi-automatic solutions provide advantages in comparison to fully-automatic solutions?
Dr. Wenzel: This technology is always applicable, when it is not practical to completely eliminate workers. We are talking about interaction between the worker, i.e. operator, and robot. This technology is practical for all types of applications where we still require the intuition, sensibility or process know-how and experience of a human worker.

The SME Robot project was just concluded a short time ago in which a robot was developed for medium-sized companies. Dr. Wenzel, which impulses do you expect from medium-sized industrial companies?
Dr. Wenzel: The SME Robot project was sponsored by the EU Commission in Brussels especially to facilitate access to robot technology for medium-sized companies. The project offers numerous facets and possibilities for simplifying access to robot technology for small to medium-sized companies. This includes a variety of applications and numerous perspectives too great to describe in one sentence.

Do you anticipate further areas of application and markets for robot systems beyond photovoltaic and medium-sized industrial companies?
Dr. Wenzel: I do in fact. Robotics and the applications for robotics are not exhausted by a long way. However, you will certainly understand that we cannot yet pass on this know-how at this time because it would certainly also interest our competitors. You will hear from us when the time is right.

CLAUDIA OTTO

Enis Ersü, Chairman of the Board at Isra Vision AG in Darmstadt: “Image processing system in production can help to produce quality, instead of simply checking quality. This means, when integrated into the production process, image processing makes it possible to analyze the problems in each process step and simultaneously allows optimum supply to the next process step.” Photo: Wagner

Intelligent production requires optimization of the production processes. Industrial image processing provides the database required for such optimization. We spoke with Enis Ersü, Chairman of the Board at Isra Vision AG in Darmstadt, about how this database can be used to produce higher quality regardless of the location.   Mr. Ersü, how can industrial image processing contribute to more intelligent production? Ersü: Industrial image processing's contribution to production begins with production design. This means that production can be influenced significantly by integrating image processing components – whether for recognition, measuring, identification or control by integration of robot vision. Thus extremely expensive mechanical solutions can be eliminated even during the design phase by integration of image processing. You can save money right from the start. For example we design the entire production line with enough flexibility that solutions can be offered even for small lots and versatile production. This means that quality can be produced simultaneously without having to check the quality subsequently. You coined the term "Production Management Intelligence“. What does it mean? Ersü: To date we, as image processers, have installed our systems only locally in the line and thereby produced only local data. However local data only reflects local truths. In a global corporations with facilities at many locations, with many production lines, managers need appropriate processing of this data – specifically data compaction – in order to make rational decisions. This means they need decision-making aids. And Production Management Intelligence means precisely editing this data to meet the requirements at various corporate management levels and therefore integrating not only local, but also global truth. Keyword "Automatic Inspection Systems": How flexibly do such systems react to varying lot sizes today? Ersü: Naturally varying lot sizes are one of the strengths of image processing. The present image processing systems, at least most of them, are laid out so that the parameters can be set very quickly. We are already integrating the future into the system today. The systems are very adaptive, i.e. capable of learning. Future system versions can be taken into consideration very quickly by simply changing the parameters. This is the reason state-of-the-art image processing systems are optimum for versatile production, particularly for small lot sizes.

Can image processing or inspection systems be interlinked so closely with production processes, that errors are practically recognized at the source, allowing the equipment to readjust itself and thereby automatically control the processes, so to speak?
Ersü: That is a very important and interesting question. Image processing system in production can help to produce quality, instead of simply checking quality. This means, when integrated into the production process, image processing makes it possible to analyze the problems in each process step and simultaneously allows optimum supply to the next process step. I believe that image processing should be considered a significant element in production for producing quality, not simply for subsequent quality checks.

Thank you for this interview, Mr. Ersü!

JÜRGEN SCHREIER

The handling system recognizes each component, grips the chaotically supplied parts and sets them down without vibration.

The Flexmotion handling system picks up a new 6 kg forged part every 3 s. This handling process requires it to pick up chaotically supplied components in a horizontal position and set them down upright, without vibration according to a set pattern for further processing at a cleaning station. Four cameras provide for precise definition of the gripping position. The Hirschvogel Automotive Group is one of the most successful producers of solid, re-shaped steel and aluminum components. More than 2700 employees at six plants worldwide produce re-shaped parts and components for the automotive industry and its suppliers. The 1,600 employees at the main production facilities in Denklingen are responsible for mass production of solid re-shaped components. In order to guarantee high production quality, Hirschvogel has focused highly on automation and specific process optimization allowing an automatic link to the cleaning station. A specific time period was required for the pick-&-place process for the components guaranteeing vibration-free set down.

Series of tests with conventional robot systems did not provide a solution
Long years of testing with conventional robot systems did not provide a solution which was economically acceptable taking the spatial factors into consideration. With its FHS 500 Flexmotion handling system, Faude production systems provided a solution which satisfied all requirements. Today, a 'ghost hand' reduces the distance for quick access every 3 s. Because the FHS 500 recognizes each component, it grips precisely even when the parts are supplied lying down or unsorted. The Flexmotion handling system can set down forged parts with weights up to 6 kg without vibration in an upright position and according to a specified pattern.
Then everything is ready for further processing at the cleaning station. This handling task is not easy, because the high center of gravity could cause the parts to tip when set down in an upright position. But this problem is excluded by the Flexmotion kinematic system. Simultaneously, the system operates with high flexibility and speed. In combination with a 180° pivot axis, the C-axis with its 270° rotation offers many possibilities for handling parts. The drives operate directly on the load without additional arm elements.

Fast and reliable gripping without machine stops
In comparison to machines with standard kinematic mechanisms such as the heavy-load Scaras or articulated robots, this provides an optimized load/weight ratio with major advantages such as significantly better dynamics, accuracy and rigidity. This is the basis for reliable, high speed gripping without machine stops and vibration-free set down without the components tipping.

The eyes and hands of the FHS 500 operate in close cooperation. An image processing system recognizes what is happening on the 1000 mm wide supply belt. Four cameras identify all components completely, determine the precise position comprehensively on the basis of the images, monitor collision of the chaotically arranged parts touching or on top of one another in the gripping area and check to ensure that they are all of the same type.

Faude Flexvision RV image processing software controls four cameras
This performance is achieved by the interaction of the camera arm designed especially for the vibration-intensive environment and the Flexvision RV Faude image processing software developed for such applications. The four cameras allow custom-tailored and customer-specific picking of all components. This link between the eye and hand – i.e. image processing with rotation sensor on the supply belt – guarantees registration of the components outside of the working area.
With this handling system it was possible for Hirschvogel to increase its degree of automation. It was easy to integrate the compact machine completely into the production chain. However, the FHS 500 is not as precise as possible, but rather only as precise as necessary. With dimensions of 2300 mm × 2300 mm and height of 3000 mm, the space requirement is low and the machine is open for everything – including access from all sides. At a higher level, the investment leads to shorter production times and simultaneously guarantees high production quality.

Operation of control conform with Windows Explorer
The control system is intuitive, compact and equipped with a standard 19-inch touch screen. Moreover, only one PC is required for machine control and image processing. Operation conforms to Windows Explorer. The system can be expanded on a modular basis to meet customer requirements and functions. The programming satisfies international standards just as do the various field bus connections, remote access via TCP/IP, synchronous data output to digital I/O as well as drives via Sercos.

The grippers used offer the following advantages:

• Precise picking of components resulting from high-speed servo rotation and pivot axes as well as image processing.
• Shape-based pattern recognition with high-performance infrared surface illumination and filter.
• Rapid cycle time without machine stops.
• 100% identification of components with four cameras.
• Handling of different types of components with weights up to 6 kg.
• Position-independent, on-the-fly picking of components.
• Vibration-free, flying set-down of components, without tipping.
• Freely teachable set down pattern.

DIETER FAUDE AND SUSI STADLER
Dieter Faude is Business Manager at Faude Produktionsanlagen GmbH in Gärtringen. Susi Stadler is PR Adviser at Stadler GmbH in Kirchheim.

The glass panels are placed in a glass storage unit for supply to the lay-up. Due to their light sensitivity, they have a maximum storage time of 1 hour, must not be subjected to sagging or dust of any kind.

Technicians worldwide are competing to increase the efficiency of solar equipment. This also includes reduction of the layer thickness of solar cells. This extremely thin wafers do, however, place maximum requirements on the process know-how of the system manufacturers and operators. The Minitec machine company has now succeeded in optimizing the production quality with shorter cycle times. Although solar energy is available at no cost in any desired quantity, construction and economic operation of solar power plants places immense challenges on the operators. Nearly 90% of all photovoltaic systems produce their power using monocrystalline or polycrystalline silicon cells which already achieve an efficiency of nearly 20%. Reduction of the layer thickness of the solar cells reduces costs Alternatives are thin-film modules – where a thin semi-conductive coating is applied to the backing material in a vapor-coating process – or organic solar cells. However, the latter technologies are still in the development stage or have significantly lower performance. To maintain the advantages of the high efficiency, the industry is taking great efforts to reduce the costs for modules with crystalline solar cells. One approach to cost reduction is to decrease the layer thickness of the solar cells. The extremely thin wafers have a thickness of only 160 µm. However, their production places extremely high requirements on the process know-how of the system manufacturers and operators. The breakage rate for the cells during production is a primary quality and cost criterion with continuously shorter cycle times. This can be achieved only with high performance production facilities.

Module production system
The production solutions from Minitec are based on a flexible profile module system. The strict module design of this system with continuously equal grid dimensions and identical groove shape makes system expansions or modifications possible without major expense. Thanks to the patented connection technology which eliminates any type of processing and ensures ESD compatibility, adaptations can be realized within the shortest possible time even on the construction site or during adjustment work.

Every assembly in the solar cell production plant is designed as an independent function module. The modules are equipped as a matter of principle with fail-safe peripheral assemblies which allow all functions of a system part to be tested even with production in progress. In the first production step, the cells are connected in a stringer with solder strips to form a string of cells. These strings, consisting of 10 to 12 cells, are taken over by the so-called lay-up in the Minitec plant and positioned precisely on the glass plate coated with an EVA foil. It is necessary to position the glass plate automatically with correct polarity and extremely high precision on the strings to an accuracy of ± 0.3 mm.

Handling of strings requires great care
Handling of the extremely sensitive strings requires great care to prevent breaking the cells. The supply containers for the strings are monitored with sensors and empty containers are reported to the operator separately for each polarity. During optional optical control of the strings using CCD cameras for damage to the individual cells, exterior contour errors, fissures and absence of solder strips, defective strings are rejected automatically, separated out and replaced.
All fault data is logged. The product and production data is read in with scanners and as an option, a label can be produced and applied to the panel. Simultaneously, the production data is recorded for later identification or ERP connection. This data is recorded and updated during the entire production process.

Freedom from dust is absolutely essential
In a preliminary working step, the glass panels are cleaned, an EVA foil applied and they are then moved to a glass storage unit for lay-up. It is necessary for the storage time in the storage device to be monitored strictly, because it is not permissible to expose the sensitive foils to light for longer than one hour. Simultaneously, it is necessary to avoid any dust deposition on the plates. It is not permissible for the sensitive plates to bend or sag at any time during transport or while in the storage unit; transportation must be accomplished without vibration. Storage and removal of the plates is accomplished automatically according to the Fifo or Lifo principle, depending on the requirements of the subsequent operations.
Special multiple tracks with particularly wide, toothed belts with dust-free coating provide for transport between the processing stations. The coating ensures a slip-proof hold during transport. Conveyors with high-temperature belts up to 200 °C are available for special applications.

Numerous versions are available for lateral transportation of the panels, laminates or modules, depending on the application requirements. Reversing stations can be integrated into the conveyor paths, if required, to properly position the modules for subsequent operations. These stations also satisfy the same conditions for extremely careful handling.
After lay-up, the strings are shifted laterally. This operation is still frequently accomplished manually, in exceptional cases, however, also with robots. Following this operation, the panels go to the laminator where they are laminated with EVA foils and rear foils and cut.

Highly sensitive control provides for precision pressing
The vast majority of photovoltaic modules are assembled with frames. For this purpose, sealing strips or pastes are first applied to all four sides of the laminate before it is inserted into the press by a portal robot or special belt conveyor. The four aluminum side channels are then pressed onto the laminate at an exactly metered pressure and screwed together, where applicable. Imprecise pressing or too high pressure easily leads to breakage of the sensitive glass panels. Essential for this process is an extremely sensitive control for the system.
The assembled modules are tested and classified in an automatic flasher. The modules are moved into the unit, positioned and contact made automatically. The system is adapted to a measuring system from a leading manufacturer of light equipment. The performance of the module is measured and documented by a 1 kW strong flash of light. The measured results from the system can be labeled on the modules as an option. Sorting according to performance classes is also possible.. The flashers can be set up either vertically or horizontally.

Profisafe bus basis for automation solution
All electrical equipment for the production facilities is based on the Profisafe bus automation system. The system parts are controlled by a master safety PLC S7 Profisafe with integrated Profibus-DP interface for increased safety requirements. Provision of the PLC with IP address for remote maintenance and diagnosis is possible if desired by the customer.

At the hygiene specialist Meiko, a fully-automatic robotic bending cell produces over 120 different parts with a bending accuracy of less than 0.1 mm. Photos: ABB

Industrial robots are increasingly becoming an alternative to conventional machine tools in mechanized metal processing. They bend, bead, cut, deburr, drill, machine and weld in continuous automated process chains with high quality and reproducibility as proven in the application at the machine producer Meiko in Offenburg. The machine company Meiko, producer of commercial dishwashing machines, realizes a bending accuracy of less than 0.1 mm over a bending length of greater than 2000 mm using a fully automatic robotic bending cell from ABB. Intelligent software tools from ABB ensure time-saving program of the robot and guarantee maximum precision. Robot-supported, active processing of sheet metal offers enormous productivity potentials. In addition to high performance industrial robots, optimum interaction with one another and with grippers and sensors are important prerequisites for exhausting the advantages of automation. Modern software tools also allow time-saving programming of the robots with production in progress. Three-shift manless production with robots Meiko Maschinenbau GmbH has increased its precision and productivity with a fully-automatic robotic bending system from ABB. This hygiene specialist from Offenburg produces over 120 different parts in high quality without humans in three-shift operation. The Offenburg company uses a 3-point bending technology for bending stainless steel plates. Here, precision is of central importance. The background is in the increasing number of bending points on the continuously more complex parts: With each additional bend, the requirements for accuracy increase as a matter of course. The robotic bending cells realized have a bending accuracy of less than 0.1 mm for bending lengths of over 2000 mm. The Robot-Studio software from ABB provides a decisive contribution to the positive results. Users can program their PC offline in a time-saving and cost-efficient manner instead of interrupting the production process on site. The Autopath function generates the required robot positions for processing even complex workpiece contours from 3D-CAD data within minutes.

True-Move function increases position of robot track
The True-Move function integrated into the control increases the precision of the robot track on the basis of a dynamic robot model. Regardless of the speed and load effect, the motion paths followed by the robot always correspond precisely to the programmed track.
Quick-Move shortens cycle times by automatic optimization of motion sequences. At different loading states, the robot always moves with the maximum possible acceleration or deceleration. With Multi-Move even complex applications in which the robots work simultaneously on one and the same part, independently of one another can be programmed simply and reliably. The intelligent software opens up new perspectives for the user for increasing quality and productivity.

ABB Portrait
More than 160,000 Robots Installed Worldwide
ABB Robotics is one of the leading suppliers of industrial robots, robotic software, module production cells offering service for highly differing automation application areas. Worldwide, ABB has installed more than 160,000 robots. In Germany, ABB achieved a turnover of 3.69 billion euros in 2008 with more than 11,000 employees.

Meiko Portrait
Commercial Dishwashing Machines
Meiko Maschinenbau GmbH & Co. KG with main offices in Offenburg is one of the best known manufacturers of commercial dishwashing machines as well as cleaning and disinfection machines. The latest figures from the group with 21 affiliate companies worldwide showed an 18% increase in turnover to 213 million euros. Over 1,600 employees contributed to this result. Strong customer proximity and an equally strong sales and service organization are considered to be primary factors for success.
For Meiko, the year 2008 was again distinguished by innovation and customer orientation. For this, the company received numerous prizes and awards, such as the "Catering Star" (Catering Inside) for the M-Commander In-Vision software and the "Star Award" (Top Hotel). As the best dishwasher manufacturer, Meiko became the "Super Partner for the Professional Association for Gastronomy and Large-Scale Catering Equipment (GGKA)".

BETTINA NEUBAUER

Industrial robots or process integrated quality control are used only by one third of the companies, according to our analysis, advised Dr. Steffen Kinkel from Fraunhofer ISI„. Photo: Fraunhofer ISI

Two out of three companies in Germany do not use custom automation technologies to date. This is the result of a study performed by the Fraunhofer Institute for System and Innovation Research (ISI) at the request of VDI, presented at the "Automation 2009" convention. "Considerable unexploited user potential is present here", emphasize Prof. Gerald Gerlach, Chairman of the VDI/VDE Association, Measuring and Automation Technology (GMA). "Many companies do not recognize the economic potential of automation technologies. For example, factors such as labor productivity and adherence to schedules can be increased considerably". For example, the labor productivity per employee with use of computer-aided-storage and material flow systems, costing 95,000 euros is nearly 20% higher than without such systems (79,000 euros). However, only 49% of the companies use such systems, according to the study. According to the ISI/VDI study, other automation technologies are also not used comprehensively by the industry. "Industrial robots or process-integrated quality control are used only by one-third of the companies, according to our analysis", advised Dr. Steffen Kinkel from Fraunhofer ISI. "Positive interrelationships to economic target values such as adherence to schedules, reject quota and labor productivity can be verified here particularly." Companies with robots deliver punctually more frequently For example, companies using industrial robots have a higher tendency to deliver their goods on time than companies without industrial robots. Process-integrated quality control results in a 30% lower reject quota, according to Kinkel. The study examined 1,600 companies in the processing branch. Gerlach indicated the strength of the automation sector on the basis of a theses entitled "Automation 2020". "In 2008, the branch achieved turnover figures of 35 billion euros in Germany. This represents every fourth job in the electrical technology sector." At least these employees are conscious of the fact that very little would function today without automation. Gerlach: "Whether in elevators, ticket machines or heating systems: automation technology is present in all products. However, for the public, this 'hidden technology' frequently remains hidden."

Automation will have to become the leading discipline for the German industry
Gerlach is convinced, this will have to change: "Automation will have to be accepted as the leading discipline in the German industry, because this sector will continue to play an important role as an employer in the future.“ VDI considers the largest areas of application and therefore chances for growth in Germany in the next few years to be in the area of machine construction as well as automotive technology.