Enabling technologies that drive Industry 4.0 and smart factories are pushing in new equipment and system development also to prevent human workers from repetitive and non-ergonomic tasks inside ...manufacturing plants. One of these tasks is the order-picking which consists in collecting parts from the warehouse and distributing them among the workstations and vice-versa. That task can be completely performed by a Mobile Manipulator that is composed by an industrial manipulator assembled on a Mobile Robot. Although the Mobile Manipulators implementation brings advantages to industrial applications, they are still not widely used due to the lack of dedicated standards on control and safety. Furthermore, there are few integrated solutions and no specific or reference point allowing the safe integration of mobile robots and cobots (already owned by company). This work faces the integration of a generic mobile robot and collaborative robot selected from an identified set of both systems. The paper presents a safe and flexible mechatronic interface developed by using MBSE principles, multi-domain modeling, and adopting preliminary assumptions on the hardware and software synchronization level of both involved systems. The interface enables the re-using of owned robot systems differently from their native tasks. Furthermore, it provides an additional and redundant safety level by enabling power and force limiting both during cobot positioning and control system faulting.
The innovation-driven Industry 5.0 leads us to consider humanity in a prominent position as the center of the manufacturing field even more than Industry 4.0. This pushes us towards the hybridization ...of manufacturing plants promoting a full collaboration between humans and robots. However, there are currently very few workplaces where effective Human–Robot Collaboration takes place. Layout designing plays a key role in assuring safe and efficient Human–Robot Collaboration. The layout design, especially in the context of collaborative robotics, is a complex problem to face, since it is related to safety, ergonomics, and productivity aspects. In the current work, a Knowledge-Based Approach (KBA) is adopted to face the complexity of the layout design problem. The framework resulting from the KBA allows for developing a modeling paradigm that enables us to define a streamlined approach for the layout design. The proposed approach allows for placing resource within the workplace according to a defined optimization criterion, and also ensures compliance with various standards. This approach is applied to an industrial case study in order to prove its feasibility. A what-if analysis is performed by applying the proposed approach. Changing three control factors (i.e., minimum distance, robot speed, logistic space configuration) on three levels, in a Design of Experiments, 27 layout configurations of the same workplace are generated. Consequently, the inputs that most affect the layout design are identified by means of an Analysis of Variance (ANOVA). The results show that only one layout is eligible to be the best configuration, and only two out of three control factors are very significant for the designing of the HRC workplace layout. Hence, the proposed approach enables the designing of standard compliant and optimized HRC workplace layouts. Therefore, several alternatives of the layout for the same workplace can be easily generated and investigated in a systematic manner.
Nowadays, several manufacturing systems are evolving towards a greater collaboration between human and robots. The development of such systems requires integrated design tasks involving many ...disciplines and domains such as systems engineering, safety analyses and multi-physics. Furthermore, the increasing presence of multiple and structured requirements makes the use of models inevitable during the designing phases and also strongly helpful during other phases of the system life-cycle. Besides, for a better efficiency, there is an increasing demand to have a Digital Twin of the system to be used for different purposes such as design improvements by playing different scenarios, virtual commissioning and controlling maintenance activities. In this paper, we first summarize the research context, the reference methodologies, and the emerging needs for Digital Twin creation. Then, we apply a design approach including Model-Based Systems Engineering (MBSE), Model-Based Safety Assessment (MBSA) and multi-physics modeling for the design of a collaborative workplace for the assembly of Electro-Mechanical Actuators on an aircraft wing. An operational flow to integrate MBSE, MBSA and multi-physics modelling activities is provided. Then, after having identified some relevant scientific barriers, we provide a meta-model for system models integration within a digital twin framework.
Optimizing and predicting the energy consumption of industrial manufacturing can increase its cost efficiency. The interaction of different aspects and components is necessary. An overarching ...framework is currently still missing, and establishing such is the central research approach in this paper. This paper provides an overview of the current demands on the manufacturing industry from the perspective of digitalization and sustainability. On the basis of the developed fundamentals and parameters, a superordinate framework is proposed that allows the modelling and simulation of energy-specific properties on several product and process levels. A detailed description of the individual methods concludes this work and demonstrates their application potential in an industrial context. As a result, this integrated conceptual framework offers the possibility of optimizing the production system, in relation to different energy flexibility criteria.
Describing and supplementing geometric shapes (parts) and layouts (assemblies) with relevant information is key for successful product design communication. 3D annotation tools are widely available ...in commercial systems, but they are generally used in the same manner as 2D annotations in traditional engineering drawings. The gap between technology and practices is particularly evident in plain text annotations. In this paper, we introduce a functional classification of text annotations to provide an information framework for shifting traditional annotation practices towards the Model-Based Definition (MBD) paradigm. In our view, the current classification of dimensions, tolerances, symbols, notes, and text does not stress the inherent properties of two broader categories: symbols and text. Symbol-based annotations use a symbolic language (mostly standardized) such as Geometric Dimensioning and Tolerancing (GD&T) to provide precise information about the implications of geometric imperfections in manufacturing, whereas notes and text are based on non-standardized and unstructured plain text, and can be used to convey design information. We advocate that text annotations can be characterized in four different functional types (objectives, requirements, rationale, and intent), which should be classified as such when annotations are added to a model. The identification and definition of a formalized structure and syntax can enable the management of the annotations as separate entities, thus leveraging their individual features, or as a group to gain a global and collective view of the design problem. The proposed classification was tested with a group of users in a redesign task that involved a series of geometric changes to an annotated assembly model.
•A classification is proposed for shifting traditional annotation practices towards the Model-Based Definition paradigm.•Four functional types are described, which should be clearly identified in the 3D model.•The classification is tested with a group of users in a redesign task.•The approach is intended to inform novel mechanisms for using annotations as a data source for engineering design.
Design process is usually based on past experiences and best practises which compose the company know-how. The challenge is to identify common patterns in the design solutions generated for different ...design problems. The present paper focuses on the identification of product patterns by using a graph-based approach. It deals with the designing of automotive gearboxes and with the development of an approach and a software tool aimed to support preliminary design and CAD modelling activities in gearbox designing. The approach is applied to two different architectures of manual transverse gearboxes characterized by two and three shafts. It aims at the identification of common design features through the detection of the directed graphs matching. A Matlab software tool for gearbox preliminary design is implemented according to the detected common features. The proposed approach and the developed software tool provide an effective way to keep and re-use company know-how, especially in the context of large automotive companies.
Abstract
In the context of Industry 4.0 and Industry 5.0, the introduction of collaborative workplaces, where humans and robots work together, represents a growing trend to improve the productivity, ...adaptability, and flexibility of production plants. Indeed, human–robot collaboration (HRC) is a very deepened topic in the scientific community and the designing of collaborative workplaces is a challenging issue due to the high level of complexity and multidisciplinary of its features. This work tackles the complexity of collaborative workplaces and proposes a structured framework to support strategic decisions in designing. A multi-level designing framework is proposed as a supporting tool for designers. Within five domains of collaborative robotics, the elements of a collaborative workplace are identified and proposed in a framework in order to better consider human safety and working conditions during the designing process. A decomposition matrix and an adjacency matrix are used to develop a multi-level designing workflow. Finally, an interactive tool is presented, named “Smart Graph Interface” (SGI), to read and exploit the contents of the framework. The SGI is applied to three case studies from the literature, to spread out principal outcomes in terms of applicability and robustness.
The purpose of this paper is to assess the main effects on the geometric errors in terms of flatness, circularity and cylindricity based on the size of the printed benchmarks and according to the ...position of the working plane of the 3D printer. Three benchmark models of different sizes, with a parallelepiped and cylinder shape placed in five different positions on the working plane are considered. The sizes of models are chosen from the Renard series R40. Benchmark models are fabricated in ABS (Acrylonitrile Butadiene Styrene) using RepRap Prusa i3 3D printer. A sample of five parts for each geometric category, as defined from the R40 geometric series of numbers, is printed close to each corner of the plate, and in the plate center position. Absolute Digimatic Height Gauge 0–450 mm with an accuracy of ± 0.03 mm by Mitutoyo is used to perform all measurements: flatness on box faces, and circularity/cylindricity on cylinders. Results show that the best performances, in terms of form accuracy, are reached in the upper-left printable area while they decrease with the sample size. Being quality a critical factor for a successful industrial application of the AM processes, the results discussed in this paper can provide the AM community with additional scientific data useful to understand how to improve the quality of parts which may be obtained through new generations of 3D printer.
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