Simulation of Human-Industrial Robot Collaboration in Machining and Logistics Environments

Sammanfattning: The retention of elderly workers by companies in industrialized nations, due to reasons of economic stagnation or changing demographics, is resulting in an increase of the average age of the workforce (Zaeh and Prasch, 2007). With the deterioration of physical human ability with age, the performance of man-power engaged in partially-automated work environments is likely to suffer as a result. Robotic automation serves as an alternative to the performance of tasks that are repetitive, hazardous and/or have requirements of high precision, speed of operation and/or strength. Human workers however, possess superior sensor-motoric and decision making capabilities, and are extremely flexible to change (Krüger, Lien & Verl, 2009). As full robotic automation is at times not possible to implement in certain situations due to issues of practicality and complexity, Human-Industrial Robot Collaboration (HIRC) may potentially enable the inclusion of an elderly workforce in value adding processes without compromising on productivity and at times even resulting in its improvement (Reinhart, Spillner & Shen, 2012). Presented in this thesis are two cases outside the traditional scope of HIRC assembly. Both industrial cases are from a heavy vehicle manufacturer and demonstrate the potential width of HIRC workstations. Case 1 simulates in machining environments, the assisted inspection of inline engine blocks and Case 2 simulates in logistics environments, material preparation for assembly line orders. Both manual cases were simulated with a DHM tool and the results evaluated with regard to ergonomics and productivity by observing the biomechanical load on the manikins and operation time through predetermined motion time system and stopwatch techniques respectively. HIRC solutions were proposed, analysed with the tools outlined above and compared with their manual counterparts. Given the limitations of the evaluation tools and simplification of simulations, preliminary results demonstrate the improvement of process ergonomics and cycle time in applications areas outside the traditional assembly scope of HIRC.