The video shows the sophisticated robot application ”Automatic control cabinet cabling”, which Fraunhofer IPA implemented together with the company Rittal. The IPA software ”pitasc” is used for force-controlled assembly processes. Two UR robot arms carry out the task together. The modular pitasc system enables the robot arms to move and rotate in parallel. They work hand in hand, with one robot holding the cable and the second bringing it to the starting position for the cabling. The robots can find, tighten, hold ready, lay, plug in, fix, move freely or immerse cables. They can also perform push-ins and pull tests.
In general, “pitasc“ is used to program force-controlled assembly tasks in a structured and modular manner. Prefabricated, reusable program modules help to implement an application faster than before. “Pitasc“ helps to re-parameterize the program for a new variant. Using force-torque sensors on the robot, “pitasc“ records the process forces and thus enables force-controlled search and joining strategies. The compensation of component and position tolerances ensures the distribution of forces even with sensitive components.
“pitasc“ is used to program force-controlled assembly tasks in a structured and modular manner
Flexibility is an often heard requirement for assembly automation with robots. So how can far-reaching flexibility be achieved? This is possible with the “pitasc“ software from Fraunhofer IPA. The video (see “Videos“) shows what it offers: An assembly task is no longer programmed point by point but in relation to the workpiece. Thus, “pitasc“ adapts the assembly process itself for new product variants with the help of updated parameters. The arrangement of robot and components is also flexible in terms of location and, for example, repositioning the robot does not require any reprogramming. Furthermore, “pitasc“ offers a force-controlled insertion strategy for robust assembly of plastic parts as well as force monitoring and strategies to prevent components from jamming during assembly.
Automated assembly by robots would be a good alternative to manual labor or expensive installations in many plants. However, application specific robot programming is often too costly and especially in times of small batch sizes and increasing variant diversity not profitable. The solution: Why not use standard hardware that can be flexibly and quickly adapted to new variants and processes, thanks to sophisticated software? The “pitasc“ software from Fraunhofer IPA makes it possible.
In a partner project with the company Wago, modularly programmed robots take over an automated mounting-rail-assembly. With the help of ready-to-use program modules, the robots equipped with sensors can be programmed in a force-controlled manner. In a test scenario, a lightweight robot picks up a rail-mounted terminal block, moves it to the mounting location and lets it click into place with a tilt-in motion. When rearranging the assembly application or mounting a different component variant, it is not necessary to reprogram the robot – a simple parameter adjustment is sufficient. “pitasc“ can be used independently of the robot manufacturer and can be flexibly adapted to individual applications. The software facilitates the handling of diverse product variants and demanding assembly processes while keeping investment costs manageable.
Exemplary robot force-controlled assembly by demonstration with a control cabinet terminal
“pitasc“ is adapting the assembly process itself for new product variants with the help of updated parameters
“pitasc“ is assembling mounting rails automatically
Fraunhofer Institute for Manufacturing Engineering and Automation IPA