Future Trends in Robotics Commercial Vehicle Megatrends India 2012 - - PowerPoint PPT Presentation

Future Trends in Robotics

Commercial Vehicle Megatrends India 2012 Raj Singh Rathee KUKA Robotics (India) Pvt. Ltd. info@kuka.in www.kuka.in

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 3

Introduction

Automotive Industry faces right now the largest period of growth in history:

REE’s (Rapidly Emerging Markets):

• China
• India
• Brazil
• Russia
• Malaysia
• Mexico
• Indonesia
• China has already replaced the US as largest

automotive market in the world

• In the “Rapidly Emerging Markets” the

sales volume will be six times larger in 2018

• 370 Mio. new cars up to 2013
• 715 Mio. New cars up to 2018
• Increasing industrialization and per-capital-

income will dramatically increase the car sales volume in general

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 4

Introduction

Actual production in India

100,000 200,000 300,000 400,000 500,000 600,000 700,000 800,000 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11

Commercial Vehicles

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 5

Introduction

To meet the requirements of a cost-effective mass- production the automotive industry worldwide will have to develop new body shop and production line concepts:

• shorter production lines with higher robot density to

minimize the required floor space

• shorter cycle time and faster cell-to-cell transport to

increase the required through-put

• higher availability to guarantee the daily output of the

body shop

• cost-efficient and multi-functional equipment to reduce the
• verall investment costs
• cost-efficient solutions for standard processes and

integration of new processes for light weight bodies

• lower life time costs specially in respect to energy

consumption

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 6

Content

• Compact Production Lines
• New Robot Generation for Future Body Shops
• Lean and Cost Effective Cell Concepts
• Multi-Functional Robot Controller
• Energy-Efficient Production Lines
• Sustainable and Energy-Efficient Robot Systems
• Reduction of Floor Space, Cycle Time and Enhanced Safety
• Safe Robot Technology

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 7

• Compact Production
• QUANTEC – The New Robot Generation

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 8

Compact Production: QUANTEC - Compact, Fast and Accurate Robots

The KUKA QUANTEC Series was especially designed for the future requirements of a compact body shop with highest output and shortest cycle time:

• extremely compact design with 25 % less volume
• intelligent material selection and latest casting technology
• 12 % weight reduction
• 30% reduced energy consumption
• minimized interference contours for enhanced accessibility
• very small foot print for maximum robot density
• reduced weight, highest stiffness of the structural elements

and new control algorithms guarantee:

• maximum dynamic and speed 25 % faster
• highest repeatability ± 0.06 mm
• highest path accuracy ± 0.15 mm

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 9

Compact Production: QUANTEC - Minimized Life Cycle Costs

The intelligent design and highly reliable components used for the KUKA robot system reduce the operating costs and the maintenance requirements drastically:

• up to 30% less energy consumption during production

and stand-by

• robust and wear free drive chain in axis 3 with straight

shafts and without belts

• well proven durable SIEMENS motors and sophisticated

drive technology

• oil change after 20.000 hours of operating time within 30

minutes

• exchange of buffer batteries after 4 years
• self-explanatory electronic mastering of all six robot

axes within 10 minutes

• easily accessible mechanical interfaces for wrist

exchange within 30 minutes

• very fast exchange of media supply without removing

the connectors through the 150mm hollow shaft

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 10

Compact Spot Robot – Increasing Robot Density

A significant reduction of the production area inside a body-in-white requires an increased robot density that can only be achieved with new robot concepts:

• a new generation of extremely compact spot-welding

robots with a low overall height

• these robots will be installed in front and between

standard or shelf-mounted robots

• the reduction of the production area leads to:
• increased energy-efficiency regarding the building
• increased number of process jobs per m2 and

shorter throughput-time

• reduction of non-value-adding transportation time
• the KUKA CSR family
• Reach approx. 1800mm
• Height approx. 1300mm
• Weight approx. 800kg
• Payloads 180kg, 150kg, 120kg, 90kg

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 11

Compact Production: QUANTEC - Productivity Benchmark

200 400 600 800 1000 1200 1400 1600

Productivity / Cycles per hour Power Consumption [Wh]

1000 2000 3000 4000 5000 6000 7000

Competitor QUANTEC

Productivity is a measure of the efficiency of a production process and is measured as a ratio

• f output per hour and costs per part:
• the energy-efficient design of the KUKA robot

reduces the required energy per production cycle compared to our competitors significantly

• Reduction of costs per part at the

same production volume

• Significant increase of production

volume without effects on the part costs

• Lower investment costs for a

cost-effective production

• the unmatched speed and acceleration of the KUKA

robot allow shorter cycle times without a significant increase in power consumption

200 400 600 800 1000 1200 1400 1600

Productivity / Cycles per hour Part Costs / Energy per Part [W]

1 2 3 4 5 6 7

Competitor QUANTEC 15% 20%

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 12

Compact Production: QUANTEC - Productivity Benchmark

Due to fluctuation in demand the production volume often has to be adapted to meet the market requirement immediately:

• installing the new KUKA robot system guarantees

shorter cycle times and higher part throughput in comparison to our competitors

• Scalable productivity buffer due

to different robot models

• Increased production capacities

for the same investment costs

• Highest volume flexibility to react
• n market fluctuations
• flexible adaptation of the production volume

without adding additional robots and almost no adverse effects on the part costs

Production Benchmark Program Automotive

45 55 65 75 85 95 105

Productivity / Parts per hour Power Consumption [Wh]

500 1000 1500 2000 2500 3000 3500

Competitor QUANTEC

QUANTEC PRIME + 32% QUANTEC EXTRA + 18% Competitors

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 13

• Lean and Cost-Effective Production Concepts
• Multi-Functional Robot Controller

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 14

SW-based Closed Loop Control

DSE

SW-based Safety PLC

ESC SRDW

SW-based ProfiNet / ProfiSafe

CP1616 ET200S/F

KR C4 Controller: Software Replaces Hardware-Components

SW-based Master-Stack

MFC

SW-based Main Contactor

K1/2

SW-based Visualization

VGA

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 15

KR C4 Controller: Software Replaces Hardware-Components

SW-based Closed Loop Control SW-based Closed Loop Control

SW-based Safety PLC SW-based Safety PLC

SW-based ProfiNet / ProfiSafe SW-based ProfiNet / ProfiSafe

SW-based Master-Stack SW-based Master-Stack

SW-based Main Contactor SW-based Main Contactor

SW-based Visualization SW-based Visualization

SW-based Closed Loop Control SW-based Closed Loop Control

SW-based Closed Loop Control SW-based Closed Loop Control

SW-based Safety PLC SW-based Safety PLC

SW-based Safety PLC SW-based Safety PLC

SW-based ProfiNet / ProfiSafe SW-based ProfiNet / ProfiSafe

SW-based ProfiNet / ProfiSafe SW-based ProfiNet / ProfiSafe

SW-based Master-Stack SW-based Master-Stack

SW-based Master-Stack SW-based Master-Stack

SW-based Main Contactor SW-based Main Contactor

SW-based Main Contactor SW-based Main Contactor

SW-based Visualization SW-based Visualization

SW-based Visualization SW-based Visualization

A powerful multi-core processor allows the general replacement of formerly hardware-based functionalities with software-based tasks:

• increase of system availability
• smaller spare part stock
• higher adaptability to customer’s requirements
• 30% more compact controller
• 35% reduction of controller hardware

components

• 50% reduction of controller cables and

connectors The reduction of controller hardware components results in a significant

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 16

Energy-efficient production Sustainable and energy-efficient robot systems

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 17

Energy Efficiency: Development of energy prices

Development of Energy Prices (approx. 6% Inflation)

End Customer Stock Exchange Price

Development of Energy Prices (approx. 6% Inflation)

End Customer Stock Exchange Price

Source: www.stromvergleich.de

Energy prices will definitely rise during the coming years – it is only the exact magnitude

• f this increase that cannot be predicted:
• Within the service life of a robot system, the

energy price for the automotive industry will more than double from €0.10 to €0.20 for 1 kWh.

• As natural resources become scarcer, this will

affect energy prices. This is because the development of competitive renewable energy sources has only just begun.

• Saving energy by installing energy-efficient robot

systems will be one new “source of energy”.

Incalculable energy costs as a corporate risk

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 18

Requirements for an energy management system that will allow companies to reduce their energy consumption systematically and continuously:

• Reduced costs – Up to 10% of energy costs could be saved in

the first few years after implementation of an energy management system.

• Environmental protection – Efficient energy management is an

important element, as it can make a major contribution to the reduction of greenhouse gas emissions.

• Sustainable industry – New energy concepts and innovative

energy technologies are the key to operating successfully in the market in the coming years.

• Improved image – Ecological requirements are tending to play

a greater role in public image.

Energy Efficiency: Energy management systems in acc. with DIN EN 16001:2009

Energy-intensive companies can benefit from legislative relief

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 19

Sustainable Product Development

Energy Efficiency: The Consequences

The Energy-Efficient Robot System

• Involves all steps during planning, engineering and final design of the

robot system including materials and production processes

• Supports the energy-efficient use of the robot system during the

complete life span by online condition monitoring

• Considers the possibilities of recycling parts of the robot system or

the reuse of the complete system

• Reduced power consumption during motion
• Reduced power consumption during stand-by
• Online monitoring of energy consumption during production
• Report of energy consumption data to energy management
• Strategies for an energy-efficient programming
• Recuperation of brake energy

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 20

Engineering and design

• 12% weight reduction
• 30% reduction of volume
• Sustainable materials

Supply chain logistics:

• Innovative logistics concept
• 60% reduction of CO2 emissions

Robust robot systems:

• Service life of more than 15 years
• Repurchase of used systems

Energy efficiency: Sustainability throughout the entire life cycle

Energy efficiency on the shop floor

• Up to 30% less energy consumption

in motion

• Up to 80% less energy consumption

in standby mode

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 21

Energy Efficiency: Energy consumption in a car plant

Energy Consumption Plant

Paint Shop Body Shop Final Assembly Press Shop Components Air Conditioning Light Water-cooling

Energy Consumption Body Shop

With an average share of 22 % less than one third

• f the energy required in an automotive plant is

consumed in the body shop:

• in the body shop approx. 50% of the energy is

consumed by the building including light, air conditioning and water cooling

• the other 50 % are consumed by robot

systems, process equipment, transportation systems etc.

• at an average only 5% of the plant-wide energy

demand is consumed by the robot systems

• next to the possible energy savings that are possible

with the new generation robot systems the building itself has the biggest potential for energy conservation concepts

• shorter and more compact production lines with

significantly increased robot density

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 22

In a typical tree-shift-production with a production stop over the weekend the robot systems show different levels of energy consumption:

• Robot in Motion
• 19 % robot system is moving with an average

energy consumption of 2,5 kW to 3,5 kW

• Robot is stopped 2sec to 20sec
• 10 % brakes are not activated with an average

energy consumption of 650 W to 800 W

• Robot is stopped 20sec to 10min
• 26 % brakes are activated with an average energy

consumption of 220 W

• Robot is stopped 10min to 3h
• 17 % brakes are activated with an average energy

consumption of 220 W

• Robot is stopped over the weekend
• 28 % brakes are activated with an average energy

consumption of 220 W

Energy Efficiency: Energetic States of a Robot in Production

Energy consumption states of a robot system in a three-shift-production

19% 10% 26% 17% 28% Robot in Motion Wait 2sec - 20sec Wait 20sec - 10min Wait 10min - 3h Wait Weekend

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 23

• 80 %
• 30 %
• 15 %
• 60 %
• 30 %

Robot in Motion Wait 20sec – 10min Wait 2sec – 20sec Wait 10min – 3h

Blended Breaking Temperatur Controlled Fan

Wait Weekend

KR C4 and QUANTEC Standby-Mode 2 Standby-Mode 3

Energy Efficiency: KUKA Energy-Efficiency Functions 19 % 26 % 10 % 17 % 28 %

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 24

Energy consumption of a robot system in a three- shift-production with production break over the weekend:

• Assumption:
• Energy consumption in motion 3.0 kW
• 5.000.000 brake cycles

32 h Robot in Motion 16,8 h Wait 2sec – 20 sec 43,7 h Wait 20sec – 10min 28,5 h Wait 10min – 3h 47 h Wait Weekend

168 h per Week

Energetic State Energy Consumption Energy Consumption 96 kWh → 9,60 € 11,8 kWh → 1,18 € 9,6 kWh → 0,96 € 6,3 kWh → 0,63 € 10,6 kWh → 1,06 €

134,3 kWh → 13,43 €

67,2 kWh → 6,72 € 4,7 kWh → 0,47 € 8,1 kWh → 0,81 € 4,4 kWh → 0,44 € 2.2 kWh → 0,22 €

86,6 kWh → 8,66 €

KR C4 and QUANTEC

• 30%
• 60%
• 15%
• 30%
• 80%
• 36%
• 2480 kWh per Year
• 1426 kg CO2 per Year
• 248 € per Year

CO2 – Emission related to Energy 2009: 575 g CO2 / kWh

Energy Efficiency: KUKA Sustainability in Numbers

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 25

Energy consumption

The KR C4 and QUANTEC series are market leaders in terms of speed and energy efficiency

Energy efficiency – Reduced energy consumption in the production motion

– 30%

• 15% reduction in weld gun weight by means of

robot-based gun compensation

• 12% reduction in weight of robot structure
• Optimized gear units with minimized friction
• Energy-efficient motor and drive technology
• Model-based closed loop control for energy-efficient

motion and positioning

• Intelligent brake control system
• Temperature-controlled cabinet fan

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 26

KR C4 supports the PROFIenergy profile for reducing energy consumption in standby mode and for efficient energy management

• The standard was defined by the German automotive

industry together with SIEMENS and KUKA

• During breaks in production, the robot controller

automatically reduces energy consumption

• The breaks in production are initiated by the line PLC using

standardized PROFInet services

• The KR C4 supports two different standby modes which are

activated according to the length of the break

• The KR C4 supports, by means of configurable

measurement points, all necessary information for a future plant-wide energy management system.

Standby 2 Standby 3

– 30% – 80%

Energy efficiency – Virtual main switch in standby mode

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Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 27

Robot simulation

Model-based energy consumption forecast Analysis Checking Settings

• Payload category of the robot
• Tooling – Weight – Center of gravity
• Adaptation of velocity and acceleration
• Energy-optimized motion profiles
• Energy-optimized robot paths
• Optimized robot selection
• Cycle time and energy-optimized paths

Energy efficiency must be taken into consideration as early as the planning phase:

• The expected energy consumption of the application must

be forecast on the basis of a robot path programmed

• ffline.
• The energy efficiency is improved by adapting the payload

category, the tool parameters and the velocity.

• Optimization of robot and tool selection, as well as the path and

velocity, ensures maximum energy efficiency.

Energy efficiency – Consumption forecasts during planning

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 28

• Reduction of Floor Space, Cycle Time and Enhanced Safety
• Safe Robot Technology

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 29

In the case of manual loading/unloading stations, additional measures must be taken to protect the operator:

• separation of operator and robot and intermediate supports

(additional tools and increased space requirements)

• if parts are loaded directly into the gripper, the robot drives

must be safely deactivated (cycle time losses due to restarting)

Safe Robot Technology: Simplification of Manual Loading Station

Safe Robot Technology:

• the safe operational stop greatly simplifies direct loading of

parts into the robot gripper

• the velocity of the robot moving in and out the loading area is

safely monitored and the drives remain activated during loading

• Reduced space and shorter cycle times
• No costs for additional positioning systems
• Lower costs for additional safety components

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 30

Until now, the workspaces of the operator and the robot were strictly separated – assembly tasks were either fully manual or fully automated:

• complex sensor systems are required for automation
• cost-optimized partial automation was not possible

Safe Robot Technology: Partial Automation of Manual Tasks

Safe Robot Technology:

• robot tasks are optimally broken down into autonomous and
• perator-guided sequences
• utilizes the high-availability sensory capabilities of the operator
• Reduces costs by means of scalable

automation

• Implements cost-effective intermediate

steps on the way to full automation

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 31

Until now, the workspaces of the operator and the robot were strictly separated – robots were always surrounded by safety fences that hampered production flow and the flow of materials:

• safety fences increase the space requirements and make an

unobstructed production flow more difficult

• very low degree of automation in final assembly

100% 60% 40% 20% 80% 100% 60% 40% 20% 80%

Sensor unit Space with restricted detection capability 6.4 x 4.8 m 9.8 x 7.4 m (maximum field of vision) 1.5 m 5.0 m 7.5 m reach

Safe Robot Technology: Cooperation of Robot and Worker

Safe Robot Technology:

• robot and operator work next to one another without physical

safeguards

• if the operator gets closer to the robot, the velocity of the robot

is gradually reduced and failsafe monitored

• Reduction of costs for access control and

access protection (roll doors, light curtains and laser scanners)

• Unimpeded flow of materials and production

flow combined with low space requirements

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 32

KUKA Robots in CV production in India

• Ashok Leyland
• Bharat Benz
• M&M
• TATA

www.kuka-robotics.com

Future Trends in Robotics

KUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 33

Thank You