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November 2019

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2019

Robotics Handbook

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Contents

2019 • therobotreport.com

•

C OBOTS

D EVELOPMENT

06_ TRI teaches mobile manipulator for

household use with VR, simulation

10 _ DHL on the state of warehouse robotics

14 _ Robotics and 5G enable remote surgeries in China

18 _ 5 design process elements for successful

robot production

M OBILE ROBOTS

22 _ 6 River Systems acquisition: Mobile robots

optimize internal logistics

32 _ 6 trends to watch in autonomous mobile robots S OFTWARE

38 _ OpenAI teaches robot hand to single-handedly

solve Rubik’s Cube

42 _ How the power of cloud computing benefits robotics

52 _ When will high-DOF robot arms matter? 56 _ UR5 cobot makes automation a snap at Zippertubing

60 _ Surgical system uses KUKA cobot for

sensitive precision

M OTION CONTROL

64 _ Examining motion control at the Healthcare

Robotics Engineering Forum

66 _ Consider your environment when designing or selecting robot joints

a must in new economy

28 _ Ford Spain uses MiR mobile robots to

E XOSKELETONS

74 _ Designing lightweight, upper-body exoskeletons E ND EFFECTORS

80 _ Grippers grow with collaborative robotics market

86 _ How to design precise parallel grippers for cobots S ENSING/VISION

90 _ 6 common mistakes when setting up

safety laser scanners

96 _ Cleo Robotics compact drone taking on dangerous jobs

November 2019

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THE ROBOT REPORT

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DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

DIGITAL MARKETING

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EVENTS

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EDITORIAL

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November 2019

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THE ROBOT REPORT

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Design & Development •• •• •

•• •• •

•• ••

TRI teaches

mobile manipulator for household use with VR, simulation Toyota Research Institute is working to make it easier for robots to learn tasks.

By Eugene Demaitre • Senior Editor, The Robot Report

Robust mobile manipulation, which is starting to appear in supply chain operations, is a step toward service robots with more generalized capabilities. Toyota Research Institute recently shared the state of its research on household robots. Aging populations in Europe, East Asia, and North America pose challenges, according to a United Nations study cited by Toyota Research Institute (TRI). One of the goals of service robotics is to enable people to “age in place,” or remain in their homes with as much autonomy as possible and without scarce human aid. Unlike other technology enterprises and automakers working on self-driving cars, Toyota has positioned itself as a “mobility company” as it looks to diversify its offerings beyond vehicles and into assisting households. As part of that effort, the company set an internal challenge of teaching robots to perform a variety of tasks in actual homes. “Teaching robots to perform tasks is a key element of advancing fleet learning for enabling useful robot assistants in homes,” Jeremy Ma, senior manager of robotics at TRI, told The Robot Report. “Using an immersive telepresence system makes teaching and performing these tasks much more efficient, and we hope our progress can benefit others in the robotics community.” Perception, navigation, and mobile manipulation in the household Rather than map each home, as iRobot has done with recent floor-cleaning robots, TRI wanted its autonomous mobile robot to move around on its own as humans do. The prototype robot chooses a path based on what it has learned, explained Dan Helmick, software engineer and senior robotics manager at TRI. He is also co-author of “A Mobile Manipulation System for One-Shot Teaching of Complex Tasks in Homes,” a study published by Cornell University. The robot can stop if it encounters something unexpected, Helmick said.

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TRI has trained its prototype household robot to conduct multi-step tasks. | Source: Toyota Research Institute

TRI’s mobile manipulator uses a combination of off-the-shelf and custom hardware. It includes four Intel RealSense cameras and two 5-megapixel Basler cameras for a wide field of view. The robot also has an ATI mini-45 force/torque sensor and runs on an 18-core Intel i9 CPU and an NVIDIA TitanV graphics processing unit running Linux. The vaguely humanoid robot uses industrial arms rather than collaborative arms, or cobots, because it is designed for ease of learning, not yet to operate alongside people, said TRI. Joints in its Kinova Jaco2 arms and body provide 31 redundant degrees of freedom so that it can turn and reach items in, say, a kitchen cabinet, as needed. They include maxon motors and planetary gearheads. The robot also uses Sake Robotics grippers with under-actuated fingers, TRI said. VR requires less data to train robot A major challenge for making robots smarter has been the massive amounts of data that they need to be trained on. TRI claimed that its methods, which include using simulations and virtual reality (VR) to train a robot to conduct certain tasks, require less data. THE ROBOT REPORT

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TRI’s mobile manipulator has 31 degrees of freedom. | Source: TRI

November 2019

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Design & Development “More is not necessarily better,” said Helmick. By teaching a robot about parameters rather than specific items, it can learn with just a few examples of what parts of an object are important for grasping, said Ma. The mobile manipulator can also learn how to move on uneven surfaces, interpret voice commands, and conduct complex tasks, he said. After a single demonstration by a human using VR, the robot can autonomously perform multi-step tasks, said TRI. Toyota’s mobile manipulation system also includes dense visual representations of a scene with embedded objects, and a task graph of taught behaviors. With simulations, a mobile manipulator can be trained to handle complex tasks such as loading a dishwasher, said Russ Tedrake, vice president of robotics research at TRI. Rather than train a robot on each item, it can learn how to reliably handle multiple objects. Sharing lessons with fleet learning For robots to truly spread in people’s daily lives, they need to become useful for a wide variety of applications. Cloud computing, machine vision, and deep learning will lead to a flowering of

TRI’s software architecture enables autonomous execution of taught tasks by processing visual and audio data, building a world model, mapping visual inputs | Source: TRI to taught behaviors, and executing sequences of behaviors. capabilities similar to the “Cambrian Explosion” wrote TRI CEO Gill Pratt. In short, the idea is that if one robot learns, that lesson can be shared among many robots rather than programming each one for a specific task or environment. According to TRI, its mobile manipulator “can successfully perform a relatively complex human-level task about 85% of the time.” Each of the three tasks consisted of up to 45 behaviors,

TRI’s household robot is designed to follow vocal commands. | Source: TRI

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such as moving in a kitchen, opening and closing a refrigerator door, grasping a cup or container, and putting it on a table. Recoverable failures for individual behaviors — things the robot needed to do again — had a 99.6% success rate. Toyota aims to aid all service robots Toyota Research Institute noted that its approach could be useful for teaching mobile manipulators in manufacturing, pick-and-place operations, packing, and logistics, but much work remains to be done for generalizing tasks. VR, teleoperation, and fleet learning could make robots more flexible and easier to instruct. TRI said it is improving key behaviors for all robots. Rather than replacing human workers, TRI said it is working on robots to “amplify, assist, and empower human performance.” Toyota AI Ventures, which launched its second $100 million fund in May, has been investing in startups such as Freedom Robotics with similar goals. In August, Toyota Motor Corp. announced a partnership with Preferred Networks Inc. to develop the Human Support Robot platform. “We believe teaching a robot tasks is a promising first step to achieving our broader vision of fleet learning, specifically for assisting and empowering people in their home,” stated TRI. RR

THE ROBOT REPORT

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Design & Development •• •• •

•• •• •

•• ••

DHL on state

warehouse robotics “We are on the verge of the rise of robots in warehousing.”

By Steve Crowe • Editor, The Robot Report

DHL recently opened a 28,000-square-foot Americas Innovation Center in Rosemont, Ill., a suburb of Chicago. This is DHL’s third innovation center, joining the initial center in Cologne, Germany, and a center in Singapore. DHL’s U.S.-based Innovation Center showcases the latest in logistics technology, including robotics. DHL has been exploring how robots can enhance its logistics operations, especially mobile robots for materials handling applications. For example, DHL has piloted and deployed robots from Avidbots, 6 River Systems, Fetch Robotics, Locus Robotics, Mobile Industrial Robots, Seegrid, and Vecna Robotics. “The DHL Innovation Center Grand opening was impressive,” Daniel Theobald, Founder and CEO of Vecna Robotics, told The Robot Report. “I really admire the approach DHL has taken with its commitment to open innovation. They set a good example for the rest of us to follow. When we work together as an industry to solve common problems, everybody will prosper more.” The Robot Report attended a private tour of the Innovation Center and several DHL facilities in and around Chicago. We spoke to Matthias Heutger, Global Head of Innovation and Commercial Development at DHL, to learn how the company is currently using robots and what improvements need to be made for robotics to have an even bigger impact on its logistics capabilities. How does the DHL Innovation Center push forward the logistics robotics industry? We talk about robots, but what does it actually mean? If we get customers here, they get to see robots here and say, “I can really see how that will fit into my operations.” That’s different from just going to a customer site and presenting about Locus Robotics. We then do a two-day workshop on innovation projects to address the customer’s challenges. We look at which technologies we’re using that could help solve their challenges. Then we do pilots with them.

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A piece-picking demo at DHL’s Innovation Center featuring a Universal Robots collaborative robot, a Robotiq gripper, and AI software from Covariant.ai. | Courtesy of DHL

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Design & Development It also creates social acceptance of robotics. You come here and touch and feel the robots, you realize they’re not that dangerous. It helps overcome some of those perceptions. How would you categorize the current state of warehouse robotics? We are on the verge of the rise of robots in warehousing. The majority of work done in warehouses — 70% to 80% — is still manual. There’s a huge opportunity right now, especially driven by e-commerce. We are not able to cope with the volume, neither in delivery or in fulfillment. We need to find new ways of doing it. In the past, the problem was that automation wasn’t flexible enough and was too cost-intensive. Now with collaborative robots, increased computing power, and lower costs, we see a huge investment in implementing robotics in our warehouses. For example, we have one site in the U.S. with 100 LocusBots [from Locus Robotics]. It gives us tremendous improvements and helps us cope with volumes. The robots are relatively simple. But now that we’ve done it, we know how to deploy them better and will be replicating this at other sites. How does DHL evaluate what robots are best for warehousing operations? It always comes down to a few things. Locus and Fetch Robotics, for example, started as robotics companies for logistics. From the very beginning, they focused on logistics applications. This is different from other robotics companies that start somewhere [else], and they also now do logistics. It’s also important to find a partner we can actually work with. Typically when a potential partner comes in, the product as it is doesn’t work 100%. We have to iterate with them. In many of these mobile robots, the navigation is a big part of it. The hardware

Matthias Heutger, Global Head of Innovation and Commercial Development, DHL

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A Locus Robotics mobile robot, with DHL branding, on display at DHL’s new Innovation Center in Chicago. | Courtesy of DHL

is very similar — the robot itself, the sensors — so it’s about the software. In some of our operations, we don’t have many orientation points. Navigation software is key. Warehouse automation startup 6 River Systems was recently acquired by Shopify for $450 million. Amazon in 2012 purchased Kiva Systems for $775 million. Would DHL ever buy a robotics company? “Would we ever?” is always a hard question. I wouldn’t personally suggest to do that. I would not bet everything on one technology or one company. Right now, there are so many companies out there, and they all have strengths and weaknesses. We need to work with different technologies and providers because we have different use cases. If you only have one use case, and maybe Shopify has that, then it might work — “This is the best solution; let’s

go for it.” But we have so many different applications, processes, products, and setups that we want to be unbiased to what technology we’re going to use. What is more important for DHL is to understand how to integrate robotics. So would I invest in robotics integration services? Probably. How would you like to see robots continue to improve? The mobile robot companies that are moving materials are on a good track. For them, it’s now about more precision and faster navigation. Picking is clearly the “holy grail,” particularly piece picking. We have some solutions, but the speed just isn’t there. We did a challenge last year, but the technology is still slow. The human hand is very difficult to replicate. Piece-picking is an area that needs the most development. It’s not mature enough yet to really deploy. They need to

In the past, the problem was that automation wasn’t flexible enough and was too cost-intensive. Now with collaborative robots, increased computing power, and lower costs, we see a huge investment in implementing robotics in our warehouses.

www.therobotreport.com

THE ROBOT REPORT

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be faster at recognizing the pieces and grabbing them. There are so many different pieces, some are hard and some are soft; we intuitively know how to grab them with our hands. We need better AI to make the right conclusions and have the physical arm to grab the pieces as fast as a human hand, which is pretty fast. How is DHL evaluating drones and autonomous vehicles? It’s a matter of timing and application. For drones, we started with cycle counting in warehouses. We have drones on a leash right now, as indoor navigation for drones is not good enough right now. That might change with 5G, but drones can’t really navigate well if they don’t have GPS in terms of height of the shelf. We put the drones on leash on a self-driving robot to do cycle counting. It’s a workaround. But we do see drones in niche applications like disaster areas. For fully self-driving vehicles, the first thing you’ll see is self-driving trucks. We’re piloting platooning already in the U.K. The first truck is still manned, then a couple of unmanned trucks follow behind. Then you will see certain highways with fully autonomous trucks. Last-mile delivery is tricky because of the regulations and obstacles around it. It’s coming, but just like drones, self-driving vehicles needs to make sense for us. If you want to deliver thousands of packages in one neighborhood, it makes more economic sense to send one van instead of drones. If you single packages in remote areas, it makes more sense to send a drone. Technology isn’t the question anymore. RR

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Design & Development •• •• •

•• •• •

•• ••

Robotics and 5G

enable remote surgeries

in China

Multiple teleoperation tests are considered a success, as competitive concerns rise.

By Eugene Demaitre • Senior Editor, The Robot Report

Telecommunications providers worldwide are racing to provide 5G, as well as to encourage the development of industrial applications for the next-generation wireless networks. One promising application is remote, robot-assisted surgical procedures. Physicians in China have taken an early lead in testing the technology. This past summer, doctors in China remotely monitored portions of three simultaneous orthopedic procedures using surgical robots and 5G. All three operations were considered successful, in a milestone for remote surgery. Each robot conducted preset commands in Zhangjiakou in Hebei province, Karamay in the Xinjiang Uygur autonomous region, and the city of Tianjin, while the doctors monitoring the remote surgery were in Beijing, reported China Daily. The operations went from 9:30 a.m. to 1:00 p.m. local time. Human surgeons still managed procedures such as implanting devices within bones. Both still images and real-time video from the remote surgeries were clear, thanks to 5G, said Jiang Wenxue, head of orthopedics at Tianjin First Central Hospital. Tianjin is 136km (84.5 mi.) from Beijing.

Prof. Tian Wei, president of Beijing Jishuitan Hospital, communicates with doctors from a teleoperation center in a robotic remote surgery demonstration with Yan Taishan and Jia Xing No. 2 Hospital. | Source: Beijing Jishuitan Hospital

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Western telecom providers such as Verizon and Sprint, as well as processor makers such as Qualcomm, have promoted 5G in the U.S. with initiatives such as the 5G Robotics Challenge. Meanwhile, China Telecom, Huawei, and power suppliers such as State Grid Group have been touting the speed, bandwidth, and reliability of the technology in China.

Surgeons in China conduct two remote operations simultaneously over 5G. | Source: New China TV, Xinhua Video

Other remote surgery trials In January, a doctor in Fujian, a province in southeastern China, removed the liver of a test animal about 30 miles away. It was reportedly the world’s first remote surgery over 5G, which kept the lag time to 0.1 seconds. In March, Ling Zhipei, chief physician at the First Medical Center at PLA General Hospital, worked with Huawei and China Mobile to guide THE ROBOT REPORT

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Design & Development

Dr. Ling Zheipei used a robot and 5G to remotely place a stimulation device in the brain of a patient with Parkinson’s Disease. | Source: South China Morning Post

This past summer, doctors in China remotely monitored portions of three simultaneous orthopedic procedures using surgical robots and 5G. All three operations were considered successful, in a milestone for remote surgery.

Remote surgery beyond China Since December 2018, a doctor in India has performed percutaneous coronary interventions on patients 20 miles away using a Corindus CorPath system. In April, a doctor carried out a “5G-powered tele-monitored operation” at Mobile World Congress in Barcelona, Spain. Dr. Antonio de Lacy used his finger to draw on a screen and instruct remote colleagues 5km (3 mi.) away with only 0.01 seconds of lag time. Many operations over 5G so far involve such guidance rather than remote robotic control. There have not yet been any 5G remote surgery trials involving robotics in the U.S., partly because of U.S. Food and Drug Administration concerns about outcomes and safety. As of July, China reportedly had more than 7,800 5G base stations. U.S. telecommunications carriers are rolling out 5G to certain cities over this year and next.

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Remote surgery promises to democratize quality of care in remote areas. | Source: Verizon

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the placement of a stimulation device in a patient with Parkinson’s disease. It was the first remote surgery on the brain over 5G. “The 5G network has solved problems like video lag and remote-control delay experienced under the 4G network, ensuring a nearly real-time operation,” he said. “And you barely feel that the patient is 3,000 km [1,864 mi.] away.” Cardiologist Huiming Guo at Guangdong General Hospital performed a remote surgery on a patient in Gaozhou People’s Hospital, 400km (248.5 mi.) away. In June, surgeons at Beijing Jishuitan Hospital performed remote surgery via China Telecom’s 5G on a patient in Yantai in Shandong Province, about 316 miles southeast of China’s capital. China Mobile also assisted in a gallbladder removal in a remote surgery procedure over 200km (124 mi.). That same month, orthopedic surgeons conducted two remote surgeries with the participation of China Telecom and Huawei. In August, 5G and a mixed reality interface were used in a thoracic remote surgery between First Affiliated Hospital of Nanjing and Pukou Central Hospital, 13km (8 mi.) apart. The first remote robotic dental procedure was also conducted in China.

Pursuing the promise of 5G “The combination of 5G technology with surgical robots is a huge technological advance that will help us share our skills with more patients in distant regions,” said Tian Wei, head of the team at Jishuitan Hospital. “People across society can now have access to top medical resources. In the future, using robots and 5G will be common. The medical community will be smarter.” Several technology observers have expressed concern that the U.S. is falling behind China in developing 5G amid ongoing trade disputes. There is a geopolitical element to such announcements, not to mention bragging rights. China Daily is a stateowned media outlet, while the U.S. government prefers to let the private sector take the lead. At the same time, proponents of the technology say that American telecommunications providers and application developers should rally to take advantage of 5G’s capabilities for the benefit of customers, patients, and business. RR

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Design & Development •• •• •

•• •• •

•• ••

design 5process elements

for successful robot production There are a lot of moving parts to keep track of when designing a robot, and sometimes

manufacturing is not at the top of the list. But successfully transitioning a robot from design to production requires some design time and attention. By Cirtronics

For example, early selection and engagement with a trusted manufacturing partner can provide

additional resources and perspectives that ensure the design is as manufacturable as it is functional. Long experience has shown there are at least five partner-selection elements that contribute to a collaborative design process, blending functional design with manufacturing considerations to achieve ultimate program success. 1 Capability assessment Start by internally assessing the capabilities and strengths of the design team, and look for a trusted partner to complement those skill sets. As the design moves to the next phase, the team moves to address the resource constraint, resulting in a shift of focus. One way to optimize use of resources is to seek support early in the product-design phase. This allows the team to remain attentive to the areas that bring strength and success to the robot launch. Those areas may include developing a robust design and strong customer interaction. Identify internal strengths, and then it is time to seek a trusted partner to bring the product to the next stage. 2 Competence Next, look for a manufacturing partner with competence and expertise in robotics manufacturing and a proven record of success. An experienced partner works side by side with the engineers as an extension of the business. Ideally, the partner will actively engage in learning from the engineers to understand the robot build and the application requirements, known as a co-build procedure.

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Evaluate capabilities and robotics experience in potential partners. | Source: Cirtronics

Look for a partner that can demonstrate expertise in pre-production design reviews that can ease the transition to manufacturing. The ability to demonstrate a quality mind-set, continuous improvement processes, and documentation is significant. Choose a manufacturing partner that can support all build stages and an integrated data platform to allow ease of information sharing. Early engagement with a qualified partner encompassing the above skillsets results in a product manufactured on time and at the right cost. 3 Cooperation and collaboration A competent partner is flexible and will expect many iterations early in the design process. Even a robot prototype that is successfully built and tested will require further review before being production-ready. A cooperative partner helps ease the transition to production by tailoring “DFx” (design for…) services to achieve seamless shift to manufacturing. An example of this transition is when both engineer teams collaborate to create, optimize, validate, document, and build a manufacturable process and product. THE ROBOT REPORT

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Design & Development A competent partner is flexible and will expect many iterations early in the design process. Even a robot prototype that is successfully built and tested will require further review before being production-ready. This co-build model requires transparency, resulting in a cohesive mindshare. Finding a partner that cooperates and collaborates to identify challenges and offers suggestions will help both businesses be prosperous.

Cirtronics is the contract manufacturer for Ava Robotics, a spinoff of iRobot. | Source: Cirtronics

4 Communication A flexible partner has great listening skills. Communication is key throughout all stages of the process. This becomes especially important when the robot is moving from design to production. The right partner will provide a direct contact that proactively manages all communication between the teams. This resource is responsible for the relationship focusing on overall customer satisfaction. This dedicated communication resource is responsible for budget and adherence to timeline. A partner that provides this level of service will be more accessible and proactively streamline a consistent flow of information between teams. 5 Culture Earning a reputation for excellence and integrity truly matters in long-term relationships. Sharing in the same values as the manufacturing partner contributes to the success of the product. Effective cultures that serve the customer with a quality-minded approach can positively influence the result. The team that will co-build, review documentation, manage suppliers and build the robot is made up of unique individuals. Each individual contributes to a team vested in the success of the partnership. Cultures that empower accountability practices will share in the responsibility of a successful robot build. That is what

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is important about culture. It is not just a mind-set. It is a way of being in the world that comes from a place of service, ownership and cooperation. Incorporating these five design process elements in a program will contribute to a successful transition of a robot into production. Pay attention to these elements earlier in the design phase with a trusted manufacturing partner, and you will save time and money when the robot is in full production. RR To get started and learn more with a manufacturing partner early in the process, contact Cirtronics at 603-249-9190 or visitÂ cirtronics.com.

A successful robotics relationship requires clear communications. | Source: Cirtronics

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Mobile Robots •• •• •

•• •• •

•• ••

River Systems acquisition:

Mobile robots a must in new economy Shopify takes a page from Amazon’s playbook.

By Daniel Theobald • CEO, Vecna Robotics, and Matthew Cherewka • Solutions Design Manager Vecna Robotics

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In early September, Shopify announced the intent to acquire 6 River Systems, a Boston-based automation firm that provides solutions for e-commerce fulfillment. This is the first major acquisition that has happened in this space since Amazon purchased Kiva Systems in 2012. In the broader collaborative robotics industry, two of the three major acquisitions (the third being Teradyne’s purchase of Universal Robots in 2015) were for autonomous mobile robot (AMR) solution providers. This landmark deal is significant for a number of reasons and is evidence the AMR market is on the verge of exponential growth.

6 River Systems’ Chuck autonomous mobile robot. | Courtesy of 6 River Systems

Mobile robotics industry here to stay The market’s response to AMRs has shifted from skepticism to acceptance to fear of missing out (FOMO) in a relatively short period of time. There is no longer any question as to whether AMRs provide value, or whether they can be safe and play well THE ROBOT REPORT

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Mobile Robots with humans. Companies like 6 River Systems, Locus Robotics, NextShift, Vecna Robotics and others have provided the answers in real-world deployments. Not only do they create greater efficiencies and supercharge productivity, AMR-based solutions from several companies have also been warmly accepted by distribution center and warehouse staff despite early worries of job loss due to automation. Easy implementation, simple training, improved workplace safety, and fewer stressful, physically demanding, repetitive tasks are all factors that have led to higher employee morale. Better morale lowers turnover, and in an industry that often experiences turnover of more than 200%, that means lower costs and higher productivity. This allows the company to remain competitive, stay in business, expand, and offer more jobs. What’s more, these low-cost, easy-to-implement solutions offer low-risk, low-barrier-to-entry options for organizations of all sizes. They act as a workforce multiplier, thus leveling the playing field for small and medium enterprises to compete in the global economy. Novelty has no sway Robotics companies can no longer rely on the “novelty play” alone to sell a product. In the 2000s, iRobot rode the novelty wave with great skill. They brilliantly sold the Roomba robotic vacuum at a low enough price that middle-class consumers could purchase them with disposable income. At that price, the novelty of having a robot in the home was a major part of the value proposition. This provided iRobot the runway needed to improve the product to the point where the larger value proposition was that it cleaned floors effectively, and in the process

6 River Systems founders (left to right) Chris Cacioppo, Jerome Dubois, and Rylan Hamilton. | Courtesy of 6 River Systems

Inside the acquisition The acquisition, Shopify said, “is a critical step to accelerate its growth.” 6 River Systems’ fulfillment software and robotics technology will help increase the speed and efficiency of the warehouses in Shopify’s Fulfillment Network, which launched in June. The Fulfillment Network is designed to speed up delivery times and lower shipping costs for Shopfiy’s customers. There are a lot of players in the warehouse robotics space, but 6 River Systems was founded by some of the best — Jerome Dubois, Rylan Hamilton, and Chris Cacioppo. Dubois and Hamilton met while working as executives at Kiva Systems, which was acquired by Amazon in 2012 for $775 million. 6 Rivers Systems will continue to sell its solutions to other warehouses, not just Shopify’s. This is a different approach than Amazon took with the Kiva robots, which are used exclusively by Amazon. The Chuck AMR uses machine learning and artificial intelligence to help human workers minimize walking, and it integrates with leading warehouse management systems. The company also offers Mobile Sort smart kiosks. Its customers include DHL, Lockheed Martin, Office Depot, and XPO Logistics.

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Mobile Robots created a whole new market segment. But the time of the novelty play for the robotics industry is waning. For the average consumer to the shrewdest CEO, robots are no longer “cool” merely because they are new technology – now a rock-solid value proposition is required to make the sale. 6 River Systems created a product with the customer’s ROI – not novelty – in mind. In fact, the robot was not the solution. Rather, it was the: • Software-driven workflow • The intelligent application of machines to optimize traditionally- manual processes • The ability to adapt it to specific organizational needs The 6 River Systems team, some of whom worked for Kiva, no doubt knew this from experience. They approached the problem with less enthusiasm for the technology and more focus on solving a real customer pain point. Fundamentally, 6 River Systems is a solution provider, not a robotics company. This is a critical distinction, and an important lesson for others in the field of automation. Novelty no longer sells. An automation provider must solve problems. Companies like Shopify are taking notes from Amazon’s playbook and realize a solid automation solution is the key to scaling up rapidly and competing in the new economy. This, of course, requires more than cute robots.

Thankfully, Tom Ryden and the great team at MassRobotics have introduced new models to help robotics startups overcome many of these challenges, and investors are learning to love again. It is important to recognize the distinction between the robotics startups of the last decade that built robots and the solution providers like 6 River Systems that address a clear and specific market need. The savvy investor recognizes these distinctions and is likely to invest accordingly before the broader market catches on. When we founded MassRobotics, it was specifically with the intent of helping to move the industry from “cool” robots to real-world solutions that provide concrete value. This success is a great example to the hundreds of other robotics startups in the MassRobotics ecosystem, and even to Boston Dynamics, which has recently taken steps (pun intended) to get into the logistics automation game. But don’t worry, it has pledged to continue kicking its robots. Congratulations to 6 River Systems and the broader mobile robotics industry for this achievement! RR

Now is the time to invest A number of investor-backed robotics companies closed up shop within the last few years after raising significant sums (interestingly, none of them were AMR-focused companies). Hence, it is not surprising that robotics investments would be viewed with skepticism. Investors have been wary of engaging with robotics companies for several other reasons too: • Automation solutions are capital intensive to develop in terms of materials, equipment and talent • Hardware is costly to prototype and challenging to scale • There have been relatively few major successes to date.

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Mobile Robots •• •• •

•• •• •

•• ••

Ford Spain

uses MiR mobile robots to optimize internal logistics

Automaker needed robots that were easy to install and use for delivering parts within plant.

Ford Motor Co. is no stranger to robots, but its manufacturing plant in Almussafes-Valencia, Spain, needed to automate a manual and time-consuming process. To do so, Ford Spain has deployed collaborative mobile robots from Mobile Industrial Robots ApS. Ford Spain makes 2,000 vehicles per day in its Valencia plant, including models popular in Europe such as the Kuga, Mondeo, and S-Max. Optimizing its internal logistics would affect both workers and overall productivity.

Ford Spain deployed three mobile robots at its plant in Valencia. | Source: Mobile Industrial Robots

By The Robot Report Staff

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Challenge Industrial automation is already used to assemble automobiles at Ford Spain, but the delivery of industrial and welding materials to different robotic stations of the body and stamping plant was repetitive and time-consuming. Retrieving spare parts to feed robots was not a value-added task for employees, according to Ford Spain. Ford Spain decided to be the first Ford plant in Europe to try collaborative mobile robots, turning to Odense, Denmark-based Mobile Industrial Robots (MiR), which is owned by U.S.-based Teradyne Inc.

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Mobile Robots Case Study Breakdown Company: Ford Motor Co. Location: Almussafes-Valencia, Spain Industry: Automotive manufacturing and assembly Challenge: To relieve human employees of tedious and time-consuming materials handling work at body and stamping plant Partner: Mobile Industrial Robots ApS Robots: Three MiR100 autonomous mobile robots Tasks: Bringing spare parts and welding materials to workers and robotic stations Value Drivers: Increasing productivity without requiring additional infrastructure or a lot of training Results: Robots freed up to 40 staff-hours per day

Ford Spain needed AMRs that required minimal infrastructure and could operate around other vehicles and people. | Source: Mobile Industrial Robots

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Solution Ford Spain bought its first MiR100 robot a year and a half ago. The autonomous mobile robot (AMR) is named for its payload capacity of 100kg (220.4 lb.) and delivers spare parts in the plant. It is able to avoid unforeseen obstacles, modify its route as necessary, and work alongside humans and other vehicles. The autonomous navigation system of the MiR robots provided the flexibility that Ford Spain sought. The company eventually acquired two more AMRs. “For us, it was important that the three MiR robots had one key feature — that for the navigation of the robot, no external elements were needed, such as external beacons, magnets, or tapes on the ground,” said Miguel Montaña, a maintenance control analyst at Ford Spain. “So, we simply mapped the test area, and the robot began to work, just like that. In an environment as complex as ours, that is very important.” “Of the three MiR100 robots we currently use, the first one that arrived at our factory was baptized with the name ‘Survival,’ because it has survived in a very hostile environment,” said Eduardo Garcia Magraner, engineering manager of the body and stamping area at Ford Spain. “We programmed it to learn the entire plant map, and this, together with the sensors with which it is equipped, means that it does not need any external help to circulate safely.” “One of the first applications that we developed in [the] Ford Spain body and stamping plant with the MiR autonomous collaborative robot was to transport spare parts for production equipment from the warehouse to the production lines,” he recalled. “And now, we can say that Survival has survived in this hostile environment, and today it continues to distribute these items from the warehouse to the production lines.” Ease of use was another important factor for adoption, said Garcia Magraner. “The robot is well configured so that it can be used by anyone, even if they are not familiar with the world of collaborative mobile robots,” he said. “The system is very user-friendly, as the three MiR robots have their own routes throughout the extensive factory area.” THE ROBOT REPORT

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Results at Ford Spain “We are proud to have one of the most innovative factories in Europe and [to be] pioneers in the use of collaborative mobile robots for the distribution of industrial materials that allow us to be more efficient with our intralogistics,” said Pepe Pérez, corporate communications manager at Ford Spain. “When the tests started, the operators were staring at the robot as it passed by, as if in a science fiction movie,” said Magraner. “Now, they go on with their work knowing that the robot is smart enough to work around them.” After testing the MiR100, Ford Spain concluded that “it worked flawlessly and has become a very valuable member of the team,” he added. “Hopefully, we can take it to other Ford facilities.” Ford Spain found that one MiR AMR freed up to 40 staff hours per day, enabling employees to take on more complex and engaging tasks.

We are proud to have one of the most innovative factories in Europe and [to be] pioneers in the use of collaborative mobile robots for the distribution of industrial materials that allow us to be more efficient with our intra-logistics.

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The MiR100 robots at Ford Spain have compartments providing workers access only to the materials they need. | Source: Mobile Industrial Robots

To further suit its needs, Ford Spain added an automated shelving system with 17 slots for materials of different sizes and weights. Operators in each area of the plant have access to only the shelves with the materials they need. “The incorporation of the three MiR robots has allowed us to turn a routine distribution of spare items into a highly qualified job,” said Helios Alvarez, manager of the body and stamping plant. He said he expects Ford Spain to find more uses for the robots. “The satisfaction we have achieved with the implementation of the MiR robots in the distribution of industrial materials is allowing us to open new fields of expansion to incorporate new MiR robots within the scope of the body and stamping plant and even going beyond, to other areas within the factory,” said Alvarez. “We have been able to demonstrate that these robots are capable of learning their way by themselves and also interact perfectly well with our employees and forklift trucks or any other moving element with total safety.” RR

www.therobotreport.com

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Mobile Robots •• •• •

•• •• •

•• ••

trends to watch in autonomous mobile robots

Standards efforts, mobile manipulation, and how to manage heterogenous environments were discussed at a recent RIA conference.

By Eugene Demaitre • Senior Editor, The Robot Report

LOUISVILLE, Ky. — Autonomous mobile robots have reached new levels of maturity and adoption, but technical and business challenges remain, said speakers and attendees at a September conference here. More than 430 people attended the 2019 Autonomous Mobile Robot Conference, which was produced by the Association for Advancing Automation (A3) and the Robotic Industries Association (RIA). The sessions on autonomous mobile robots (AMRs) covered topics including the development of AMRs, standards efforts, and mobile manipulation. The conference also included exhibits by robotics vendors such as Harmonic Drive, Kaarta, Precise Automation, Universal Robots, Vecna Robotics, and Waypoint Robotics.

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The RIA’s Autonomous Mobile Robot Conference featured different AMRs. | Courtesy Mobile Industrial Robots

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Mobile Robots Here are six takeaways from the RIA’s first Autonomous Mobile Robot Conference: AMR accuracy improving, but approaches vary Most AMRs are similar, but the differences in how they work affects their safety and usefulness in different environments, explained Melonee Wise, CEO of Fetch Robotics, which recently raised $46 million. She noted the design options for sensors, odometry, localization, mapping, navigation, obstacle avoidance, and object detection. For instance, depending on the sensors and algorithms used, an AMR’s estimation of its location and surroundings could be more or less accurate, said Wise. “All AMR companies have different methods for localization and mapping,” she said. “Users should evaluate mapping at scale — if you have 10,000 sq. ft., don’t test in lab situations.” Energy and payload requirements have created demand for even smaller and faster components, Juan Avalos, an application engineer at Brother Gearmotors, told The Robot Report. “Lights-out operations are still a ways away, but we’re now optimizing designs for efficiency,” he said. In the near term, advances in artificial intelligence (AI) and machine learning will lead to improved path planning with remote sensing, obstacle avoidance, and object recognition, said Josh Cloer, sales director at Mobile Industrial Robots ApS (MiR). He described MiR’s AI Camera, which can detect and classify objects and communicate with other robots and vehicles. In the long term, AI, the industrial Internet of Things, 5G and the cloud could work with AMRs for reliable, low-latency “limitless computing power with what’s onboard plus the cloud,” Cloer said. “Robots could someday perceive their environments through every connected sensor in real time, learn naturally and use naturallanguage processing, maintain their own hardware by predicting failures and be fixed by other robots, and consult with people on increasing overall efficiency within the facility.” “We need a lot more sensor fusion,” said said Brandon Coats, product manager at Material Handling Systems Inc. (MHS), which hosted a facilities tour after the conference. “Vision-based SLAM [simultaneous localization and mapping] will be a key player in the next few years. Robots will also

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| Source: Melonee Wise, Fetch Robotics, and RIA

MHS gave a tour of its R&D facility after the AMR Conference. | Source: Material Handling Systems Inc.

be able to detect and classify anything, change their behavior based on what the obstacle is, read bar and QR codes, and know what to pick up.” Safety standards work continues The U.S. Occupational Safety and Health Administration (OSHA) doesn’t have a specific robot safety standard, not even for robot arms, noted Wise. However, robots need to legally comply with National Recognized Testing Laboratories such as (but not limited to) UL, and the RIA is developing ANSI R15.08 for industrial mobile robots.

www.therobotreport.com

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as 99% uptime,” he said. “Think of how many deliveries are needed per hour.” The number of AMRs in a facility will affect Wi-Fi network demand and fleet manager capacity, so virtual testing, policies for quality Defining AGVs and AMRs is part of the R15.08 standard of service, and an understanding of diagnostics in progress for mobile robot safety. and reporting are necessary, said Rendall. He | Source: Michael Gerstenberger, RIA showed an example “spaghetti” heat map of robot movements and materials flow. In designing for The RIA has been working on the scale, think of “How standard for four years and is currently would my operation focusing on the first part, which covers run entirely with definitions, design requirements and AMRs?” Rendall said. protective measures, verification and “You can’t directly validation, and information for equipment automate people use, explained Michael Gerstenberger, on trucks. You need chair of the RIA standards committee. event and process The other parts will focus on site- and simulation, and application-specific requirements and you need to answer guidance to AMR users. questions at the “We’ve made good progress this process level, not the week,” said Carole Franklin, director of floor or machine level.” standards development at the RIA, which “Matching the held committee meetings around the A map of AMR movements. | Source: Matthew Rendall, OTTO, via RIA technology to the use conference. case is paramount,” In a panel on the business case for said David Clear, vice president of business cobots and AMRs,” said Bob Doyle, vice AMRs, Harry Chase, director of advance development at Vecna Robotics. “You need president of the RIA and A3 Mexico. materials at GE Appliances, said that to get buy-in from different levels of the “I visited an integrator who said the companies like his are looking for AMRs organization, find the right application, and biggest competition is inaction. Many to improve safety and reduce damage. demonstrate value. It’s easy to sell one robot companies are not yet at Industry 3.0, let GE Appliances had set a goal of reducing but harder to get to the next one or a fleet.” forklift accidents by 50% within two years. alone Industry 4.0, and our session on “There are a lot of material handling ‘Automation 101’ at Automate was full.” opportunities — in manufacturing, Rendall said that AMR developers Developers and suppliers must warehouses, hospitality, retail, and healthcare, need to design for safety, secure data 3 know their customers where we started. Don’t focus so much on collection and sharing, and scale. Although some analysts, politicians, and the technology but on what you need to do,” “Operational availability is not as simple media outlets have expressed concern about robots taking skilled jobs, there will be 3.4 million manufacturing jobs in the next decade, 2 million of which will go unfilled, according to a Deloitte study cited by Matthew Rendall, CEO of Clearpath, the industrial division of OTTO Motors. In addition, “consumer expectations are rising, with demand rising for locally produced, personalized, low-cost, sameday free shipping and returns,” he said. This creates both opportunities and challenges for AMR designers, suppliers, U.S. logistics hubs. and users. | Source: Aaron Prather, FedEx, via RIA “Education is still important, as industrial automation grows to include

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Mobile Robots said Tony Melanson, vice president of marketing at Aethon. “There are lots of different types of AMRs and supporting software. We need to go beyond the robot to supporting technologies and connected services.” In response to a question, Melanson explained an example of how Aethon integrated its TUG to work with laundry cleaning providers. Robotics-as-a-service (RaaS) business models are good for some use cases, but larger enterprises prefer to capitalize their investments, said Aaron Prather, senior technical advisor at FedEx. He also recommended that AMR companies have a stronger presence around major logistics hubs such as Louisville and Memphis.

4 Interoperability is in demand

Rather than look to one robot or supplier to solve every supply chain problem, there are different types of robots for different applications, noted Denise Ebenhoech, regional head of advanced robotic applications at KUKA AG. She said that since each AMR is designed for different payloads, maneuverability (such as moving with omnidirectional wheels), and degrees of safe collaboration with people, users must work with suppliers to find the best fit. In addition, both software developers and integrators must prepare to manage heterogenous environments. “There will be more demand for interoperability among different technologies and cooperation among vendors,” said Vecna’s Clear. “How will end users manage multi-

Robotic unloader for quickly taking boxes off of trucks. | Source: Honeywell Intelligrated

AMR environments? How will MiR, Vecna, Locus, and OTTO talk with one another?” asked FedEx’s Prather. “A recent audit of ground-support equipment at our Memphis hub found 32 different manufacturers. We use a real-time location system to track all the GSE inside our four walls.” An attendee from a major automaker said that his organization wasn’t satisfied with existing fleet-management software for AMRs from multiple vendors and plans to develop its own. Mobile manipulation promising but just getting started Advances in sensors, controls, user interfaces, and end effectors are finally making mobile manipulation a reality, said Norm Williams, director of robotics at OMRON. He noted that robots need to perceive a wider area when dealing

Panel at RIA AMR Conference, from left: Doug Wilmot, Humatics; Harry Chase, GE Appliances; David Clear, Vecna Robotics; Brandon Coats, Material Handling Systems 36

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with grasping as well as two-dimensional motion and that power requirements also rise when combining arms with mobile platforms. Robotics developers should also have a clear understanding of the intended function and design for stability and safety, Williams said, citing OMRON’s new mobile manipulator as an example. One of the more impressive videos shown at the RIA Autonomous Mobile Robot conference was of a robot capable of rolling into a trailer to unload its contents, first seen at Automate 2019. Eric Harty, vice president of strategic marketing at Honeywell Intelligrated, described how the suction cups, rollers, advanced vision, onboard intelligence, machine learning went into the AMR. He explained the potential labor savings: Normally, it would take three people making $15 an hour to unload 400 to 800 cases in an hour, while the robot could unload boxes at a rate of 800 to 1,000 per hour. This would equal annual savings of $438,000 to $702,000 per truck, not including the costs of injuries, rehiring, and training. “AMRs combine navigation and sensing, while autonomous mobile manipulation systems or AMMRs combine navigation, sensing, and manipulation,” said John Cameron, chief robotics engineer at IAM Robotics. AMMRs offer a lower potential cost and can relieve employees of tedious work. DESIGN WORLD

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However, they also may result in a lower increase in pick rates and require more setup, he said. New frontiers for AMRs “The [autonomous mobile robot] industry is still in its infancy,” said MHS’ Coats. “We’re looking at robot-to-robot interaction, how to manage large fleets, swarm or decentralized robot behavior. We had to track total cost of ownership for all cases, including robots, conveyors, sensors, and cameras and compare that with customer operations.” “Single use-case robotics will grow into multi-use robots, like smartphones as a platform for apps,” said Dave Ross, vice president of business development at Brain Corp. For instance, Tenant Co. uses Brain Corp.’s software as a service for its autonomous floor cleaners. With a robotics platform-as-aservice model and optimized data collection and navigation, a 1,000-lb., $40,000 cleaning robot can provide a return on investment in one year, said Botond Szatmáry, head of technology partnerships at Brain Corp.

Among the new frontiers for AMRs is the great outdoors, including the area between trucks and loading docks. “We have five large 800,000-sq.ft. buildings around Louisville, and we’re trying to push the market to outside AGVs,” said GE’s Chase. “We’ve worked with [autonomous mobile robot suppliers] on different applications and environments, and they need to work with internal structures and other robots and vehicles. There needs to be more integration from the dock to line side.” “Logistics is more than warehousing and involves various levels of outdoor use,” said FedEx’s Prather, who described canopy operations, which are currently forklift-intensive operations but range in temperature, humidity, and the distance for materials to be moved to and from trucks. “FedEx’s Memphis hub is 1.5 miles across, and the same equipment is used by the airlines, so it presents a huge opportunity,” he said. “We want suppliers to make AMRs able to handle various conditions, and there will be costs associated with this.” RR

FedEx uses mobile robots, including some from Vecna Robotics, in its facilities. | Source: FedEx

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Software •• •• •

•• •• •

•• ••

OpenAI teaches

robot hand to single-handedly

solve Rubik’s Cube Automatic domain randomization could help robots learn to be more useful in the home.

By Eugene Demaitre • Senior Editor • The Robot Report

Most robotic grippers do not closely resemble human hands because they are designed for a limited range of functions or high precision and repeatability. However, human hands can be very dexterous and perform feats difficult for robots. The key to robotic manipulation is not the hardware but the software, according OpenAI. The company recently posted to its blog about how it trained a robot hand to solve a Rubik’s Cube. San Francisco-based OpenAI has been working on artificial general intelligence, in which robots learn to solve problems independently rather than be programmed with specific solutions. In July, Microsoft Corp. said it was investing $1 billion in OpenAI and partnering with it to develop AI on the Azure platform. OpenAI’s blog post refers to a research paper its team wrote explaining how models trained in simulation could “solve a manipulation problem of unprecedented complexity on a real robot.” The company has been working since May 2017 to train a robot hand to solve a Rubik’s Cube. While it was able to do so in simulation by July 2017, the physical robot achieved that capability only in July 2019. The goal is to help train robots to eventually be general-purpose household assistants. Mobile manipulators for have also received

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interest for e-commerce order fulfillment, packing, manufacturing, and other tasks. Applying machine learning to complex manipulation “Solving a Rubik’s Cube one-handed is a challenging task even for humans, and it takes children several years to gain the dexterity required to master it,” said OpenAI. “Our robot still hasn’t perfected its technique, though, as it solves the Rubik’s Cube 60% of the time (and only 20% of the time for a maximally difficult scramble).” The goal wasn’t just to solve a Rubik’s Cube, which other robots can do faster, but to be able to manipulate it without having data on all possible orientations and combinations first. To get to that point, OpenAI kept the hardware it has been using for the past 15 years — a Shadow Dextrous E Series Hand — with a PhaseSpace motion-capture system for coordinating the five fingertips. The company also kept its 3 RGB Basler camera for visual pose estimation. It made only minor modifications for grip THE ROBOT REPORT

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| Source: OpenAI

and robustness to the Dactyl system. The researchers did modify the Rubik’s Cube for its testing to include built-in sensors and a Bluetooth module. This enabled the cube to report its state and helped with the manipulation and testing. While Dactyl’s hardware remained mostly the same, OpenAI’s latest research was different because of the techniques it used with two neural networks. It included the custom robot platform and automatic domain randomization (ADR). Normal randomization was not enough to train AI and robots to apply generalized lessons. “The biggest challenge we faced was to create environments in simulation diverse enough to capture the physics of the real world,” OpenAI wrote. “Factors like friction, elasticity and dynamics are incredibly difficult to measure and model for objects as complex as Rubik’s Cubes or robotic hands, and we found that domain randomization alone is not enough.” THE ROBOT REPORT

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While the Dactyl hardware stayed the same, the robotic hand used updated machine learning techniques to handle and solve a Rubik’s Cube. | Source: OpenAI

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Software ADR generated simulations of increasing complexity, and the control policy learned to solve them using a recurrent neural network and reinforcement learning. The convolutional neural network for pose prediction was trained on the same data but separately from the control policy, said OpenAI. “Control policies and vision-state estimators trained with ADR exhibit vastly improved sim2real [simulationto-reality] transfer,” stated OpenAI. “For control policies, memory-augmented models trained on an ADRgenerated distribution of environments show clear signs of emergent meta-learning at test time.” By “meta-learning,” OpenAI meant that the algorithm — and, by extension, robots — should be able to learn without prior knowledge and react accordingly to unforeseen factors in the environment. MIT and other research institutions are also working on the problem.

OpenAI modeled the problem in simulation and then transferred the lessons to the physical robot. | Source: OpenAI

Overcoming random obstacles to Rubik’s Cube solution As a neural network got better at solving the Rubik’s Cube, the amount of domain randomization is automatically increased, forcing the network to generalize its lessons. Random factors included the size and mass of the cube, the amount of friction, and the visible parts of the hand itself. In addition to setting the challenges of manipulating and solving the Rubik’s Cube, the researchers added a rubber glove, a blanket, and a stuffed giraffe as environmental obstacles. After repeated simulations and randomizations, the robot exceeded performance thresholds for both manipulating the block and solving the puzzle. “We find that our system trained with ADR is surprisingly robust to perturbations, even though we never trained with them,” said OpenAI. “The robot can successfully perform most flips and face rotations under all tested perturbations, though not at peak performance.” OpenAI found that visually representing how the neural networks solve problems helped associate semantic behaviors with the data gathered during simulations. This provided insight into the steps the algorithm took to move and solve the Rubik’s Cube. While a Rubik’s Cube might seem a long way from figuring out how to open a refrigerator and fetch a beverage, developing human-level dexterity is an important step toward service robots that can observe, decide, and react to a wide variety of circumstances, said OpenAI. RR

The robotic gripper needed to be able to respond to unexpected distractions. | Source: OpenAI

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•• •• •

•• ••

How the power of

cloud computing benefits robotics The cloud offers robotics developers and users new ways to deploy and manage intelligent systems and data.

By Robotic Industries Association

Melonee Wise demonstrates the FetchCore cloud-based mobile robot management system. 42

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| Source: Fetch Robotics

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Software

Cloud computing has transformed how people do things in their daily lives. Now, cloud technology has come to robotics. “The cloud” is a term used to describe software and services on a global network, operating off the Internet and allowing users to access information on virtually any device. Servers are designed to store and manage data, run applications, and deliver content. These applications are now seeing massive growth in the robotic industries space, as cloud robotics are enabling the use of cloud computing, cloud storage, and other technologies that focus on a centralized infrastructure and the benefits of shared services. The cloud offers faster robot deployment The emerging trend is already being implemented in Fetch Robotics Inc. claims that its cloud robotics on the move in logistics, healthcare, mining, robotics platform provides the only agriculture, construction and more, and is enabling autonomous mobile robot (AMR) solution for supervised autonomy and machine learning. material handling and data collection that Cloud robotics allows for higher levels of human-robot interaction and learning, and it is contributing to the digital deploys in hours versus weeks, and it doesn’t require immediate integration to show transformation of companies. As with any developing value. The company calls it “on-demand technology, enabling cloud systems raises questions about automation.” safety and security, and companies are working to swiftly “We’re one of the only companies that address these concerns. have all of our systems supported in the The cloud provides the power to handle cloud,” said Melonee Wise, CEO of Fetch computationally heavy tasks for cognitive collaboration, Robotics in San Jose, Calif. “You don’t have increasing the ability of robots to share data with other to install infrastructure. You don’t have to machines and humans. A cloud software platform efficiently manages a fleet of cart-carrying AMRs at this third-party logistics warehouse for an automotive manufacturer. | Source: Fetch Robotics

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Software install stickers or QR codes. You don’t have to install IT equipment or dedicated Wi-Fi.” “You don’t need WMS integration to get started, but you can certainly add in later once you have proven value out of your workflows,” she added. ”You can just unbox the robot, connect it to your internal Wi-Fi, and the robot will start working on Day 1.” Wise said return on investment is also quick, at only three to six months. Fetch Robotics’ AMRs include two large-payload platforms that transport pallet loads of up to 500 kg (1,102.3 lb.) or 1,500 kg (3,306.9 lb.). Part and parcel transport platforms come in a variety of configurations, including one model that transports wheeled carts, one with a modular conveyor top, and another platform with an integrated touchscreen and adjustable shelving. Data-collection AMRs automate inventory counting by tracking RFID tags on products and bins in warehouses and factories. Established in 2014, Fetch closed a $49.5 million Series C funding round in July 2019 and has raised nearly $100 million in total venture funding. Its ustomers include third-party logistics providers DHL Group, Universal Logistics Holdings, Ryder System and other 3PLs, plus manufacturers in the automotive, aerospace and electronics industries. Over-the-air updates, upgrades, and management FetchCore Cloud Software handles all of the robot management. Scheduling the robots, pushing overthe-air software updates, and communicating with third-party devices, such as conveyors, automatic doors, elevators and hand scanners, are all managed in the

Melonee Wise shows how to use FetchCore to set up an AMR workflow. | Source: Fetch Robotics

cloud. Beyond supporting all of the different AMR configurations, the software supports large numbers of robots. “We can deploy 1 to 100 robots without any difference, even more than 100,” said Wise. “The scale doesn’t matter. It gives us a big advantage because typically if you want to scale up a system with a lot of robots, you have to add more servers. For us, since we’re in the cloud, it’s done automatically.” Regardless of payload, or whether it’s a cart-transporting robot or one with a conveyor top, the software is the same. Wise said the software knows the capabilities of each of the robots, so tasks are allocated to the robots dynamically based on those individual capabilities. For example, when a warehouse operator picks a bunch of goods to a cart and then deposits the cart at the end of an aisle, they typically scan a barcode. This triggers the system to request a robot with the cart transport capability to come pick up the cart. The different robots communicate with Fetch’s cloud-based

Offload computation-heavy processes The story of cloud robotics begins with robot developers, said Roger Barga, general manager of robotics and autonomous services at Amazon Web Services (AWS). Robot developers are no longer limited by the amount of processing power and software they can cram onboard their robots. “Many of the algorithms developers would like to run won’t fit in the memory footprint,” said Barga. “Developers can now partition work by what should run on the robot and push the more computationally heavy tasks that can tolerate latency over to the cloud.” AWS is one of the world’s most comprehensive and broadly adopted cloud platforms. Millions of users, including the fastest-growing startups, largest enterprises and leading government agencies, trust the Amazon Cloud to power their network infrastructure. Other leading cloud platforms such as Microsoft Azure and Google Cloud also have notable rosters. All three support cloud robotics. Innovative robotics companies are increasingly seeking out cloud providers to support their Internet-connected robots. Many are pursuing a multi-cloud approach, where you pick and choose services from different providers. Others are exploring private, on-premises cloud options. More service options and the typical payas-you-go pricing model for cloud services makes it easier for both large multinationals and startups to access only the computing power, storage and application resources they need.

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Software software and the correct type of robot is dispatched to autonomously move that cart from location to another. At any given moment, the system knows where each robot is and what it’s doing, and chooses the closest or most opportune robot for each task. Using the cloud-based Web interface, a warehouse manager can designate what Wise calls “the rules of the road” for their facility by creating robot-executable workflows. An example of a workflow might be for a robot to visit these five stations every 15 minutes, or when someone scans this barcode or presses that button, go do this task. “It gives our customers the ability to create whatever they want the robot to do,” said Wise. “But they don’t have to be physically with the robot, and the workflows can be transmitted to hundreds of robots over the cloud.” For ease of use, Fetch’s cloudbased user interface is all drag and drop, requiring no robot programming knowledge on the user’s part, she said. Supervised autonomy These robots may have their heads in the cloud, but that doesn’t mean there’s no brain on board. All of the robots are autonomous units, each with their own intelligence.

Mobile robots, especially those in the intralogistics space, must navigate warehouses, factories and distribution centers while safely maneuvering around workers, forklifts and other equipment. This requires a fusion of sensors and software packed on board the robot. To safely navigate the space, the robot must first map its environment. That data can be pushed to the cloud for processing and building the map, which can then be transmitted back down to robot for local navigation. The same map is transmitted to other robots in the facility using the cloud. If a robot encounters a problem it can’t resolve on its own, a warehouse manager can assist the robot via the cloud. “In the user interface, you can click on the map and ask the robot to go there. You can also tell the robot where it is on the map,” said Wise. “That’s very unique to cloud-based systems.” This level of human-robot assistance is called “supervised autonomy.” “Being in the cloud gives us a lot of power for supporting the platforms,” said Wise. “We know everything about the robots all the time. We can support customers globally 24/7.” Fetch Robotics partnered with Ricoh USA two years ago. Ricoh is better known

Roller-top robot communicates via the cloud with third-party devices to facilitate conveyor-to-conveyor material transport. 46

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| Source: Fetch Robotics

www.therobotreport.com

as a printer and copier company, but they also offer a suite of enterprise support services. “They have a call center team that supports all of our robots around the clock,” said Wise. “Our support team can react to any customer issues immediately. That’s really important to us, because we’re deployed in 19 different countries.” A note on safety: Supervised autonomy should not be confused with teleoperation, which implies full control. “We typically don’t give the user full control of the robot at any one time,” explained Wise. “They have to be working in conjunction with the autonomous system. Supervised autonomy is giving a robot a task, not direct commands. We don’t tell the AMR how to get there and at what speed, merely where to go.” The robot will figure out the optimal, safe route, avoiding obstacles and yielding to humans. Wise said they don’t want people to have complete control of the robot, for safety reasons. Human error could spell the difference between driving the robot into a wall, or worse, a person. “The function of the AMR in terms of its safety comes from the software on the robot. It’s not in the cloud,” said Wise. “We don’t care about latency issues, because we don’t give robots real-time commands. We give them task-level commands.” “Getting a task command three seconds late doesn’t matter,” she said. “Getting a stop command three seconds late really matters.” Cognitive collaboration Plus One Robotics builds perception software and integrated solutions for each picking, case packing, and parcel induction applications. Their quick deployment solution consists of a robotic arm with base and gripper, their robotagnostic AI-enabled perception software, lights and cameras, and Yonder, a cloud-based remote robot management system. “We provide the eyes and the brain,” said Dan Grollman, Ph.D., Senior Engineer at Plus One Robotics, a San Antoniobased company. Grollman leads the startup’s satellite office in Boulder, Colo. “We sell to customers in the logistics THE ROBOT REPORT

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The Yonder cloud software platform for logistics applications enables people and warehouse robots to work collaboratively and efficiently in parcel handling and each picking. | Source: Plus One Robotics space who want their valuable humans to do more interesting work and leave the drudgery to robots.” That’s why the company slogan is “Robots work. People rule.” This is where cognitive collaboration comes in. Through the cloud, Yonder empowers a human supervisor, called the crew chief, to assist the robot whenever it encounters a situation in which it’s not sure what to do next. For example, the item or parcel may be askew and difficult to grasp or perceive properly. The robotic system will provide the crew chief with the information they need -- such as camera images -- so they can make the required decision. “The crew chief clicks on a pick point [onscreen] and provides any additional information needed,” explained Grollman. “That data gets sent back down to the robot, and the robot continues autonomously. “Our goal is to provide the crew chief with enough situation awareness that they can make an appropriate decision to assist the robot,” he continued. “The robot

is in one location and the human could be any place else. Doesn’t matter what time zone, what part of the world. That interaction between the robot and the crew chief all takes place in the cloud.” The crew chief can be customer personnel or a Plus One team member. The latter is more common. “We have a median response time of under 10 seconds, from robot request to a human response,” said Grollman. “Our goal is to get it lower. Still, if you compare that to a human having to walk over to a robot, even if it’s across the room, it’s a huge timesaver. The nice thing about the remote crew chief is that one person can service many different robots.” The remote robot management solution can connect a crew chief with an unlimited number of robots across the cloud. “The reason we call it cognitive collaboration is because it’s remote decision assistance,” said Grollman. “It’s at the level of decision-making and not at the level of direct control. “We’re not trying to do 100%

Supervised autonomy, or cognitive collaboration, is the “missing middle” of automation, said Eric Nieves, co-founder and CEO of Plus One Robotics. | Source: Plus One Robotics

Fetch Robotics’ cloud platform provides telemetry and analytics. If a customer wants to know data about their different workflows, how long each one took and how far the robot traveled, for example, that information is readily available. THE ROBOT REPORT

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Software The LEA cloud-connected robotic walker for patients with Parkinson’s and other musculoskeletal conditions automatically maneuvers around obstacles and responds to voice commands. | Source: Robot Care Systems

Data collection and sharing, for insights Big data is a welcome byproduct of all that extra computing power the cloud affords to robots. While the robots go about their picking tasks or transport duties, or any other robotic job, they’re moving through our physical world on an all-digital highway. Just by the nature of their digital service lives, robots are collecting massive amounts of data about their movements, the environments around them, process variables and outcomes, and even what we humans may be up to at any given moment. Fetch Robotics cloud platform provides telemetry and analytics. If a customer wants to know data about their different workflows, how long each one took and how far the robot traveled, for example, that information is readily available. “It’s not just what the robot did, but also what the robot observed,” said Wise. “If you have 20 robots, they can see almost an entire 300,000-squarefoot facility at one time. They can build a model of the warehouse. We can show where people walk over time, or where forklifts drive over time. We can show a warehouse manager how congested their facility is. That’s part of our advanced data analytics. It’s an algorithm we have on our robots and we use that to provide extra value to the customer. It’s something they can opt-in.” Wise said they’re only collecting and using a small fraction of that data off of their robots right now. The robots

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generate 30 to 60 gigabytes of data a day. She would like to be able to move all of that data to the cloud, but current network technology doesn’t support it. Industry’s promise of 5G on the horizon may or may not be the end-all, be-all solution. AWS’ Barga noted that the reality is that most software runs locally on robots. It’s the data that comes off of the robots that’s valuable to send up to the cloud. “One of our customers is Robot Care Systems. LEA is their walker robot,” said Barga. “LEA has 72 sensors. All of the onboard processing power is used to keep the patient safe. They stream the data off of LEA and are building patient health dashboards that doctors can monitor to see how active a patient has been and if they become unstable when walking with LEA. “They have a digital exhaust that gives them insights,” he said. “They are working right now to build predictive models. For example, is someone progressing the way we think they should? Is their stability

regressing? They did not have an update mechanism before. Now, with the cloud, they can do over-the-air updates to LEA.” AWS RoboMaker is a service that makes it easy to develop, test and deploy intelligent robotics applications at scale. RoboMaker extends the most widely used open-source robotics software framework, the Robot Operating System (ROS), with connectivity to cloud services. The service provides a robotics application development environment, a robotics simulation service to accelerate application testing, and a robot fleet management service. AWS also joins the growing fan club advocating open-source software for industrial automation the Robotic Industries Association highlighted earlier this year in ROS-Industrial for Real-World Solutions. Barga said AWS is in the final stages of joining the ROS-I Consortium. AWS is also a founding member of the technical steering committee for ROS 2, the latest version of the open-source software. He’s quick to point out that Microsoft, Intel,

Roger Barga of AWS discussed the power of the RoboMaker Service at the ROS-Industrial Conference in December 2018. | Source: AWS

autonomy right out of the gate,” said Grollman. “Yonder is a great tool to get people up and running and in production quickly, and it develops from there.”

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Software Bosch, and Toyota Research Institute have also joined Amazon and other heavy hitters on the committee. “No other cloud provider has the breadth and diversity of services we have from storage to analytics, to focused services for IoT analytics,” said Barga. “All of our cloud service extensions we have released as open source. All of our contributions to ROS we have released as open source software. Fleet management is uniquely ours, but we’re very transparent on what we’ve built upon. It’s the magic we add behind the scenes that sets AWS apart.” AWS customers use computer simulation to validate that their applications are running correctly before they allow their developers to check in any new code. “For them as a robotics company to have racks of machines sitting around to run simulations every time a developer checks in code, that’s a perfect example of how to use our cloud service that runs simulation-as-a-service.” More powerful solutions Amazon AI services add voice commands to the robotic walker’s capabilities. The Lex speech recognition and Polly speech generation services allow patients to talk to the robot and the robot to respond. Users can change the language and run multiple languages. “If you’re deploying a robot in Japan, we have the Japanese Polly and Lex versions of Amazon cloud service integration services,” said Barga. “That’s also how people interact with LEA. When they summon LEA to come to them from across the room. That voice command is picked up by a microphone on LEA and sent up to a cloud service which does the translation into text. It understands what

Woodside Energy conducted robot and advanced sensor trials at its onshore | Source: Woodside Energy liquid natural gas facilities.

the customer is saying and then sends commands back to LEA.” “We’re not trying to build everything ourselves,” he said. “Instead, we’re trying to help make it easy for roboticists to add power to their robot through AWS services.” Machine learning Plus One uses the cloud for continuous improvement through machine learning, Grollman explains. “We use machine learning in two places. One is in the onboard system. During autonomous operation, we use a machine learning system to improve the autonomy. The second place is every time a human interacts with the robot. That is a teaching point. We can use that information to improve the system’s own capability and confidence, so perhaps next time it doesn’t need to ask for help.” He said the goal is algorithmic adaptation, versus a software developer

analyzing the data and writing new code or updating the system. Their remote robot management solution also includes an API for publishing performance data to thirdparty software. As the system runs, it publishes statistics on its activities, which can be analyzed to identify any bottlenecks. “That’s one of the nice things about cloud robotics, even apart from Yonder and the crew chief, just having that data exposed and people having access to it, is a reason to put your robot on the cloud.” Wise said Fetch Robotics is very focused on the long-term vision of doing machine learning with the data from the robots. “We build models. Those models are trained on the data we get from the robots and then we use that to improve the system constantly. We also use that data to provide insights to

Cloud technology and its impact on cloud robotics is interesting, indeed. Companies worldwide are just starting to embrace the Internet of Robotic Things. It will be fascinating to see what comes down the pipeline next.

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the customer. We can actually take large datasets and make the robots better.” She cites an example. It’s lunchtime at a warehouse facility and two drivers park their forklifts at the ends of an aisle, completely blocking access in or out. “We have an alert that looks for when a robot drives back and forth between two points several times in a short amount of time. We have a whole bunch of detectors that look for weird behaviors or very specific behaviors in the robots. Then the robots alert us when there is a problem.” Machine learning is computeintensive. All of that learning training runs in the cloud. Digital transformation AWS customer Woodside Energy, a mining company in Australia, was moving materials from one side of their operation to another. Rather than expending valuable human capital to drive a transport vehicle, they deployed ground mobility robots on their mining field. As the robots were carrying equipment from Point A to Point B, they would pass by the company’s seethrough glass reservoirs that contain oil for lubricating equipment. They decided to put a camera on the robot to record the oil level. Woodside used AWS machine learning services to label the image data collected by the robot-mounted camera. Engineers labeled shots of the reservoirs as different percentages of full, for example, 60% full or 20% full. They built up a machine learning training set that ran the machine learning model on their robots. Each time the camera sees one of the oil reservoirs, it runs the machine learning model. If the oil level is below a certain percentage, it sends a notification back to a Woodside manager for a maintenance request to fill the reservoir. “That digital transformation is helping a robot automate a task, but it’s also sending valuable data back so you can make your business run more efficiently,” said Barga. “That’s a story people don’t typically consider when they start thinking about robots and automation. When they do, they realize they need to

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have a long-term plan for the services they’ll use to ingest the data and the kind of analytics they can build around it to run their business better. Then things start getting really interesting.” AWS offers the last word on security We’ll give Barga the last word on security, a critical subject especially when it comes to Internet-connected robots. His AWS team, in collaboration with other roboticists, built the first security threat model for ROS 2. “You have to secure the entire code chain from what runs when the operating system is running on the robot, all the way to your software that’s running on the robot. A number of companies have picked up this security model and used it to evaluate the security posture of their robot and its software stack.” AWS IoT Greengrass software hails from Amazon’s IoT team. “Think of it as a big vault running on your robot,” said Barga. “Unless you have the combination to access the vault, you can’t do anything to the software. We’ve locked down your robot so nobody can install software, nobody can communicate with it and nobody can get data off of it.” Cloud technology and its impact on cloud robotics is interesting, indeed. Companies worldwide are just starting to embrace the Internet of Robotic Things. It will be fascinating to see what comes down the pipeline next. These robots may have their heads in the cloud. But their eyes are on the prize. Productivity and greater efficiency. Better performance. Make life easier on humans. Connected robots and humans. RR

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Collaborative Robots •• •• •

•• •• •

•• ••

When will

high-DOF robot arms matter? Cost and programming difficulties are holding back high-DOF robots By Neil Tardella • CEO, Energid

High-DOF robots (robots with more than six degrees of freedom) hold the promise for a more automated future. However, the real value of high-DOF robots will only be realized when integrators move away from the “one task, one robot” mindset.

As robots become more general-purpose, the need for more axes becomes evident. Switching

tasks requires a system designed with inherent flexibility – flexibility that can only be achieved with high-DOF robots. Adoption challenges The majority of deployed industrial robots in the world have six or fewer axes. There have been attempts to popularize high-DOF industrial robots, with more than six axes, but these attempts have not been very successful. Why is that?

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There are two inter-related reasons why high-DOF robots have not caught on: cost and programming difficulties. Every axis costs money for hardware and engineering, as each additional axis adversely affects repeatability and payload. With the “one robot, one task” mindset, integrators have historically chosen a robotic solution with the minimum number of axes needed to solve the one task at hand efficiently. The belief was that using a 6-DOF robot for a 5-DOF problem added unnecessary cost and complexity to the work cell. True enough in traditional automation. However, what if one robot could be used for more than one task? THE ROBOT REPORT

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The Baxter cobot from Rethink Robotics’ features two 7-DOF arms. | Courtesy of Rethink Robotics

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Collaborative Robots

As robots become more general-purpose, the need for more axes becomes evident. Switching tasks requires a system designed with inherent flexibility – flexibility that can only be achieved with high-DOF robots.

What would it take for integrators to reconsider the “one robot, one task” paradigm? To consider this, they would need access to high-DOF robot hardware that provides flexibility in movement, and a means to program and control the robot that is no more complex than the programming required for a low-DOF one. Today, software to control high-DOF robots exists but has been mostly found in academia and R&D institutions like NASA and DARPA. But commercial solutions that can be applied to traditional automation are becoming increasingly available. Kinematic redundancy and why it matters Without specialized software, it’s extremely difficult to program high-DOF robots. The more joints a robot has, the more difficult it is to control. The complexity of control grows non-linearly with the number of joints. For lower-axis robots (with 6-DOF or less), it’s usually possible to find a closedform solution for how the joints must move to place the end effector. Robots with more than six axes are considered kinematically redundant because they can achieve a particular end effector pose from multiple joint states. It is incredibly important for high-DOF robots to be able to deal meaningfully with kinematic redundancy. Humans are experts at this. Think of all the different ways a human can reach down and pick up a ball. Our brains automatically determine how to optimally move our “axes” (a human has over 200 joints) to achieve the necessary hand motion — all while avoiding collisions

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with ourselves and the environment, preventing joints from locking up, and making micro-corrections based on visual and tactile feedback. All of this redundancy makes us humans highly generalized. We can move seamlessly from one task to the next. It’s really quite amazing. Virtually all evolved forms of life have musculoskeletal systems that allow for the exploitation of redundancy. Most industrial robots, on the other hand, have not been equipped with software that can deal with kinematic redundancy at all, let alone use it to its advantage. The lack of sufficient software is why the world of industrial automation is filled to the brim with simple, lowDOF robots that have been purchased, programmed, and deployed to perform one task, and one task only. If you would like a traditional industrial robot to perform a new task, it’s possible. But only after a very costly integration effort, and then that robot will be able to only perform that new task. It’s completely lacking in flexibility, one of the key growth drivers for robotic systems deployed in industrial automation settings.

process - being much closer to a direct replacement for a high-DOF human. When this happens, the change will not be incremental but rather a step function. RR

The future of high-DOF robots With the advent of software that can exploit kinematic redundancy and simplify programming of high-DOF robots, the cost of additional axes can easily be justified by amortizing it over a broader set of tasks the robot can perform. The real benefit will be seen when high-DOF robots are used to replace a series of steps in a given manufacturing www.therobotreport.com

THE ROBOT REPORT

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Collaborative Robots •• •• •

•• •• •

•• ••

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Despite the challenges of worker shortages and turnover, Zippertubing Co.

By The Robot Report Staff

needed to improve product quality and increase throughput. The Chandler, Ariz.-based company manufactures protective coverings for wiring and cables used in the aerospace and automotive industries. The family-owned company had no prior robotics experience. Zippertubing ultimately turned to a UR5 collaborative robot arm from Universal Robots A/S to tend its snap-set cable wrapping machines. Challenges In 2017, Zippertubing struggled with finding human workers so that it could fill a large automotive order. The company also serves the aerospace industry. “We had a lot of people who would come in, work for maybe a week, and then leave because they didn’t like the repetitive work environment,” said Tim Mead, operations manager at Zippertubing. In addition, the repetitive nature of the work, which required looking at thousands of parts per day, could lead employees to become “snow-blind” to flaws, he said. Some robot manufacturers directed Mead to integrators, “but we wanted something that we could integrate ourselves,” he said. “Something that would save us a lot of money and bring the installation down to a price point that made sense for us.”

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Mead’s background is in chemical engineering, so he was initially reluctant to build a cobot cell himself. However, a distributor and the Universal Robots Academy helped him. “The demo convincing us was done by Universal Robots’ distributor InPosition Technologies, and it looked very straightforward,” recalled Mead. “There’s also a lot of cool training stuff on the UR website.” Solution “We chose Universal Robots’ UR5 for a few reasons,” said Matt Hesselbacher, engineering manager at Zippertubing. “After a quick demo, we realized this was a collaborative robot we could integrate on our own.” “With products that change from month to month, we were also looking at the versatility,” he said. “As always, safety was a priority, as operators would be working around the robot, feeding it raw parts, and taking away the finished pieces.” THE ROBOT REPORT

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Zippertubing’s snap-set machines wrap thermal materials around cables, hoses, and pipes. To tend them, the UR5 needs machine vision to make the right decisions. “The really tricky part was ‘How do I get the robot to talk to the camera, and who’s in charge?’” said Mead. “So learning about the Universal Robots, we actually

After the male and female snaps have been inserted, the UR5 places the fabric under a vision camera lens for quality inspection and sorts it in either a “good” or “reject” pile. | Courtesy Universal Robots

Case Study Breakdown Company: Zippertubing Co. Location: Chandler, Ariz. Industries: Automotive and subcontractors Challenge: Repetitive work environment, large orders Partners: Universal Robots, In-Position Technologies Products: UR5 cobot, vision system, Millibar tool changer Tasks: Moving fabric for the addition of snaps, inspecting quality Value Drivers: Increasing productivity and quality, ease of integration Results: Redirecting 32% of workforce, specify 300% greater tolerance on parts ROI: Less than two years www.therobotreport.com

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Collaborative Robots We chose Universal Robots’ UR5 for a few reasons,” said Matt Hesselbacher, engineering manager at Zippertubing. “After a quick demo, we realized this was a collaborative robot we could integrate on our own.

Placing the fabric correctly into the snap machines was difficult to do in a uniform fashion with manual labor. The UR5 enabled Zippertubing to triple the tolerancing.

were able to make that essentially our PLC. The robot is the brain –it sends out all the commands, and it takes in all the feedback.” The robot simply looks for feedback from the camera. If it doesn’t find it, it says it’s a bad part. If it finds it, that means the part was good, and it sorts it accordingly, he explained. The UR5 picks up a precut fabric for snaps to be added. The 25-second cycle concludes as the UR5 presents the piece to a vision camera that inspects whether the snaps are added correctly. Depending on the outcome, the UR5 is directed to place the finished piece in either the “good” or the “scrap” pile. For tool changing, Zippertubing went to the UR+ online marketplace, where it found the Millibar tool changer. “The benefit of using this is quick changeability; adding a new tool to the end of the robot arm is not an issue now,” Mead said.

| Courtesy Universal Robots

Meet the new UR16e cobot

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Universal Robots added the UR16e cobot to its e-Series line. The UR16e features a 16 kg (35 lbs) payload, making it the company’s strongest cobot ever. The UR16e also has a 900 mm reach and ± 0.05 mm repeatability. The UR16e is designed for tasks such as heavy-duty material handling, heavy-part handling and machine tending. Like the rest of the e-Series, the UR16e includes built-in force sensing, 17 configurable safety functions, including customizable stopping time and stopping distance, intuitive programming flow, and compliance with safety standards EN ISO 13849-1, PLd, Category 3, and full EN ISO 10218-1. “The UR16e is the first step changing UR from a company that’s been pushing technology into a market to UR being more of a product management organization,” said Jürgen von Hollen, President of UR. “We’ve been listening to the market and customer needs.”

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Results “The biggest benefit we’ve found with the UR5 cobot is that our product quality really has improved,” said Mead. “The robot has been running for eight months now, and we have gone from having some product returns to now zero defects on parts produced.” Zippertuping said it can run its robots around the clock, redirect 32% of its workers, and improve quality. “We can have the robot run all night and double our production output. We can also have it handle two or three additional parts and cover even more of our production,” explained Mead. “We can now take that freed-up labor and move them to other more customized high-skilled, high-demand sections of our production line, where our operators can use their skills in a more beneficial way.” “With the robot itself, we can specify 300% more tolerance on our parts than with manual operation,” he said, adding that the UR5 also solved Zippertubing’s hiring problem. “It used to take three people to do all of the operations that the robot now does, so this has really opened up production capacity for us.” Zippertubing’s successful deployment of collaborative robots for inspection tasks is far from unique, said Universal Robots. Increasingly, it said, manufacturers are relying upon cobots to consistently follow processes and predefined workflows with minimum deviation. The company said it expects a two-year return on its investment. The success of Zippertubing’s Arizona plant has led it to consider automating its plant in China. The company is also looking at other processes such as sewing. “It will be a unique challenge, as we want the robot to do snaps and sewing with the same tool,” said Mead. RR

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Collaborative Robots •• •• •

•• •• •

•• ••

AOT’s CARLO system for bone surgery includes the LBR Med cobot from KUKA. | Courtesy AOT AG

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Surgical system

uses KUKA cobot for sensitive precision By The Robot Report Staff

Robots are spreading in healthcare, but collaborative robot arms are often seen as not precise or reliable enough for surgical procedures. Advanced Osteotomy Tools AG has turned to a custom cobot from KUKA AG for the CARLO bone surgery system. Dr. Alfredo Bruno, a laser researcher, wondered why precision lasers weren’t used to cut bone while educating himself about a complicated jaw surgery on his daughter. He then met Dr. Hans-Florian Zeilhofer, head of the oral and maxillofacial surgery department at the University of Basel Hospital and the Aarau Canton Hospital. In 2010, they co-founded Advanced Osteotomy Tools (AOT) in Basel, Switzerland. “Our goal was to achieve radical improvement in the results of bone surgery by replacing mechanical cutting instruments with non-contact ‘cold’ laser photoablation and medical robots,” stated Bruno, who is chief scientific officer (CSO) at AOT. Challenges Despite more than 50 years of progress in medical lasers, particularly in dermatology and ophthalmology — think of tattoo removal and cornea correction, respectively — challenges remained in bone surgery. Maintaining the integrity and health of bone tissue around incision sites was difficult. AOT claims that its CARLO (Cold Ablation Robot-guided Osteotome) robotic surgical product can cut bones without contact or generating excess heat. In addition, AOT needed a high-precision robot to work with its laser, as well as 3D planning, navigation, and control software and hardware. It needed to be small enough to fit into existing operating rooms, while balancing autonomy with responsiveness to surgeons. THE ROBOT REPORT

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Collaborative Robots Case Study Breakdown Company: Advanced Osteotomy Tools AG Location: Basel, Switzerland Industry: Healthcare Challenge: Creating a surgical system that could avoid injuring bone tissue around laser incisions Partner: KUKA AG Robots: LBR Med, based on KUKA iiwa cobot Tasks: Making precise cuts in patterns required by surgery Value Drivers: Precision, safety, responsiveness, and ease of integration Results: AOT’s CARLO system is going through device-approval process Solution According to AOT, CARLO’s design “allows the surgeon to perform bone operations with unprecedented precision and in freelydefined, curved, and functional sectional configurations, which are not achievable with conventional instruments.” The custom-designed system uses a lightweight “tactile” robot arm with navigation and control software for an “ergonomic” and precise system, said the company. For that robot, AOT chose the LBR Med from KUKA. It is based on the seven-axis LBR iiwa cobot, which includes force-torque sensors, so AOT did not need to develop safety measures from scratch. Another advantage of the LBR Med is that it is the only robotics component that has CB Scheme certification for integration into medical products. That has saved a lot of time in the medical device-approval process, which is ongoing, said AOT. The Oral and Maxillofacial Surgery Department at the University Hospital Basel has successfully used it in its first clinical trial. “Since CARLO is the first system of its kind, the supervisory authorities are understandably placing very high requirements on its safety,” explained Bruno.

Results A physician using CARLO starts by taking the CT scan and conducting preoperative planning. Then, technical staffers feed the planning data into CARLO’s navigation system. The interface for the surgical robot is designed to be intuitive and guides the team through initialization step by step. The software-guided laser system supported by LBR Med allows for highly

precise cuts in any pattern required for bone surgery, explained Zeilhofer. The cobot is sensitive enough that a surgeon merely needs to touch it gently, and it will stop immediately. “The LBR Med has a whole range of extremely fine sensors. It is quicker than stopping a human assistant,” said Zeilhofer. “The robot then moves to a wait position and resumes the procedure from precisely this position as soon as it receives the all clear.” “When there is even a little, unplanned contact, it remains still and interrupts its tasks,” he added. “This sensitivity can also be used to operate the system intuitively and manually.” AOT is already working on the development of the second generation of CARLO with enhanced safety and performance features that will place further demands on the LBR Med. “CARLO represents the future of surgery,” Zeilhofer said. “There are far more options open to the surgeon than with previous procedures.” RR

CARLO enables precise bone surgery with robot-guided laser ablation. | Courtesy AOT

According to AOT, CARLO’s design “allows the surgeon to perform bone operations with unprecedented precision and in freely-defined, curved, and functional sectional configurations, which are not achievable with conventional instruments.” 62

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Motion Control •• •• •

•• •• •

•• ••

Examining motion control at the Healthcare Robotics Engineering Forum

Panelists from leading technology and healthcare companies will discuss advances at the December event in Santa Clara, Calif.

By The Robot Report Staff

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Developers of systems for assistive, therapeutic, and medical use will have an excellent opportunity to meet and learn at the Healthcare Robotics Engineering Forum, which will be on Dec. 9 and 10, 2019. The Silicon Valley event will examine enabling technologies, tools and platforms, design and development, and management and business opportunities. The importance of motion control to healthcare robotics will be one significant discussion topic. In the panel “Advanced Motion Control Solutions for Healthcare Applications,” experts will explain how the needs for healthcare applications are different than those for other types of robots. For instance, they have strict requirements for tolerances, safety, reliability, sterility, and more. In addition, forum attendees can learn about how the latest technical advances in motion control support the development of systems for new capabilities, applications, and markets.

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Motion control panelists to share insights The distinguished speakers have years of experience and represent leading companies in the healthcare robotics and motion control space. Prabh Gowrisankaran, Performance Motion Devices As vice president of engineering and strategy at Performance Motion Devices Inc. (PMD), Prabh Gowrisankaran is responsible for future-proofing the Westford, Mass.-based company and its customers innovating in fast-paced technology environments. With a degree in electrical engineering and an MBA in finance and strategy from Babson College, Gowrisankaran has more than 20 years of technology and product management, hardware development, and engineering leadership. Dave Rollinson, HEBI Robotics Dave Rollinson is a co-founder and mechanical/ controls engineer at HEBI Robotics, an engineering services firm focusing on motion control spun out of the Biorobotics Lab at Carnegie Mellon University. It develops specialized robotics tools for a variety of markets, as well as providing a commercial family of modular force-controlled actuators and supporting software. Prior to Pittsburghbased HEBI, Rollinson worked as a robotics engineer at RedZone Robotics, designing, building, and deploying robotic sewer-inspection systems. He holds a bachelor’s in mechanical engineering and a Ph.D. in robotics from CMU.

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Bob Mullins, Harmonic Drive Bob Mullins has been with Harmonic Drive LLC for over 25 years. He started with the company as a field sales engineer in the Midwest. Today, he is vice president of sales in the U.S. corporate headquarters and manufacturing facility in Peabody, Mass. An avid engineer, Mullins works closely with today’s leading roboticists. He is a respected motion control expert, with experience participating in industry speaking engagements and authoring and presenting webinars. Mullins earned his bachelor’s in mechanical engineering at the University of Connecticut and his MBA at Illinois Benedictine University. About the Healthcare Robotics Engineering Forum The Healthcare Robotics Engineering Forum is presented by WTWH Media LLC, the parent organization of The Robot Report, the Robotics Summit & Expo in Boston, and Device Talks West, which focuses on medical devices and will be co-located with the forum. It will be on Dec. 9 and 10, 2019, at the Santa Clara Convention Center. This event is intended for the engineers designing, building, selling, evaluating, and monitoring robotics for healthcare. The forum will feature speakers from across academia, commercial robotics developers, and the industry. It will also include exhibits by cutting-edge robotics vendors, workshops, and networking opportunities. RR Register now for the Healthcare Robotics Engineering Forum at www.healthcareroboticsforum.com

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Motion Control •• •• •

•• •• •

•• ••

Consider your

environment

when designing or selecting robot joints

Temperatures, dust, and vibration are among the factors to consider for robot joints.

By Lisa Eitel • Executive Editor, WTWH Media

From automotive manufacturing to the “3Cs” of computers, communications, and consumer electronics, demand has continued to rise for industrial automation. Compared with dedicated equipment in traditional production lines, robots offer superior operational flexibility and capabilities. They’re especially suitable for multi-species and small-batch production for rapid response to shifting market and consumer demands. Since 1916, Kollmorgen Corp. has supplied machine builders. Today, the company said its knowledge of motion systems and components, automated guided vehicle software, and industry-leading quality gives machine builders a marketplace advantage. Kollmorgen added that its expertise in integrating standard and custom products delivers systems that are unmatched in performance, reliability, and ease of use. Kollmorgen’s engineering staff outlined the leading environmental factors affecting the performance and longevity of industrial robot joints. Back to basics To review, industrial robots are programmable, multi-purpose manipulators that move loads in three or more axes. Significant advances in actuator and control technology have enabled the evolution of sophisticated modular robot joints. Modular robot joints are standardized yet capable of interfacing with a myriad other parts and systems. Modularity allows for versatility in design and machine capabilities, adaptability, and ease of assembly. Integrated mechatronic modular joints outperform conventional robotics as well — with higher power density, dynamic performance, and reliability along with lower weight.

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UR+SFK LIFTKIT palletizing is an example of an application taking the environmental effects on robots into account. | Source: Universal Robots

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Motion Control Industrial robots are increasingly used in the motioncontrol industry for maximizing manufacturing productivity and throughput. | Source: Motion Control Tips

One caveat is that industrial robots can incur significant upfront investment. Decisive factors when considering the robots to replace expensive human labor are the payback period in capital investment and robot service life. Quick payback and long service life maximize return. Certain motion-component manufacturers are well versed in servo-motion components used in the robotics industry. OEM collaborative robot (cobot) designs with light payloads are optimizable by the inclusion of one or more modular robot joints. Some modular robot joints integrate frameless torque motors in the form of alternating current permanent magnet (PMAC) servo motors for simple and safe designs. Careful engineering means some frameless motors are optimized to adhere to space or weight constraints or performance and reliability requirements. Now let’s outline various environmental factors affecting the longevity and performance of industrial robot joints.

Gearing is the most significant environmental heat source if strainwave gearing is used. It can contribute up to 30% of the total power loss due to gear-mesh friction, viscous lubricant shear friction, and energy invested in repeatedly distorting the metallic flexspline every revolution. Ineffective heat dissipation will cause the robot to get hot and exhibit diminished performance. Common in robot joints: strain-wave gearing A robot joint’s output shaft typically rotates at 10 to 40 rpm. A motor typically rotates at 1,000 to 4,000 rpm for short bursts during robot joint movements. So, gearing reduces speed and increases acceleration torque at the output, for high torque density relative to its dimensional footprint (torque per unit volume) and specific torque (torque per unit mass). Strain-wave gearing mechanisms offer distinct advantages that justify their use in industrial applications and robots. They include a high gear ratio in a single stage, at or near-zero backlash and simple structure, precise torque

Thermal environmental effects reduce robot component life High temperatures can degrade the lifespan of industrial robots. For instance, a mechatronic robot joint module contains a frameless motor, servo drive, dedicated gearing system, brake, encoder or resolver, torque sensor, connection cables, and so on in a single compact housing. Normal operation generates heat inside this housing — mostly originating from the gearing, motor windings, and brake coil if applicable — along with other electric and electronic components.

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transmission, and high positioning accuracy and repeatability. Strain-wave gearing includes an ellipse-shaped wave generator, a flexspline, and a circular spline. The flexspline is the life-limiting subcomponent. During operation, it sees constantly changing amounts of elastic deformation from the rotation of the ellipse-shaped wave generator — and must rotate with minimal angular deflection. So, the flexspline must be flexible in the radial direction but stiff in the tangential direction to accurately transmit rotational motion. Power losses in the strain-wave gearing are due to various mechanisms, including:

• Friction loss due to gear meshing

between flexspline teeth and rigid circular spline in the three teeth meshing stages — engagement in, engagement, and engagement out. Unlike conventional gearing, teeth movement in a stain-wave mechanism is primarily sliding due to a small phase shift between the corresponding teeth in engagement. Sliding between the teeth causes energy losses and heats the assembly to an equilibrium of 60 to 70° C.

• Molecular friction loss due to viscous

friction in the lubricant.

• Bearing friction loss in the cross-

roller bearing, wave generator bearing, and other bearings.

Strain-wave gearing is indispensable in robotic applications but is not without its challenges. | Source: Motion Control Tips

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Motion Control • Mechanical loss due to periodically

repeated elastic strain energy, due to torsional and radial deformations of the flexspline. Some of these power losses are strongly influenced by environmental operating temperature. Conventional gearing systems usually exhibit some level of backlash. Backlash lowers the accuracy of gearing system but provides space for lubrication and thermal expansion. Given that a strain wave gearing inherently has nearly zero backlash, at high temperature, the thermal expansion on its gear elements may spur an interference between meshing gears — and increase the tooth contact pressure and meshing friction. Wear characteristics of strain-wave gearing depend heavily on the condition of the lubricant, in turn affected by operating temperature. Excessively high temperatures may spur the breakdown of the lubricant film, which in turn allows scuffing damage on the gear-teeth contact surfaces. The efficiency of strain-wave gearing is proportional to the load percentile (load torque to allowable average torque) and allowable operation temperature — and is inversely proportional to the input speed (gear ratio). Maximum temperature ratings are 50 to 70° C, depending on the manufacturer and lubricant rating. Electrically actuated brakes are another heat source Electrically actuated brakes are common on industrial robots. Brakes in these applications typically include an electromagnetic inductive coil with a mechanical spring mechanism to engage a holding friction (interference) state upon voltage removal from the coil. Brake coils energized during motor movement generate heat. Then coil electrical resistance increases with coil resistance Rc at temperature T varying linearly with the temperature differential between the operation temperature T and the ambient temperature Ta defined as:

α = 0.00393 per ° C) and Ta = Ambient temperature and with:

R c,Ta

= Electrical resistance of the coil at the ambient temperature … so if temperature rises 30° C above ambient temperature, coil resistance increases 12%. Environmental temperature and frameless motors Frameless motors fit applications where size and weight are top design objectives. Compared with housed motors, this motor type may offer end users commercial and technical competitive advantages — including high torque density, enhanced heat dissipation capabilities, and flexibility for customized designs. Integrating frameless (stator and rotor) motors directly onto the bearings already supporting the gearing components minimizes overall robot-joint size and eliminates redundant components. The latter might include extra bearings to support the rotor, separate shaft and coupling to between the motor shaft and gear set’s wave generator. Rated continuous-torque values listed in motor manufacturer catalogs are based on set ambient temperatures — usually 40° C. When actual environmental temperature exceeds rated values, motor performance deteriorates and at low speeds near stall the its output torque reduces:

T c,d = T c

t max - t a,r t max - t a

Where tmax = Maximum motor winding temperature, ta = Rated ambient temperature, ta,r = Real ambient temperature, Tc = Rated continuous (low speed) torque, and Tc,d = Derated torque at real ambient temperature. So, with tmax = 80° C, ta = 40° C, and ta,r = 60° C, derated torque is 70.7% of the original continuous torque. At low speeds, the frameless-motor power losses are dominated by the cooper losses in the motor windings. Power loss due to winding resistance Pl is related to current i and electrical winding resistance Rw : 2 l w

P =i R

As demonstrated by the Rc,T equation discussed earlier related to brake coils, higher temperature directly causes a higher winding resistance Rw … and that in turn makes for higher power loss in the robot joint arm. The torque de-rating formula doesn’t account for non-I2R motor losses such as iron losses. As these iron losses increase as a function of speed, the torque derating will be more pronounced than this calculation predicts. The iron losses in the motor’s core are a function of both the fundamental electrical frequency and flux density levels of the motor’s magnetic circuit. The

Frameless PM motors are the top motor choice for many robot-joint designs. They offer compactness and minimize weight for lower overall system inertia — to help make robotic arms nimbler and more reliable. | Source: Motion Control Tips

R c,T =R c,Ta [1 + α (T - Ta)]

Where α = Material temperature coefficient (for copper magnetic wire

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pole count of the motor determines the fundamental frequency and the design of the stator core and permanent magnets set the flux density levels. In particular, the eddy current iron loss is a function of both the fundamental frequency squared and flux density squared. The operating speeds of the robot’s application are a key factor in the electromagnetic design of the framelessmotor as the selection of the motor pole count and design of the stator core determine the balance of I2R and iron losses. An optimized electromagnetic design results in the best motor efficiency across the robots operating speed range. Robot sensors sensitive to heat Robots use many sensors — including encoders, resolvers, and torque sensors. A key characteristic of these sensors is their sensitivity to environmental temperature. For optical encoders, the increase in temperature causes a decrease in the LED’s light output. Thermal expansion also impacts optical encoder performance. In fact, thermal expansion can narrow the air gap between the disk and the source (detector) by 0.020 in. (0.51 mm) in some situations. Extreme instances of such thermal expansion can bring the subcomponents into contact and cause encoder damage or even catastrophic failure. For magnetic encoders, thermal expansion and contraction of the magnetic wheel can alter the pitch of the magnetic poles and thus alter the output.

Servo drives and other electronic components Servo drives are key in a variety of robots including cobots, industrial articulated robots, and medical robots. But electronic component failure rates skyrocket at high temperatures. The Arrhenius law states that for every 10° C increase in operating temperature above the rated temperature, life expectancy will be halved. As one of the major sources of electric noise, thermal noise arises from the thermal fluctuations in the electron density within a conductor and thus is always present in electronic circuits. It highly depends upon the temperature — in other words, the higher the temperature, the higher the thermal noise level. The only way to reduce the thermal noise content is to reduce the temperature of operation. Bearing lubrication in robot joints Lubrication has significant influence on the performance of both motors and strain-wave gearing. Several bearings types are used in robots — cross-roller bearings, wave generator bearings, and regular deep-groove ball bearings. These bearings are lubricated by mineral oilbase greases. Of course, bearing friction is affected by several factors — including temperature, velocity, load, lubricant properties, and environmental conditions. Temperature changes causes significant grease-viscosity and molecular-friction changes. Cold can significantly reduce the oil-release

characteristics of grease and lead to insufficient lubrication — with the potential for wear and system failure. As a comparison, high temperatures can sheer or crack the oil molecules into smaller molecules for decreased viscosity. This may induce oil leakage from the bearing. In fact, high temperatures can also trigger two other grease failure mechanisms: Oil oxidation can lead to increased oil viscosity, deposits, and the loss of the ability to form a protective lubricant film. The second failure mechanism unique to grease is a waning ability of the thickener to retain the oil phase. Under extreme conditions, the latter can induce permanent loss of lubricating oil. As a rule of thumb, the rate of chemical reactions (which includes oxidative and thermal degradation) changes by a factor of two for every 10° C change in temperature. That means increasing temperature by 10° C doubles the rate of reaction — halving expected life. Elevated temperatures drive grease failure modes quickly as they increase. Harsh environmental effects on robots Some types of industrial robots are designed to operate in harsh environmental conditions such as spray-painting robots, welding robots, and polishing and grinding robots. Such extreme conditions like wet or muddy terrain, dust, humidity, vibration and shock, corrosion, toxic conditions (such as radiation) and so on can significantly influence the robot’s performance and life.

Military and other field robots can be subject to harsh environmental conditions. | Source: Kollmorgen

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Motion Control Industrial robots with different exterior coatings, materials, and seals differ in their ability to withstand such environmental conditions. Most robots arrive at the end user already sealed. But after an extended period of service, thermal cycling may cause pressure changes and seal failures — for ingress paths and places that allow external debris to get inside the robot. Optical encoders detect rotary motion with optoelectronic components (including fine-pitch scales, LEDs, and photodetectors) that can be seriously harmed by contamination. Exposure to dust, dirt, water, or oil can cause partial or complete encoder failure over time. Optical encoders subject to significant vibration or shock can also fail if the optical disk cracks or shatters — especially those using a glass disk. Bearings are also sensitive to contamination. Dirt, dust, and other foreign objects that enter a bearing can cause scratches, pits, and lapping on the raceway surface — as well as premature damage. Moisture can degrade a bearing in several ways. Bearings exposed to moisture may corrode or become etched on its exposed surfaces for localized spots of corrosion. This pattern of corrosion in turn makes for excessive noise, unplanned clearances, and corrosion fatigue in corroded zones. All other robot parts, from electric motors to electronic components, can corrode when exposed to environmental factors. The miniaturizing design of the servo drive integrated into a robot joint has greatly reduced the space between electronic components, making them easier to integrate into a robot. But such designs also heighten the risk of exposure in corrosive settings. In practice, corrosion may occur throughout the robot’s entire life cycle during various stages of manufacturing, assembly, transport and storage of robots, as well as field operations. Loading and vibration during operation Robot payload and overall system inertia affect robot dynamic characteristics and position control accuracy. Robot payload refers to the weight a robot can lift and move beyond just its own structural

mass. When a robot carries very high load, fractures may occur on the teeth of the gearing. In fact, tooth breakage is often caused by mechanical overloads that exceed the gear materials’ tensile strength. Overall system inertia is the sum of the load inertia and robot inertia. It plays a key role in rotational kinetics and represents the tendency of the loaded object and robot to resist changes in motion — namely to speed and direction. Higher system inertia generally makes for lower positioning control accuracy. That said, today’s latest high-bandwidth drive technology with high-resolution feedback devices has minimized many of these effects and limitations. A robot arm in operation is subject to a variety of external loads and inertia forces depending on its position, orientation, and moving velocity. When the robot executes certain tasks — such as carrying payloads exceeding its published rating, performing fast maneuvers, and interacting large forces or moments within the unstructured environment — the robot may lose its dynamic balance and motion stability. Where a robot experiences an acceptable payload but a very high inertia, it may cause the robot to accelerate slowly, not work properly, or even render the robot incapable of making the commanded move. So safe robot operation depends on careful consideration of both the payload (inertia) and effective contact force control. A strain-wave gear may have several types of failure modes. Fatigue fracture of the flexspline is the most common failure mode. Testing on strain-wave gearing indicate that as early as four million input revolutions (for a motor running at 3,000 rpm this is equivalent to 22.2 service hours) the tooth profile was completely obliterated and damaged across the entire width of the flexspline teeth — and most of the width of the circular spline — from improper operation. What’s more, strainwave gearing exhibits high-frequency oscillation (torque ripple) in its output torque. This mainly arises from gearmeshing vibration. Every robot system has its own resonant frequency at which vibration occurs. For rotation-excited vibration, the resonance is known as the critical speed.

November 2019 www.therobotreport.com

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End users must avoid operating robots near their inherent resonant frequencies. Industrial robots often operate in complex environments while interacting closely with human workers and performing a wide variety of tasks. In fact, dynamic stability is one of the most crucial factors affecting robot performance and workplace safety, especially for robots with large payloads, wide movement ranges, and high moving speeds. RR References: [1] Schafer, I. et. al. (2005). Space lubrication and performance of harmonic drive. Proceedings of the 11th ESMATS Symposium, pp. 65-72, Lucerne, Switzerland

[2] Kircanski, N. M. and Goldenberg, A. A. 1997. An experimental study of nonlinear stiffness, hysteresis, and friction effects in robot joints with harmonic drive and torque sensors. Intl. Journal of Robotics Research 16(2): 214-230. [3] Dynapar: How temperature and humidity affect encoder performance. [4] Bilgin, B., Sathyan, A. (2014). Fundamentals of electric machines, in Advanced Electric Drive Vehicles (edited by Ali Emadi). CRC Press: Boca Raton, Fla. [5] Exxon Mobil Corp. 2012: Lubricating grease basics. [6] Lojans, A. and Kakitis, A. 2012. Evaluation of environmental factors influencing robots in greenhouses. Proceedings of 11th Intl. Scientific Conference – Engineering for Rural Development, pp. 151-156. Jelgava, Latvia [7] Schafer, I, Bourlier P, Hantschack, F, Roberts, E. W., Lewis, S. D, Forster, D. J., et al. 2005. Space lubrication and performance of harmonic drive gears. Proceedings of the 11th ESMATS Symposium, pp. 65-72. Lucerne, Switzerland [8] Johnson, M. R., Gehling, R., and Head, R. 2006. Failure of harmonic gears during verification of a two-axis gimbal for the Mars reconnaissance orbiter spacecraft. Proceedings of the 38 Aerospace Mechanisms Symposium. Williamsburg, Va. [9] Bhadeshia, H. K. D. H. 2016. Prevention of hydrogen embrittlement in steels. ISIJ Intl. 56(1): 24-36.

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Exoskeletons •• •• •

•• •• •

•• ••

Designing

lightweight, upper-body exoskeletons

Closed-loop, torque-controlled actuators with high refresh rates biggest challenge

In human anatomy, the shoulder presents one of the most challenging and complex physical problems for physicians and therapists. Shoulders and their intricate anatomical patterns also provide a unique test for developers of exoskeletons, who need to keep their units light and compact while incorporating an extensive range of movement. Those were the challenges faced by Austin, Texas-based Harmonic Bionics. Building upon the fundamental research carried out in the Mechanical Engineering Department at The University of Texas, Harmonic Bionics designed an exoskeleton, called Harmony, that tracks the shoulder joint as well as the scapular movement of the shoulder girdle. The exoskeleton maximizes the range of motion of the human shoulder and the shoulder girdle while ensuring safety with physical and programmed

By Matt Mowry • DryLin Product Manager igus North America

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Harmony is an exoskeleton designed to assist patients with stroke rehabilitation and focuses on the shoulder. | Courtesy Harmonic Bionics

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Exoskeletons

body sizes. Oil-based lubrication for the linear bearings cause many issues, including the accumulation of dirt, which allows for bacteria to accumulate.

Many therapy and assistive devices have focused on the improved functionality of legs. Harmony is designed to help stroke survivors become more independent and restore function to their upper body. | Courtesy Harmonic Bionics

interlocks. Actuator and controller technology allow Harmony to customize gravity compensation, assistance, and impedance as needed for the patient. Harmony is a treatment and therapy device that allows therapists to work with the patients to improve the functionality and healing from neuromuscular damage. It is especially helpful for victims of stroke. There are more than 800,000 new cases of stroke every year in the U.S. alone. “Development of robust closed-loop torque-controlled actuators with high refresh rates was our biggest challenge,” said Rohit John Varghese, Harmonic Bionics’ head of product development. “The design team built out all of the motor control and communication electronics in-house, and this has enabled the level of performance that the therapists whom we work with require.” “Our robotic solution frees the therapist to do what they do best and that is to interact with the human, which is an underrated but critical part of the recovery process,” Varghese added. “It creates an intimate dynamic between the therapist, the patient and the robot. The result is that survivors of stroke will get better faster and more effectively.”

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Examining Harmonic Bionics’ exoskeleton The project began in the ReNeu Robotics Lab at The University of Texas’ Cockrell School of Engineering in 2011 with funding from National Science Foundation and NASA. “The critical piece in Harmony is a novel shoulder mechanism that powers coordinated motions of five joints in the shoulder complex, which is the key to shoulder rehabilitation,” said Ashish Deshpande, director of the ReNeu Robotics Lab. Ensuring alignment between the exoskeleton and the patient is critical to prevent stress on the patient’s joints and protect them from injury. Each side of the robot seamlessly moves the subject’s arm and shoulder through full natural range of motion, and it can be adjusted for people of all shapes and sizes. Harmonic Bionics used information from NASA databases to collect its anthropometric size data, based on which Harmony has been designed to adjust its size to fit more than 95% of the American population. To be effective in a clinical setting, it is important for the exoskeleton to quickly and smoothly change its physical dimensions to align with these different

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High-performance plastics In addition, due to the complexity of the robot, the resizing mechanisms need to be highly compact to allow room for the electronics and actuators. All linear bearing mechanisms need to be able to lock once in position to prevent unwanted changes in size. Harmonic Bionics solved multiple issues by choosing linear bearings from igus, a Germany-based manufacturer of motion plastics. The company runs its North American operations out of Providence, R.I. The company’s products are lubrication- and maintenance-free. The bearings allow for smooth and bindfree size adjustment without lubrication, as well as size and weight reduction. Harmony includes six of igus’ iglide J bearings, a versatile endurance performer that exhibits low wear against different shaft materials and low coefficients of friction in dry operation. They are costeffective bearings when low-pressure loads are needed, and are frequently used in automation, printing, beverage technology and aerospace engineering. A custom bearing housing compresses on a DryLin R liner, which reduced the size significantly compared with previous models of the exoskeleton. Compression from the housing locks shafts, eliminating the need for an additional shaft collar. DryLin R products are made with the iglide J materials, and are frequently used in packaging, 3D printing, and laboratories. The shoulder mechanism also includes DryLin R bearings, which operate dry and tolerate frequent cleanings. DryLin-T rail guide systems manufactured by igus ensure high rigidity in the stand for the exoskeleton. The guides are extremely resistant to dirt and offer a low coefficient of friction and wear. They are also frequently used in machine building, machine tools, package handling, and the woodworking industry.

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Exoskeletons Tackling the shoulder Several factors played into Harmonic’s decision to focus on the development of the exoskeleton for shoulders. First, the staggering incidences of strokes figures to rise over the next 10 years and has been increasing significantly. “As medical care gets better, people live longer,” Deshpande said. “Also, trend lines show incidences of stroke among younger populations. The result is lost productivity and longer durations of suffering.” Many therapy and assistive devices have focused on ambulation – improved functionality of the legs. “Thanks to the success of the ADA in the United States, a lot of that problem is being solved with wheelchair accessibility,” Deshpande said. But the next stage to enabling the basic activities of daily living, is helping stroke survivors and other people with neuromuscular diseases to become more independent and restore function to the upper body. Finally, research on improving physical therapy techniques of the shoulders if greatly hindered by the highly subjective metrics that are used for assessment of recovery. “The gold standard assessment scale for recovery is still a subjective assessment by the therapist on the scale of 1-5,” Varghese said. “It’s difficult to come up with an alternative form of measurement without a device like Harmony, especially for the shoulder. It’s such a complicated joint. Not just the ball and socket, but the complex motion of the shoulder girdle as well. We must make sure the arm and the shoulder move in coordination. The exoskeleton re-teaches that coordination.”

focused on building a device that could be a game-changing development in the way therapists work with patients who have suffered strokes. Testing with stroke patients is being planned at five top rehabilitation hospitals across the country, ushering in a new era in rehabilitation for stroke patients. RR

The exoskeleton includes multiple components manufactured by Germany-based igus, including this iglide J bearing. | Courtesy igus

Solving the challenges The entire scope of the project posed significant challenges for the team at Harmonic. The complexities of the shoulder movements, safety of patients, and finding durable, lubrication-free components made the design of the device a time-consuming and laborious process. But with stroke such a serious and widespread medical concern, the team at Harmonic stayed committed and

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End Effectors •• •• •

•• •• •

•• ••

Grippers

Grow

with collaborative robotics market End-of-arm tooling is critical for widening cobot applications.

ODENSE, Denmark -- This year, for the first time ever, the International Federation of Robotics’ annual “World Robotics” report includes an analysis of the market for collaborative robot arms, or cobots. From 2017 to 2018, there was a 23% increase in annual installations of cobots, with almost 14,000 new arms installed in 2018 alone. This directly affects the user potential for robotic grippers. The International Federation of Robotics (IFR) concluded that drivers for cobot adoption include more intelligent components or end-of-arm-tooling (EOAT) such as smart grippers, “plug & play” interfaces, and programming by demonstration. If this rise in cobot sales continues, the number of installed units will likely double in approximately three years, creating an unprecedented EOAT market opportunity. Where we are -- and where we’re going Of all the areas represented in the report, the top five robot markets accounted for 74% of global installations in 2018. They include China, Japan, the Republic of Korea, the U.S., and Germany. Note that the U.S. market is far from saturated. When looking at robot density, measured in number of robots per 10,000 people, the U.S. ranks only eighth on the world scale, slipping two places down since 2017, overtaken by By Enrico Krog Iversen • OnRobot countries such as Sweden and Korea. With record-low unemployment, U.S. manufacturers face labor shortages. Many are also struggling to compete with low-wage countries. Automation is their only solution to this multi-faceted challenge, and EOAT is the key to achieving their complicated objectives. EOATs to the rescue Intelligent grippers can collect and communicate crucial data to robots in real time to improve their accuracy and overall performance. Capable of safely passing products to human operators, these state-of-the-art grippers can essentially function as automated co-workers. In fact, for machine tending, dual grippers can operate up to 50% faster.

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Companies are also adding grippers to their cobots because of their ability to sort and handle parts of various sizes without any extra programming or machining. One such company that made this choice is Tomenson Machine

Works, a manufacturer of precision hydraulic manifolds in West Chicago, Ill. Tomenson started its venture into automation by deploying a Universal Robots UR3 cobot with an RG6 gripper from OnRobot placing parts into a

Cobots and EOAT work alongside people at Tomenson Machine Works. | Source: OnRobot

| Source: IFR

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Cobot EOAT at Tomenson Machine Works.

End Effectors pin-stamping machine. This was a very repetitive task that employees disliked doing for hours on end. The same RG6 gripper was able to pick up the many different part numbers going into the pin stamp without having to change out any tooling between parts. The company stores about 40 different programs in the cobot’s teach pendant for the different part numbers handled, and it simply switches between them when needed. “Integrating the RG6 was as simple as plugging it in, and it’s ready to go,” said Alex Roake, operations manager at Tomenson. “The entire cobot system took about two weeks to set everything up, but for the gripper, it was less than a

| Source: OnRobot

day. The amount of time we saved, while gaining both efficiency and precision, was nothing like we’d seen before.” What’s next for cobot grippers? The World Robotics report demonstrates that more companies are experiencing the benefits of automation with collaborative robots for a variety of uses. In some cases, manufacturers have installed cobots because they are simply unable to find available workers due to the low unemployment rates or the undesirable, repetitive tasks the jobs require.

The World Robotics report demonstrates that more companies are experiencing the benefits of automation with collaborative robots for a variety of uses.

IFR: Cobots a fast-growing segment of industrial automation The International Federation of Robotics defined collaborative industrial robots in January 2019. It said some follow the ISO 10218-1 safety standard, and others may follow other norms. According to the IFR, collaborative industrial robots are designed for tedious, repetitive, and unergonomic tasks; operate in production lines that include human workers; and are intended for short or variable production runs. In 2017, only 4% of the 381,000 industrial robots installed at the time, or 11,100 units, were collaborative, the organization said. By last year, 14,000 cobots were installed out of a total of more than 400,000 industrial robots in 2018, estimated the IFR in its “World Robotics Report.” “The range of industrial robots continues to expand -- from traditional caged robots capable of handling all payloads, fast and precise, to newer collaborative robots that can work safely alongside humans and robots that can be fully integrated into workbenches,” said the IFR in its executive summary.

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| Source: IFR

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End Effectors In other cases, manufacturers are simply looking for ways to be more efficient, even if that means shaving mere seconds off their run times. Those seconds add up quickly and lead to more products being produced, which means more are being sold. That revenue goes back into the company so it can hire more workers, make improvements, and buy more cobots and grippers. Whatever the case, the latest IFR report shows that companies should pay close attention not only to how they automate, but also to what additional tools they can use to achieve their production goals in a smarter, more streamlined way. By including EOATs as part of their automation strategy, companies will be able to do more and grow faster, enabling them to maintain their competitive edge in an often overcrowded and highly competitive manufacturing market. RR

About the author Enrico Krog Iversen is the CEO of gripper maker OnRobot A/S. He previously led On Robot, one of three companies that joined to create OnRobot. Krog Iversen was also CEO of collaborative robot arm maker Universal Robots A/S.

Enrico Krog Iversen | Source: OnRobot

www.designworldonline.com October 2019

It’s not a web page, it’s an industry information site

inside:

Reference direction: Looking into motor’s

lead-exit end B

MOTION CONTROL:

Get the commutation right

p. 86

N Clockwise rotation Phases A, B, C

LINEAR MOTION:

Actuators work reliably far under the sea

p. 96

AEROSPACE / DEFENSE:

Material science allows cables to be solution for 5G and aerospace test equipment

p. 60

Stay current with the latest technologies, resources, and news, visit

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What have we learned in 30 years?

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End Effectors •• •• •

•• •• •

•• ••

How to design

precise parallel grippers for cobots Size, positioning, and ease of use are important for end effectors, as New Scale Robotics found when it built its latest parallel grippers.

As collaborative robots find new applications, the demand for a variety of end effectors has grown. For instance, the automated gauging and measurement of small parts can be quite challenging. The resolution must be as low as 2.5 micrometers to continually provide positioning data for decision-making software. This need for precision is why Victor, N.Y.-based New Scale Robotics (NSR), a division of New Scale Technologies Inc., decided to design and manufacture one of its latest parallel grippers.

By maxon precision motors

November 2019

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Built for the smallest collaborative robots, or cobots, the NSR-PG-10-20 Precision Parallel Gripper is a mechatronic system that integrates motor, sensors, precision bearing guides, drive, and control electronics, as well as embedded firmware for automation, into one device. During the design process, NSR decided that the end effector had to offer plug-and-play integration so it could be installed in minutes to Universal Robots’ UR line of small cobots. The NSR-PG-10-20 offers users the smallest size and mass with the highest precision, said the company. All power and control circuitry is located through the robot tool port and slip rings so that no external cable or electronics boards are required. To install the gripper, simply mount it to the UR robot tool flange and connect the single cable to the UR tool I/O port. Motion commands are received through the robot’s eightpin tool I/O interface. No external wires or separate electronics are needed, which allows for full 360-degree or infinite rotation of the UR robot wrist joint without cable interference. The Precision Parallel Gripper incorporates an internal absolute position sensor specifically for automated metrology applications offering high precision for intricate small part handling, measurement, sorting, and assembly. The parallel grippers had to provide fast, precise movements repeatedly over a long lifecycle.

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The Precision Parallel Grippers are ready for operation within a few minutes. | Source: New Scale Technologies

Parallel grippers require precise motion control During the design process, NSR researched the needs of its Precision Parallel Gripper and selected the EC-20 Flat brushless DC motor (BLDC) designed and manufactured by maxon. This motor offers up to five winding types, as well as built-in encoders. Multiple power outputs are available, and the motors provides high stability and quiet operation. The motors were primarily selected because of their extremely small mass of only 15 grams as well as their high continuous torque of 3.75 mN-m. The motors’ excellent torque-to-mass ratio means that the NSR-PG-10-20 can achieve an adjustable gripping force of ±3 to 10 N while using a modest gear ratio of 16:1.

The gripper incorporates a symmetric timing belt drive with a range of 20 mm. Plus, the operational voltage, current, and torque were a good match with the internal robot power supply, according to New Scale. The BLDC rotary motor drives gear reduction to a timing belt that converts rotation to linear motion. A separate angle sensor is used to measure the motor shaft angle, while separate digital electronics are used to generate the three-phase drive current needed for operation. This mechanism provides the linear motion necessary to open and close the gripper fingers used to grab and release small parts. Gripper fingers are able to grip from the outside or inside of the part depending on the application. Through the use of the embedded sensor, the linear part measurement resolution of the gripper is 2.5 micrometers. The open/close speed of the gripper is 20 mm/second, and the open/close range is 20 mm. “The tricky parts of the design were maintaining the small size, height, and low mass of the gripper while providing closed-loop position and velocity characteristics,”

The NSR-PG-10-20 Precision Parallel Gripper incorporates maxon’s EC-20 flat motor for high-precision operations. | Source: New Scale Technologies

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End Effectors

The EC-20 Flat is the smallest motor with the proper torque capabilities to best handle the requirements of the NSR-GP-10-20 parallel grippers. | Source: maxon

The gripper also provides teachable finger positions when used with Universal Robotics’ UR3, UR5, UR10 robot arms as well as the company’s latest line of e-Series cobots.

said David Henderson, CEO of NSR. “It was also a challenge to find a low-power and -current motor that allowed us to use the internal power on the robot.” maxon’s EC-20 Flat allowed NSR the leverage it needed to deliver the product in the most demand from customers — and still be easy to install and operate. The mechanical integration was the easiest part. The company used an EC-20 Flat without an angle sensor and instead provided its own external angle sensor for commutation. “In the future, we expect to extend our product range to include grippers with higher gripping forces — and correspondingly higher-mass and higherpower motors — longer gripping ranges, and embedded force sensors to improve force control,” Henderson said. The gripper is equipped with interchangeable fingers. The NSR-PG ships with factory fingers installed so that users can get right to work. The fingers are designed to handle workpieces up to about 60mm and 100 grams. They are easily interchangeable using standard flange interfaces with a precision, pinlocated finger reference mounting surface. A metrology fingertips kit is available for the NSR-PG-10-20. It provides three types of fingertips that easily attach to the parallel grippers’ factory fingers. Flat fingertips are used to measure flat features, or convex spherical and

Factory fingers are meant to be easy to install on the NSG-PG precision parallel gripper. | Source: New Scale Technologies

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The grippers can be taught manually when used with UR cobot arms. | Source: New Scale Technologies

cylindrical features, such as measuring the diameter of a sphere. Spherical fingertips are used to measure flat features, or concave spherical and cylindrical features, such as measuring the distance between two flat surfaces. Cylindrical fingertips are another option to measure flat or concave cylindrical surfaces, such as the inside diameter of a part. Different fingertip shapes can be paired together to accommodate a wide variety of part features using well-established metrology methods. The fingers can also be modified or customized to specific parts. maxon’s EC-20 Flat provides the smallest size motor with the proper torque capabilities to best handle the requirements of the NSR-GP-10-20 Precision Parallel Gripper. The gripper also provides teachable finger positions when used with Universal Robotics’ UR3, UR5, UR10 robot arms as well as the company’s latest line of e-Series cobots. Manually move fingers to the desired position, and set them using the teach pendant — a process familiar to anyone who has used a UR robot in teach mode. Position is repeatable to 0.01 mm. Setting finger open and close positions that match a user’s workpiece allows the user to minimize the finger motion (stroke) for each operation, saving time and energy. Overall, the NSRPG-10-20 allows the user to automate repetitive, labor-intensive measurement

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and quality-control tasks so that the UR cobot becomes a powerful tool for metrology applications, said the company. Finding the right motor for such specific applications can be daunting. Having the availability of the latest technology in the smallest package motor has allowed NSR to fulfill the needs of its customers. maxon’s EC-20 Flat was a key component in the design and manufacture of the NSR-PG-10-20 Precision Parallel Grippers. RR

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•• •• •

•• ••

Figure 1: Typical AGV scanner mounting and integration

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Sensing and Vision

common mistakes when

setting up safety laser scanners Having worked in industrial automation for most of my career, I like to think I have

built up a wealth of experience in the field of industrial safety sensors. Familiar with safety laser scanners for over a decade, I have been involved in many designs and installations.

I currently work for SICK (UK) Ltd., which invented the safety laser scanner. I continually see people

making the same mistakes time and time again. This piece highlights, in my opinion, the most common of them.

By Martin Kidman, SICK Inc.

1 Installation and mounting: Thinking about safety last If you are going to remember just one point, then this is it. Too many times, I have been present at an “almost finished” machine and asked, “Where can I stick this scanner?” Inevitably, what ends up happening is that blind spots (shadows created by obstacles) become apparent all over the place. This requires mechanical “bodges” and maybe even additional scanners to cover the complete area when one scanner may have been sufficient if the cell was designed properly in the first place. In safety, designing something out is by far the most cost-effective and robust solution. If you know you are going to be using a safety laser scanner, then design it in from the beginning — it could save you a world of pain. Consider blind zones, coverage, and the location of hazards. This also goes for automated guided vehicles (AGVs). For example, the most appropriate position to completely cover an AGV is to have two scanners adjacent to each other on the corners integrated into the vehicle (See Figure 1). 2 Incorrect multiple sampling values configured An often misunderstood concept, multiple sampling indicates how often an object has to be scanned in succession before a safety laser scanner reacts. By default

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and out of the box, this value is usually x2 scans, which is the minimum value. However, this value may range from manufacturer to manufacturer. A higher multiple sampling value reduces the possibility that insects, weld sparks, weather (for outdoor scanners), or other particles cause the machine to shut down. Increasing the multiple sampling can make it possible to increase a machine’s availability, but it can also have negative effects on the application. Increasing the number of samples is basically adding an OFF-Delay to the system, meaning that your protective field may need to be bigger due to the increase in the total response time. If a scanner has a robust detection algorithm, then you shouldn’t have to increase this value too much, but when this value is changed, you could be creating a hazard due to lack of effectiveness of the protective device. If the value is changed, you should make a note of the safety laser scanner’s new response time and adjust the November 2019

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minimum distance from the hazardous point accordingly to ensure it remains safe. Furthermore, in vertical applications, if the multiple sampling is set too high, then it may be possible for a person to pass through the protective field without being detected so care must be taken. For one our latest safety laser scanners, the microScan3, we provide the following advice: Recommended Multiple

Application

Stationary application, such as horizontal hazardous area protection or vertical hazardous point protection under clean ambient conditions

Stationary application, such as vertical access protection (only two-time multiple sampling may be used for vertical access protection)

Mobile applications

Stationary application, such as horizontal hazardous area protection under dusty ambient conditions

Figure 2: Recommended multiple sampling values

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3 Incorrect selection of safety laser scanner The maximum protective field that a scanner can facilitate is an important feature, but this value alone should not be a deciding factor on whether the scanner is suitable for an application. A safety laser scanner is a Type 3 device, according to IEC 61496, and an Active Opto-Electric Protective Devices responsive to Diffuse Reflection (AOPDDR). This means that it depends on diffuse reflections off of objects. Therefore, to achieve longer ranges, scanners must be more sensitive. In reality, this means that sometimes scanning angle but certainly detection robustness can be sacrificed. This could lead to a requirement for an increasing number of samples and maybe lack of angular resolution. The increased response times and lack of angle could mean that larger protective fields are required and even additional scanners â&#x20AC;&#x201D; even though you bought the longer-range one. A protective field should be as large as required but as small as possible. A shorter-range scanner may be more robust than its longer-range big brother and, hence, keep the response time down, reduce the footprint, reduce cost, and eliminate annoying false trips. 4 Incorrect resolution selected The harmonized standard EN ISO 13855 can be used for the positioning of safeguards with respect to the approach speeds of the human body. Persons or parts of the body to be protected may not be recognized or recognized in time if the positioning or configuration is incorrect. The safety laser scanner should be mounted so that crawling beneath, climbing over, and standing behind the protective fields is not possible.

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Sensing and Vision If crawling under could create a hazardous situation, then the safety laser scanner should not be mounted any higher than 300 mm. At this height, a resolution of up 70 mm can be selected to ensure that it is possible to detect a human leg. However, it is sometimes not possible to mount the safety laser scanner at this height. If mounted below 300 mm, then a resolution of 50 mm should be used. It is a very common mistake to mount the scanner lower than 300 mm and leave the resolution on 70mm. Reducing the resolution may also reduce the maximum protective field possible on a safety laser scanner, so it is important to check. 5 Not considering environmental conditions Sometimes safety laser scanners just aren’t suitable in an application. Coming from someone who sells and supports these devices, that is a difficult thing to say. However, scanners are electrosensitive protective equipment, and infrared light can be a tricky thing to work with. Scanners have become very robust devices over the past decade with increasingly complex detection techniques, and there are even safety laser scanners certified to work outdoors.

However, there is a big difference between safety and availability, and expectations need to be realistic right from the beginning. A scanner might not maintain 100% machine availability if there is heavy dust, thick steam, excessive wood chippings, or even dandelions constantly in front of the field of view. Even though the scanner will continue to be safe and react to such situations, trips due to ambient conditions may not be acceptable to a user. For extreme environments, the following question should be asked: “What happens when the scanner is not available due to extreme conditions?” This can be especially true in outdoor application in heavy rain, snow, or fog. A full assessment of the ambient conditions and even potentially proof tests should be carried out. This particular issue can become a very difficult, and sometimes impossible and expensive thing to fix. 6 Non-safe switching of field sets A field set in a safety laser scanner can consist of multiple different field types. For example, a field set could consist of four safe protection fields (Field Set 1), or it could consist of 1 safe protective field, two non-safe warning fields, and a safe detection field (Field Set 2). See Figure 3.

A scanner can store lots of different fields that can be selected using either hardwired inputs or safe networked inputs (CIP Safety, PROFISAFE, EFI Pro). This is a feature that industry finds very useful for both safety and productivity in Industry 4.0 applications. However, the safety function (as per EN ISO 13849/EN 62061) for selecting the field set at any particular point in time should normally have the same safety robustness (PL/SIL) as the scanner itself. A safety laser scanner can be used in safety functions up to PLd/SIL2. If we look at AGVs, for example, usually two rotary encoders are used to switch between fields achieving field switching up to PLe/SIL3. There are now also safety-rated rotary encoders that can be used alone to achieve field switching to PLd/SIL2. However, sometimes the safety of the mode selection is overlooked. For example, if a standard PLC or a single channel limit switch is used for selecting a field set, then this would reduce the PL/SIL of the whole system to possibly PLc or even PLa. An incorrect selection of field set could mean that an AGV is operating with small protective field in combination with a high speed and hence long stopping time, creating a hazardous situation. Summary Scanners are complex devices and have been around for a long time with lots of choice in the market with regards to range, connectivity, size, and robustness. There are also a lot of variables to consider when designing a safety solution using scanners. If you are new to this technology, then it is a good idea to contact the manufacturer for advice on the application of these devices. RR

Figure 3: Safety laser scanner field sets

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| Courtesy Cleo Robotics

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Cleo Robotics

compact drone taking on dangerous jobs

By Steve Crowe • Editor, The Robot Report

Manual inspection of pressure vessels for oil and gas production is not a glamorous job. Just ask Omar Eleryan, who had to this as part of his job after he graduated from the University of Calgary with a mechanical engineering degree. Calgary, Alberta is the oil and gas capital of Canada. “I had to put on protective clothing and a safety harness, and crawl into a tiny manway down to the bottom of a vessel and just look around for 10 minutes to do a visual inspection,” he said. “This made me think about why people have to do these tasks in potentially dangerous environments. Cameras can do these jobs safer, cheaper, and more efficiently. “ This lead Eleryan and Simon Czarnota to create Cleo Robotics in 2016. The Boston-based startup is developing the Cleo Dronut, a compact and rugged drone designed for safe operation indoors and in confined spaces for reconnaissance and inspection applications. The company started out in Calgary, but it spent a short amount of time in Silicon Valley before settling down in Boston in May 2019. Meet the Cleo Dronut The Cleo Dronut (donut-shaped drone) has a 15-minute flight time, a speed of 3 m/sec, and a carbon fiber body. At 5.5 inches in diameter, 3.3 inches in height and a weight of just 10.5 oz, the Cleo Dronut fits in the palm of your hand without having to be Cleo Robotics disassembled or folded. It can gather real-time video data and still images and has < 90 ms Location: Boston latency. Founded: 2016 Eleryan said the Cleo Dronut is not just a Founders: Omar Eleryan & Simon Czarnota quadcopter with an enclosure. To overcome Full time employees: 4 efficiency problems, the drone uses counterrotating propellers that are on top of each other Product: Cleo Robotics developed the Dronut, a compact and rugged drone surrounded by an enclosure. How Cleo controls designed to operate indoors and in confined spaces for reconnaissance and inspection applications. It eliminates the need for humans to enter hazardous or this unique propeller design is its secret sauce. The technology is patent-pending, so Eleryan hostile environments. understandably would not delve into it too Cost: $9,800

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Sensing and Vision much. But he said it is similar to thrust vectoring, which is the way aircraft and space rockets manipulate the direction of the thrust from motors and re-direct airflow. “Most drones are multi-rotors or quadcopters with four propellers beside one another,” said Eleryan. “If you scale that down to a 5-inch diameter, the propellers are so small, maybe two inches each, that they can’t lift much so they end up having tiny batteries. That creates efficiency issues where these drones can fly no longer than seven or eight minutes.” At the moment, the Cleo Dronut is controlled by a human operator. But the drone can locate itself in space and fly itself if the operator lets go of the controls. And thanks to solid-state LiDAR, Optical Flow technology, two cameras, an IMU and barometer, the Cleo Dronut can fly in GPS-denied environments. ”We built a robot designed to carry sensors and cameras into places too dangerous or hazardous for people,” said Eleryan. “Current drones are too large to navigate or too dangerous to be around. And those types of environments are also inaccessible to ground-based robots at the moment.” The Cleo Dronut actually started off even smaller at 3 inches in diameter. But as the company interacted with more potential customers, it discovered a slightly larger design was more favorable for more payload and flight time. “Often times engineers get too excited about the tech and forget about the problem they’re trying to solve,” said Eleryan. “In the initial stages, you need

to take a leap of faith because not a lot of people will talk to you. We talked to more than 100 potential customers. We currently have paid pilots in defense space, law enforcement and the industrial space. I can’t stress how important it is to talk to the customers.” Journey to Boston Cleo Robotics currently resides inside MassRobotics, a non-profit organization serving as the innovation hub for robotics and connected devices. That certainly was not part of the plan. “Initially, we thought we’d end up in Silicon Valley. We’re a tech company at the end of the day, and where do tech companies go? Silicon Valley,” said Eleryan. “We spent some time there, but hardware is not an area of interest there. We kept hearing that hardware is too hard. The atmosphere was very trendy when we were there in 2017. Nobody was interested in drones.” Cleo Robotics came to Boston in the summer of 2018 to join the local branch of MassChallenge, which is a global network of zero-equity startup accelerators. “We knew Boston had a strong tech ecosystem, but we were also attracted to the talent pool from the universities,” Eleryan said. “When we got here for MassChallenge, it was clear the environment here is more supportive of hardware startups.” Cleo Robotics returned in early 2019 to join the Air Force Accelerator Powered

by Techstars. It ultimately decided Boston was its home and found space inside MassRobotics. “We first saw Cleo Robotics when they were a MassChallenge company. It has been great to have them in MassRobotics and watch them further develop the design,” said Joyce Sidopoulos, Cofounder and Community and Programs Director, MassRobotics. “The compact and safe indoor flying robot operates well in confined spaces, allowing companies to better inspect and maintain their assets while keeping their employees safe, and law enforcement and first responders to get a first look in potentially dangerous areas. Plus, it is nice to have a SciFi-looking drone cruising around our space.” What’s next Cleo Robotics is currently working on pilot projects, and it hopes to officially be on the market in the second quarter of 2020. “As for long-term goals, we want our robot to be working alongside people. We want the robot to do these dangerous, dirty jobs people currently have to do. People don’t have to risk their lives to go into a pressure vessel to inspect it. Let’s eliminate any fatalities in that space.” While Cleo Robotics is currently focusing 100% of its attention on commercial applications, it has not completely ruled out the consumer market. After all, it was named an Innovation Awards Honoree at the 2017 Consumer Electronics Show (CES), which is the world’s largest consumer electronics show. “We’re in the final stages of getting our patent,” said Eleryan. “For some markets, we’d license our technology. The one that comes to mind is the consumer market, for which our drone has a lot of uses. But that’s a very challenging market.” RR

| Courtesy Cleo Robotics

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Mechanical Drive Solutions For Robotic Applications

GCR Robotic Cycloidal Gearbox with integral Dyna Series right angle Pre-Stage

SPH High Performance Helical Gearbox 2-week lead time, drops in for competitor gearboxes

GPL Robotic Planetary Gearbox Maintains lifetime zero backlash

Helical Rack & Pinion System Pairs with GAM Gearboxes for optimized system performance

From zero-backlash gearboxes to rack & pinion, GAM has the flexibility and broad product range for all your robotic applications With one of the largest product offerings in the motion control industry as well as the engineering expertise and manufacturing capabilities to develop customized solutions, GAM can help with your application. GAM Can.

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Servo Coupings Zero-backlash bellows, elastomer, safety, and distance couplings custom bored to order

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CGI Inc. Advanced Products for Robotics and Automation At CGI we serve a wide array of industries including medical, robotics, aerospace, defense, semiconductor, industrial automation, motion control, and many others. Our core business is manufacturing precision motion control solutions. CGI’s diverse customer base and wide range of applications have earned us a reputation for quality, reliability, and flexibility. One of the distinct competitive advantages we are able to provide our customers is an engineering team that is knowledgeable and easy to work with. CGI is certified to ISO9001 and ISO13485 quality management systems. In addition, we are FDA and AS9100 compliant. Our unique quality control environment is weaved into the fabric of our manufacturing facility. We work daily with customers who demand both precision and rapid turnarounds.

ISO QUALITY MANAGEMENT SYSTEMS: ISO 9001• ISO 13485 • AS9100 • ITAR SIX SIGMA AND LEAN PRACTICES ARE EMBRACED DAILY WITHIN THE CULTURE

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FAULHABER MICROMO Power in New Dimensions: New BXT Flat Brushless Motor New winding technology, optimized design, & impressive performance make the new FAULHABER BXT Flat Brushless DC Motor Series ideal for applications in robotics, exoskeletons, & automation. The external rotor BXT motors are designed for continuous output power up to 100 W, and deliver torque up to 134 mNm. • Flat design for space-critical applications • Outstanding ratio of torque to weight & size • Available in 22mm, 32mm, 42mm diameters • Available with or without housing • Matching encoders, gearheads & controllers available Since 1961, FAULHABER MICROMO has been the micro DC motor expert, serving OEM engineers to deliver outstanding service and the highest quality products. As the exclusive provider for FAULHABER micro motion products to North America, FAULHABER MICROMO creates value through advanced design and engineering services.

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CGI Inc. 3400 Arrowhead Drive Carson City, NV 89706

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FAULHABER MICROMO 14881 Evergreen Ave Clearwater, FL 33762 USA Phone: (800) 807-9166

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10/24/19 2:16 PM

Robotics Robotics

GAM Revolutionary Gearbox Maintains Lifetime Precision The GAM GPL series robotic planetary gearbox features a revolutionary design ensuring zero backlash (≤0.1 arcmin) for the life of the gearbox. With a high tilting rigidity, 95% efficiency, and an impressive life of 20,000 hours, the GPL can stand up to the most demanding applications. The GPL is available in 7 sizes up to 7000 Nm torque with many configurations including solid or hollow flange output,

component or fully enclosed with motor mount and optional inline or right-angle pre-stage. The GAM GPL series robotic planetary gearbox offers a unique level of precision, lifetime, and efficiency unseen in other gearboxes on the market today!

GAM 901 E. Business Center Drive Mount Prospect, IL 60056 888.GAM.7117 847.649.2500 www.gamweb.com info@gamweb.com

Harmonic Drive FHA Actuator with Integrated Servo Drive Just Released: FHA mini actuator with an integrated servo drive utilizing CANopen® communication. Eliminating the need for an external servo drive, it features a single cable connection with only 4 wires needed: CANH, CANL, +24VDC, 0VDC. A single-turn 14bit (16384 cpr) gear output sensing encoder has been integrated along with a single-turn 15bit (32768 cpr) motor input sensing encoder providing a true absolute encoder that does not require a battery within 360° of rotation of the output. The FHA-C mini Series is a family of extremely compact actuators that deliver high torque with exceptional accuracy and repeatability.

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247 Lynnfield Street Peabody, MA 01960 United States www.harmonicdrive.net

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Honeywell Intelligrated® Robotic Solutions By leveraging advanced robotic technology with extensive material handling experience, warehouse automation solutions from Honeywell Robotics provide the speed, accuracy and efﬁciency to satisfy a broad and growing range of operational requirements. Innovative designs, application expertise and committed support ensure maximum dependability and round-theclock productivity. Robotic solutions also relieve workers of some of the most arduous, repetitive and injury-prone tasks, freeing up limited labor for more rewarding, higher-value jobs. Honeywell Intelligrated is recognized by the Robotic Industries Association (RIA) as a Certiﬁed Robot Integrator, with more than a quarter-century of experience providing single-source robotic solutions for high-performance distribution and manufacturing operations. From system concepting, simulation, fabrication and integration to installation and commissioning, training and ongoing support, each solution is approached with a comprehensive lifecycle view to maximize the value of your system.

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igus Optimized cable management solutions for six-axis robots triflex® R from igus® is a multi-axis energy chain designed for use on various robotic applications. Unlike traditional corrugated tubing, triflex® R is available in nine sizes and offers a defined radius, built-in torsion stop, and a split cavity to keep cables separated. These features greatly reduce cable damage and premature wear, decreasing downtime and improving production. Additionally, the system’s ball and socket link design allows for easy replacement of individual pieces if one of them is damaged. To learn more about triflex® R, visit https://www.igus.com/info/

robotics-multi-axis-cable-carriers

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Website: www.igus.com Email: sales@igus.com Phone: 800.521.2747

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10/24/19 2:16 PM

Robotics Robotics

IKO International Inc. Industrial Robots Demand Versatile Crossed Roller Bearings Robotics and automated machinery demand highly versatile bearings. Not only must bearings carry diverse loads with high precision, robotic motion is also becoming more complex. Machine designers must also fit their bearings into shrinking mechanisms like articulating arms that position and rotate objects. Crossed roller bearings are designed to make line-contact with the raceway surface to give them their excellent rigidity and load handling ability while minimizing deformation and maximizing accuracy. The same construction that allows them to achieve heavy-duty performance also gives them the versatility today’s robotic applications demand. For instance, IKO International’s crossed roller bearings are engineered to

IKO International Inc. Fox Hill Industrial Park 91 Walsh Drive Parsippany, NJ 07054

handle radial, thrust and moment loads at the same time, which makes them particularly suitable for applications with complex motion.

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Keystone Electronics Corp. A world class manufacturer of precision electronic components & hardware for over 75 years. Manufacture precision stampings, in metallic or non-metallic materials for all industries. Specialists in progressive dies, fourslides, wire forming, in-die tapping and high-speed blanking. Screw machine products on automatic machinery and support equipment produce competitively priced precision turnings from .020” to 1.00” diameters, in metallic or non-metallic materials. Cost effective assembly procedures in eyeleting, riveting, staking, swaging, inserting, crimping, soldering or screw insertion, with automatic & semi-automatic operations to assemble metallic or non-metallic components into finished products.

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Keystone Electronics 55 S. Denton Ave. New Hyde Park, NY 11040

www.keyelco.com

www.therobotreport.com

Tel: 1.800.221.5510 www.keyelco.com

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Robotics Robotics

Kollmorgen Kollmorgen TBM™ Offers Optimal Performance in a Compact Package As new applications for robots continue to emerge the market for high power density motors also grows. Kollmorgen’s TBM series of Direct Drive Frameless motors offer the flexibility to help you push the limits of what’s possible by working seamlessly within your design. Kollmorgen TBM series of Direct Drive Frameless motors are designed to be directly embedded into machines, using the machine’s own bearings to support the rotor. TBM technology is optimized for applications that require high power in a small, compact package with minimal weight and inertia. Additional features include: • Efficient electromagnet design leads to lower temperature rise • Low voltage design is optimized for applications up to 48 VDC • High quality materials ensure a long service life

Want to learn more about Kollmorgen TBM frameless motors? Contact info: Gene Matthews Kollmorgen 203A West Rock Road Radford, VA 24141 Phone: 1.540.633.3545 Email: www.kollmorgen.com

maxon Drive Systems for Robotics Reliable, Powerful, Efficient A complete joint actuation unit. Includes a brushless DC motor, an internal high resolution encoder, planetary gearhead with absolute encoder and position controller with CAN and RS232 interface. Exoskeleton Joint Actuator • Compact Housing • Integrated Controller • Reduced Weight and Cost • For Use in Hip and Knee Exoskeletons maxon is your single source for motion solutions. When you choose maxon, you can expect outstanding service, creative options and quality without question. Want to get your ideas moving? Contact maxon today. Learn more about the maxon solutions and visit www.maxongroup.us

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maxon precision motors, inc. 125 Dever Drive Taunton, MA 02780 Phone: 508.677.0520 www.maxongroup.us info.us@maxongroup.com

www.therobotreport.com

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10/24/19 2:17 PM

Robotics Robotics

Memory Protection Devices MPD is one of the world’s largest creators and suppliers of innovative and cost-effective battery and coin cell holders and contacts. We created the coin cell holder, and it is still the core of our product line. MPD also offers a full line of automotive plugs, cord sets and other components like fuse holders and power plugs, jacks and adapters. Another advanced concept introduced by MPD is our line of “Gliders’: hybrid coin cell holders that combine the low cost of retainers with even higher reliability than standard coin cell battery holders. Gliders and SnapDragon are the next chapter in the story of MPD’s quest to make sure that battery holders are as technology-driven as the products in which they are used.

Products Products and services include electronic design, prototypes and mass production for Battery holders, contacts and sockets and other power connection related products. Since 1980, Memory Protection Devices, Inc has been offering battery holders and contacts for lithium coin cells and alkaline cells. We offer products based on a range of standard products and custom proprietary solutions.

Memory Protection Devices 200 Broad Hollow Rd. Farmingdale, New York 11735 Phone: 631.249.0001 Fax: 631.249.0002

www.memoryprotectiondevices.com

Mobile Industrial Robots

Mobile Industrial Robots is a leading manufacturer of collaborative mobile robots. We are dedicated to developing user-friendly, flexible and safe robots to help companies increase the efficiency of their operations. Our autonomous robots are a new generation of advanced mobile robots which give you a rapid return on investment, often with a payback period of less than a year. These unique, collaborative robots are now used by manufacturers in a wide range of industries and healthcare sectors to automate their in-house transportation.

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Mobile Industrial Robots Inc. www.mobile-industrial-robots.com Phone: 631 675 1838

www.therobotreport.com

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Robotics Robotics

Mitsubishi Electric FR Series Next Generation, High Performance Industrial Robots Integrate Seamlessly with iQ Platform Controllers for Advanced Cooperative Functions “FA-IT Integration Functions” with the full line of Mitsubishi Electric FA products such as PLCs, motion controllers, VFDs, HMIs, and CNC, as well as MES/SCADA packages provide a level of performance, functionality and ease of use unparalleled in the industry. In addition, the open platform architecture OS enables integration with 3rd party devices normally difficult or impossible to use on closed platforms. With such flexibility, capability and performance, increases to both productivity and maintainability can be achieved, resulting in a lower TCO (Total Cost of Ownership).

• With an extensive selection of arm sizes, configurations, protection ratings,

Website: us.MitsubishiElectric.com/fa/en Address: 500 Corporate Woods Pkwy Vernon Hills, IL 60061 Phone: 847.478.2100

backed with “Next-Generation” features, and options, the MELFA FR-Series line of robots are ready to handle all of your automation needs. Vertically articulated, horizontally articulated SCARA, ceiling mounted horizontal type, and dual arm high precision for micro-assembly • Industry’s best initial warranty - 3 year on-site for most models

mk North America Enhance Your Automation with Pallet-Handling Conveyors Pallet-handling conveyors utilize pallets to transport workpieces asynchronously between stations. Pallets range in size from 10x10 inches to 48x48 inches, and are capable of carrying loads of nearly 1,000 lbs. Pallet-handling Conveyor Benefits Are Delivered By: • Continuously moving materials from point to point • Handling every item in the same fashion with no variance • Removing production inefficiencies and wasteful delay by streamlining and standardizing the movement of material • Consistent material handling routines, ultimately reduces work in process and allows greater throughput

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• Eliminating bottlenecks and operations that require labor but, do not add value

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• Easily adapt to changing demands and production requirements

Website: www.mkversamove.com

• Efficiently handle changes to work flow by adding in new stops, locates or transfer components

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Email: info@mknorthamerica.com

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10/24/19 2:18 PM

Robotics Robotics

New England Wire Technologies Advancing innovation for over 100 years Why accept a standard product for your custom application? NEWT is committed to being the premier manufacturer of choice for customers requiring specialty wire, cable and extruded tubing to meet existing and emerging worldwide markets. Our custom products and solutions are not only engineered to the exacting specifications of our customers, but designed to perform under the harsh conditions of today’s advanced manufacturing processes. Cables we specialize in are LITZ, multi-conductor cables, hybrid configurations, coaxial, twin axial, miniature and micro-miniature coaxial cables, ultra flexible, high flex life, low/high temperature cables, braids, and a variety of proprietary cable designs. Contact us today and let us help you dream beyond today’s technology and achieve the impossible.

NEW ENGLAND WIRE T E C H N O LO G I E S

New England Wire Technologies www.newenglandwire.com 603.838.6624

NSK Precision For Maintenance Free Operation Choose NSK K1TM Lubrication Unit NSK’s K1TM is a uniquely designed system that not only lubricates but also helps minimize contamination. K1 material composition consists of 70% mineral

oil

and 30% polyolefin resin which ensures long-term, maintenancefree operation even under tough lubrication environments. K1TM offers no maintenance for up to 5 years or 10,000 km operational distance. K1 is ideal for environments where the lubricant is hard to replace or is easily washed away. Available in ball screws, linear guides, monocarriers and tough carriers.

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Contact info:

NSK Americas www.nskamericas.com

www.therobotreport.com

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Robotics Robotics

Posital-Fraba Upgrade Your Motor Feedback with POSITAL ABSOLUTE Kit Encoders POSITAL ABSOLUTE Kit Encoders offer a great upgrade path for the traditional incremental kit encoders used for servomotors. Compact, rugged and cost effective, they provide accurate position feedback for precision motion control in robots, production machinery, autonomous vehicles and other motion and position control application. They can also be used to provide closed-loop feedback control for stepper motors. Rotational resolution is up to 17-bit (one part in 130,000) with a multi-turn range of

POSITAL-FRABA Inc.

more than 8 million revolutions.

1800 East State Street, Suite 148 Hamilton, NJ 08609

Standardized compact form factors make POSITAL absolute

USA

kit encoder a straightforward replacement for US Digital or

Website: www.posital.com

Broadcom incremental kit encoders in existing machinery or

Email: info@fraba.com

in new designs.

Phone: +1 609.750.8705

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The ATOM DXTM encoder series is Renishaw’s smallest

Constructed with Renishaw’s integrated set-up LED,

incremental optical encoder with digital output direct

for an intuitive and simple installation process based on

from the read-head, providing positional feedback,

the well-established auto-calibration routine, ATOM DX

on-board interpolation, and filtering optics all in a

is ready to install straight from the box.

miniature package. ATOM DX builds on the market-proven optical system of the ATOM™ encoder platform and integrates Renishaw’s high-performance interpolation technology, reducing system size and removing the need for additional adapters and interfaces. ATOM DX is suitable for the most space constrained applications where performance cannot be compromised.

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Contact Info: 1001 Wesemann Drive West Dundee, IL 60118 Website: www.renishaw.com Phone: 847.286.9953 Email: usa@renishaw.com

www.therobotreport.com

THE ROBOT REPORT

10/24/19 2:19 PM

Robotics Robotics

Retaining Ring Solutions to Reduce Noise, Vibration and Harshness for Applications with High RPMs and Balancing Needs Retaining rings are often used in high RPM applications to fix bearings on shafts or in bores. One frequent problem that contributes to NVH during high rotational speeds is axial endplay as a result of accumulated tolerances. Rotor Clip offers beveled retaining rings that are designed for rigid endplay take up. Beveled retaining rings feature a 15º bevel that allows them to act like a wedge between the retained part and the ring groove wall, rigidly taking up endplay space. This permits manufacturers to work with larger tolerances in the parts being assembled and still achieve required performance characteristics. Rotor Clip Company, Inc. 187 Davidson Avenue Somerset, NJ 08873 www.rotorclip.com sales@rotorclip.com Tel: 1.732.469.7333

Ruland Manufacturing Zero-Backlash Couplings for Robotic Systems Ruland Manufacturing offers a variety of zero-backlash servo couplings designed for use in high precision applications like automation and robotics. Ruland offers beam, bellows, disc, oldham, jaw, and newly-released Controlflex couplings in thousands of off-the-shelf combinations and sizes to help designers optimize their systems. Robotic vision systems, material handling robots, and automated guided vehicles have infamously strict requirements that require engineers to balance torque, weight, dampening, and more, all while retaining extremely precise power transmission. Ruland servo couplings excel in demanding applications and can be selected based on a wide variety of performance characteristics. Visit Ruland.com for access to everything you need to make a coupling design decision including: full technical product data, 3D CAD models, installation videos, and eCommerce to make prototyping easy.

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www.therobotreport.com

Ruland Manufacturing 6 Hayes Memorial Dr. Marlborough, MA 01752 508-485-1000 www.ruland.com email: sales@ruland.com

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Schneider Electric Motion Absolute MDrive A multi-turn absolute encoder feature is available integrated with all-in-one motor and electronics Lexium MDrive products. Without increasing product size, rotary and linear stepper motors with integrated electronics deliver multi-turn absolute encoder benefits in a compact size and at an extremely competitive price. Saving time, money and energy, MDrive intelligent motors are in motion globally in a wide range of industries and applications. Delivering reliable and cost-effective closed-loop performance for EtherNet/IP, Profinet, ModbusTCP, RS-422/485 and CANopen systems.

370 N. Main Street Marlborough, CT 06447 Tel: 860-295-6102 Email: info@imshome.com www.motion.schneider-electric.com

SICK, Inc. 2D LiDAR Sensors – TiM7xx Simultaneous field evaluation and measurement data output in just one device with 2D LiDAR Sensors. Here are a few product benefits:

• Enables new solutions for mobile applications by combining intelligent field evaluation and measurement data output.

• Reliable object detection independent of the object, even with strong ambient light

• The measurement data output enables capture of additional data about parameters such as object size, shape, etc.

• Easy integration into compact AGVs thanks to small size of the sensor (60mm x 60mm x 86mm)

• Easy commissioning with rotatable connections and accessories perfectly attuned to the sensors; only a few adjustable SOPAS software parameters are necessary for commissioning

• Improved behavior for edge hits thanks to HDDM+ • Safety-rated model available for detection and measurement of objects with performance level b

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Schneider Electric Motion

www.therobotreport.com

SICK, Inc. 6900 West 110th St. Minneapolis, MN 55438 USA www.sick.com info@sick.com

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10/28/19 10:15 AM

S U M M I T

E X P O

The International Design and Development Event for Robotics and Intelligent Systems

The International Design and Development Event for Robotics and Intelligent Systems The Robotics Summit & Expo emphasizes the design and development of commercially viable robotics and intelligent systems products – wholly new products and services that are to be used outside of laboratory environments and sold at a profit. Dedicated tracks provide professionals with the information they need to develop the next generation of commercial class robotics and intelligent systems products and services. Robotics Summit Tracks • Technologies, Tools and Platforms • • Design and Development • • Manufacturability, Business Models and Business Development •

SEPTEMBER 24-25, 2020 BOSTON HYNES CONVENTION CENTER B OS TO N , M A

ro b o t i c s s u m m i t . co m EXHIBIT AND SPONSORSHIP OPPORTUNITIES For more information, contact Mike Emich 508.446.1823, memich@wtwhmedia.com, P RESE NT E D BY:

ROBOTICS SUMMIT EXPO 11-19_DW.indd 111 RSE20_10-19_Vs2.indd 510

ST R AT EGI C PAR NER :

P ROD U CED BY:

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AD INDEX AutomationDirect ............................................................ IFC

SALES

LEADERSHIP TEAM

Jami Brownlee

Publisher Mike Emich

jbrownlee@wtwhmedia.com 224-760-1055

Bodine Electric Company ......................................... 13,59

Mike Caruso

CGI Inc. ................................................................................. 29

mcaruso@wtwhmedia.com 469.855.7344

CS Hyde Company ...........................................................89

Bill Crowley

FAULHABER MICROMO ..................................................BC

bcrowley@wtwhmedia.com 610-420-2433

Festo ..................................................................................... 83

Michael Ference

GAM .......................................................................................99

mference@wtwhmedia.com 408.769.1188 @mrference

Harmonic Drive ......................................................................1

Mike Francesconi

Heidenhain Corporation ................................................ 93

memich@wtwhmedia.com 508.446.1823 @wtwh_memich

Managing Director Scott McCafferty

smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty

EVP Marshall Matheson

mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

mfrancesconi@wtwhmedia.com 630.488.9029

Honeywell Intelligrated .....................................................3

David Geltman

IDS Imaging Development Systems GmbH ............ 92 igus ......................................................................................... 21

dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david

IKO International, Inc. ...................................................... 55

Neel Gleason

ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

Keystone Electronics Corp. .............................................5 Kollmorgen .......................................................................... 33

Jim Powers

maxon .....................................................................................9

jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

Memory Protection Devices ......................................... 27

Courtney Nagle

Mitsubishi Electric Automation ................................... 85

cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

mk North America, Inc. ................................................... 79 Mobile Industrial Robots .............................................. 25 New England Wire Technologies & New England Tubing Technologies .....................69 Newark, An Avnet Company ........................................ 73 NSK Precision .................................................................... 63 POSITAL-FRABA Inc. ..........................................................17 Renishaw ..............................................................................77 Rotor Clip Company, Inc. ...............................................IBC Ruland Manufacturing Co., Inc. ................................... 95 Schneider Electric Motion USA .................................... 41 SICK, Inc. .............................................................................. 49

Sunstone Circuits ............................................................ 45

Follow the whole team on twitter @DesignWorld 112

November 2019

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