How will production of the future look? KUKA Robotics look

Huge work on creation of the plants of the future is around the world conducted. Production of the future provides intellectual, connected processes of industrial production and transportation on the basis of cyberphysical production systems (CPPS). In other words, such plants, using the advanced methods of interaction, independently and intellectually react to the changing tasks. The plant of tomorrow needs to organize and to continuously optimize the production processes. It will allow to counteract negative effects of one more process: demographic changes. Because of falling of birth rate and aging of the population of modern industrial societies essentially new solutions are necessary. Without "the smart plants" it is just impossible to reach required increase in productivity and also to effectively use the available natural resources.

The plant of tomorrow needs to organize and to continuously optimize the production processes

The KUKA company develops key technologies for creation of new high-performance and ergonomic jobs. Colleague robots, the systems of the mobile help, autonomous vehicles and intelligently connected automation systems support people in a working environment, removing from them excess loading. Cooperating with specialists of the different industries, KUKA already implements the flexible digital production processes opening new opportunities in competitive environment. They will forever change production methods.

Concept of matrix production

Increase in demand for unique products changes the modern industry. Unstable market situation even more increases relevance of economic release of small lots of products. For example, in automotive industry even more often there is a problem of release as it is possible bigger number of models and complete sets at the variable volumes of batches. The concept of matrix production provides the maximum flexibility on all chain of product output. When changing the program of release a technology system is automatically rebuilt on the run. It does possible to release batches of unique products within mass production.

The concept of matrix production provides the maximum flexibility on all chain of product output

In matrix production standard production cells which are placed in grid nodes are applied. At the same time the number of such cells can be practically any. Such cells are equipped with general technology equipment and are capable to execute all main transactions. For example, in cells industrial robots and rotary tables with the necessary industrial equipment are installed. Besides, cells are equipped also with the specialized equipment. Procurements and the equipment are transported by automatic carts between cells.

In matrix production of procurement and the equipment are transported by automatic carts between cells

Existence of the end-to-end intellectual digital trunk integrating all processes of creation of products allows to readjust easily and quickly production cells on release of new products, without interrupting production.

Advantages to the customer:

• Scalability of overall performance of the enterprise which changes step by step according to the size of a technology system
• Scalability of number of the released executions: the concept of matrix production differs in high flexibility
• Scalability at release of diverse products according to the changing demand
• Universality: simple and reliable start of production of new products
• Modularity: cutting of costs for maintenance thanks to high operational readiness, use of well familiar equipment, convenience of service and the small nomenclature of spare parts

New robots for the plants of the future

Industrial robots of the KR QUANTEC series

KR QUANTEC is the innovation generation of robots setting new standards both in traditional and in digital production. Universal KUKA robots find application practically in all industries - from automotive industry and foundry production to the medical sector.

Series of industrial KR QUANTEC robots

KR QUANTEC robots belong to the class of high loading capacity and show a wide portfolio of parameters of loading capacity and a range.

Size of the work area and loading capacity of KR QUANTEC robots

Scopes

A wide choice of executions — for example with console or ceiling mounting and also for work in foundry workshops — allows robots to carry out a set of specialized tasks.

KR QUANTEC robots can be used to accomplishment of the following transactions:

• Drawing the gluing, condensing means and similar materials
• Fastening and spressovyvaniye
• Manipulations on metalworking machines
• Laser-beam cutting
• Laser bonding
• Soldering
• Machining
• Measurement, testing and check
• Assembly, laying and loading
• Laying on pallets
• Other types of welding
• Stamping, forging is also flexible
• Packaging and completing
• Water-jet cutting
• Spot welding
• Manipulations by machines for processing of plastic
• Manipulations by the machine for casting of metal under pressure

The number of parts and nodes in new generation of robots is reduced by the value reaching 50%, and simple modular construction allows to manufacture quickly robots to order.

Low total ownership cost

Robots of the KR QUANTEC series in addition to small initial costs and low expenses on maintenance differ in low power consumption. Among the constructive measures directed to decrease in idle times and reduction of labor input of maintenance — simplification of mechanical drives, application of the innovation parts, nodes and materials. Smooth circuits of a wrist of the manipulator and the small occupied space significantly simplify exploitation of robots. As a result operating costs managed to be reduced considerably. In particular, the average time between failures was several times raised

High flexibility

Industrial robots of the KR QUANTEC series received the "choice of the optimal mode of movement" function. These are programmatically the set modes optimizing a trajectory of movement of the robot according to a specific solvable objective.

For example, "the trajectory mode" considerably increases movement accuracy on continuous trajectories. "The dynamic mode" allows to increase speed and by that reduces cycle time. These and other modes and also a possibility of upgrade with increase in loading capacity and existence of different specialized executions make KR QUANTEC robots exclusively flexible.

Mobile KMR iiwa robots

KMR iiwa is a combination from the sensitive robot of easy construction LBR iiwa and the mobile flexible platform. KMR is decrypted as KUKA Mobile Robotik (mobile robotics of KUKA). As the name and separate components testify, KMR iiwa differs in high mobility and flexibility.

Mobile KMR iiwa robot

Production processes constantly change. Therefore mobile robotic systems should be even more flexible. The maximum mobility and the autonomous principle of work allow to optimize production significantly.

Advantages

• The possibility of combination allows to create the individual complete solution. The building block system of KMR iiwa provides a number of opportunities of combination of technology of the robot, mobile platforms and industrial components.
• Sensitivity: seven special sensors of hinge moment on each axis of the robot of easy construction of LBR iiwa do it sensitive to the environment. It moves safely and without safety barrier – at any outside contact it at once stops.
• Autonomy: thanks to laser scanners the mobile platform can move completely independently too. It controls the environment. If on its way there is a person or a subject, it at once reacts.
• Mobility: specially developed wheels Ilona provide to the mobile platform polydirectional movement and rotation of 360 degrees. The wheel consists of several rollers located at an angle 45 degrees to an axis. Such mobility reduces time of movement and prevents idle times in production process.
• Accuracy: even in the conditions of limited space of KMR iiwa reaches positioning accuracy +/-5 mm.
• Intellectuality: using KUKA.NavigationSolution KMR iiwa reliably goes round any obstacle and finds a new way. The platform defines the location in real time on the basis of these laser scanners of a security system and rotational speed sensors of wheels, on independently created card of the environment.
• Independence: a power supply of the vehicle and the robot is performed at the expense of Li-ion rechargeable batteries.
• Convenience to the user: KUKA Sunrise Cabinet, the multikinematic management system for the vehicle and the robot, simplifies management and use of KMR iiwa in practice.

Mobile platform KUKA 1500

KMP 1500 is the polydirectional mobile platform, independently and flexibly moving in space. In a combination with the newest management system of KUKA Sunrise she offers for the industry of the future modular, universal and, first of all, mobile solutions of production.

Mobile platform KMP 1500

At the plant of the future there will be no set routes and tough processes. Intellectual autonomous vehicles will equip robots and mechanisms with tools directly "on the fly", allowing production to function with flexibility inconceivable earlier. The mobile KMP 1500 robotic platform is a new element of matrix production of the future.

Advantages

KMP 1500 is the polydirectional mobile platform expected automation in Industrie 4.0.

Advantages to customers:

• Limitlessness and accuracy of maneuvering. The drive KUKA omniMove equipment allows KMP 1500 to move from the place in all directions. This advanced technology of a wheel allows to execute exact positioning to +/-5 mm even in the conditions of limited space. It allows to create compact and high-precision solutions of automation in logistics.

• Off-line and flexible warehouse control. KMP 1500 independently delivers necessary parts or returns the processed parts on a warehouse. KUKA.NavigationSolution allows a system to move in space freely without classical elements of aiming at a trajectory and navigation. It simplifies integration in the changing conditions, increasing thereby profitability of management of logistic processes.

• Force, security and reliability. With a loading capacity up to 1500 kg of KMP of 1500 safely moves products throughout all production process. It meets all necessary standards of security and has the maximum flexibility. The built-in laser scanners of security do possible autonomous movement throughout all production process.

Bodies up to 1500 kg are not a problem for KMP 1500