Detta examensarbete genomfördes med syftet att undersöka möjligheten för implementering av en samarbetsrobot, en cobot, vid en ventilblockmonteringsstation. Monteringsprocessen önskas förbättras med avseende på ergonomi och effektivitet. Syftet är även att ge Volvo CE en djupare inblick och kunskap om cobots, samt dess möjligheter och begränsningar. Det utförs genom att ett utvalt anslutningsblock och dess fyra ingående komponenter monteras med hjälp av coboten. Examensarbetets omfattning består av två huvuddelar. Inledningsvis konceptuellt framtagande av fixtur till de ingående komponenterna, tryckgivare, nippel, plugg och V-nippel. Det inleddes med laborationer och prototyptillverkning för att sen skapa en kravspecifikation. Därefter genomfördes en konceptgenerering med hjälp av en Pugh-matris och en riskanalys där två slutgiltiga fixturkoncept presenterades. Andra huvuddelen av examensarbetet innebar ett konceptuellt framtagande av fabrikslayout där coboten och fixturerna är implementerade på monteringsstationen. En sexstegsmetod där arbetsmoment definieras för att sen fördelas mellan montör och cobot. Därefter skapas koncept för nya layouter som sen genomgår arbetsflödesanalys och säkerhetsanalys. Avslutningsvis genomförs RULA-analyser (Rapid Upper Limb Assessment) för att möjliggöra mätning av den ergonomiska utsattheten innan respektive efter cobotimplementation. Arbetet resulterade i två komponentfixturskoncept där båda bygger på en magasinlösning. Genom att utnyttja gravitationen matas nästa komponent fram. Båda utnyttjar plastpluggarna som kommer förmonterade på samtliga komponenter genom att de glider i en skena. Arbetets andra huvuddel resulterade i två fabrikslayoutkoncept. Ett där dagens layout är intakt och coboten inte kan utnyttjas fullt samt ett där layouten på monteringsstationer är konfigurerad för att passa en cobotimplementation. Avslutningsvis genomfördes RULA-analyser som pekar på att en cobotimplementation är fördelaktig i avseende på ergonomi och effektivitet. / This thesis work was carried out with the purpose of investigating the possibilities of implementing a collaborative robot, a cobot, at the valve block assembly station on the medium line at Volvo CE. There is a desire to improve the assembly process regarding ergonomics and efficiency, while maintaining the safety level. Another purpose is to grant Volvo CE a deeper insight and knowledge about the cobots and the possibilities and limitations that come with. To achieve this purpose, the testing will be done on a pre-selected valve block and its four ingoing components. The thesis work consists of two main parts. The first part mainly focuses on the development of conceptual fixtures for the ingoing components, pressure sensor, valve, plug and V-valve. It started with testing and prototype manufacturing to be able to create a requirements specification. Following was a concept generation carried out with the help of a Pugh-matrix and a risk analysis where two final fixture concepts were presented. The second part of the thesis work is about development of a conceptual factory layout, where the cobot and the fixtures are implemented on the assembly station. A six-step method where sub operations are defined and then distributed between operator and cobot. Concepts for new layouts are then created, which undergoes workflow analysis and security analysis. Finally RULA (Rapid Upper Limb Assessment) analyzes must be carried out to determine the value of ergonomic vulnerability before and after cobot implementation.  The work resulted in two concepts of component fixtures, where both are based on a magazine solution. By utilizing gravity, when a component is pulled out with the cobot, the next component is fed forward. Both concepts use the plastic plugs that come pre-assembled on all components, where they slide down a rail. The second part of the work resulted in two factory layout concepts, one where the current layout is intact and the cobot cannot be fully utilized. As well as one where the layout of the assembly station is changed to fit a cobot implementation. Finally, RULA analyzes were executed which indicated that a cobot implementation would be beneficial in terms of ergonomics and efficiency.

Modern product assembly is a demanding challenge due to the high number of parts, machines, tools, techniques and people involved in the process. Many assembly operators, therefore, are exposed to an intense cognitive load and also physically challenged due to a large number of repetitive tasks. Even though modern assembly lines use machines and industrial robots for physically intense, harmful or repetitive tasks, human operators still have some advantages over fully automated systems. This thesis explores how to fuse the strengths of both, industrial robots and human operators, to reduce the difficult challenges for the operators and to improve the general work environment while improving productivity and flexibility of the assembly line. To get first-hand insights of current assembly, I observed the work environments of four different manufacturers around Sweden. I analysed their setups, watched the processes, and got to interview the production managers and operatives to get to know the various challenges of today’s assembly lines. I clustered those insights into development fields and advanced ideas to improve the work environment. Then, I chose the most promising idea and started to prototype it with cardboard mockups. Roleplaying an assembly scenario using the mockups, I learned how to finetune the service and products. Then, I was able to define the complete archetype of the system. With further idea generation in sketches, I developed the form and function of the concluding product. Finally, I created the complete model in a 3D CAD platform and tested its features with CNC milled prototypes. The final result is called COOE. It is a smart table-based assembly system combining the strengths of the machine and the human. It takes human motions and behaviour into account while boosting productivity as a collaborative team.

The concept Industry 4.0 brings several technologies that could be useful for the factories and manufacturers to become more competitive. One of these technologies is the robots in collaborative environments which operate fenceless together with the operators. The interest of these robots in the manufacturing sector has been getting more attention in recent years. These implementation types require the organizations to determine their readiness levels to have success with the robot. Currently, the successful implantations of the robots in collaborative environments in industry are few, and the success factors must be mapped. Therefore, investigating the potential barriers, enablers and establishing a road map for a case company could be useful to fill this gap and assist the organizations with what is necessary to accomplish a successful implementation. A case study was conducted at a manufacturing company in Sweden, which allowed for insights into how an actual organization approaches the situation. The case company organization was in the process of acquiring a robot in a collaborative environment, hence, the data from the case company was relevant to answer the research questions. Furthermore, the data was collected using interviews, observations, and documents at the case company. A literature review was performed to provide information regarding the common factors within a RCE implementation, which also was a base for the interview guide. The data was analysed by comparing the theoretical framework and with the empirical findings to bring forth a conclusion and to establish a road map for the case company. A road map was created with sets of questions to address the identified barriers and enablers found in both literature and at the case company. The constructed road map contains questions concerning the areas of knowledge about the robot in collaborative environments, communication & information, organizational aspects, and resistance towards the change. By addressing the questions developed in the framework, the organization could get an advantage when considering the implementation of the robot. For the case company, as they are further along in the process, the road map could indicate how well they have performed in current projects. Furthermore, it could generate a more successful project the next time.

The need for automation is increasing at Sandvik Coromant. However, high equipment-, education-, and implementation costs connected to automation are usually obstacles when automating smaller and simpler tasks. During the recent years, a new type of robot has been introduced to the market. It is called a collaborative robot, or cobot. It is easy to use/program, has a lower cost and has built-in safety features. The user friendliness of the robot as well as the built-in safety features could lower the implementation costs of these robots to open new areas for automation. This thesis evaluates a cobot from Universal Robots, UR5, to determine if such technology could be useful at Sandvik Coromant’s Insert Plant in Gimo, Sweden. This would be done by performing a physical demonstration of a UR5 put into Sandvik Coromants production. The task includes identifying, conceptualizing and evaluating the possible applications where cobots could create the most value. The work showed that cobots are indeed easy to work with and could create more areas of automation. However, the way Sandvik Coromant looks at automation should change for the technology to make the biggest impact. A company guideline must be setup regarding the use of the built-in safety features to set a limit of what is acceptable when creating an open cell environment at the factory. The results and conclusion of this thesis will hopefully lead to the implementation of collaborative robots at Sandvik Coromant which will result to lower automation costs, better working environment and higher production. / Automationsbehovet på Sandvik Coromant har ökat under de senaste åren. Höga utrustnings-, utbildnings-, och utvecklingskostnader kopplade till automation sätter oftast stopp för automation av mindre och enklare uppgifter. Under de senaste åren har en ny typ av robot blivit introducerad på marknaden. Den kallas för samverkansrobot, eller cobot. Den är enkel att använda/programmera, har lägre kostnad och inbyggda säkerhetsfunktioner. Användarvänligheten av roboten samt de inbyggda säkerhetsfunktionerna kan leda till lägre implementationskostnader, som öppnar nya möjligheter för automation. Detta mastersarbete utvärderar en cobot från Universal Robots, UR5, för att fastställa om sådan teknologi kan vara användbar på Sandvik Coromants skärfabrik i Gimo, Sverige. Utvärderingen kan göras genom att fysisk demonstration av UR5 i Sandvik Coromants produktion genomförs. Uppgiften består av att identifiera, konceptualisera och utvärdera de applikationer i fabriken där samarbetsrobotar skulle kunna skapa mest värde. Arbetet visade att cobots är enkla att arbeta med och kan skapa mer möjligheter för automation. Dock så måste sättet Sandvik Coromant ser på automation att ändras för att teknologin ska ha störst inverkan. En intern riktlinje måste skapas angående användandet av de inbyggda säkerhetssystemen för att sätta en gräns på vad som är accepterat ur en arbetsmiljösynpunkt när det gäller öppna robotceller. Resultaten och slutsatsen av arbetet kommer förhoppningsvis leda till implementering av samverkansrobotar på Sandvik Coromant som i sin tur leder till lägre automationskostnader, bättre arbetsmiljö och högre produktion.

Detta arbete utförs för att använda en kollaborativ robot i en monteringsprocess med målet att lösa en typ av dold montering, där kugghjul ska synkroniseras. Eftersom delarna är ömtåliga och tunga blir de svåra för montören att hantera, vilket kan leda till skador på material eller ännu värre på montören. Ett gripverktyg ska därför konstrueras för att användas med en kollaborativ robot vid denna typ av montering. En jämförelse av kollaborativa robotar utförs, utifrån två nödvändiga krav,  där robotens lyftförmåga måste vara minst 10 kg och att robotarna säkerhetsmässigt uppfyller säkerhetsstandarder. Där coboten KUKA LBR IIWA 14 visas uppfylla dessa krav och anses vara lämpligast till att utföra arbetsuppgiften. Roboten har en lyftförmåga på 14 kg, vilket betyder att den klarar av gripverktyget och transmissionskåpans massa, roboten anses också vara väldigt enkel att programmera. LBR iiwa är en väldigt mångsidig robot och har inte några stora brister och därför anses valet av robot vara väl genomfört. Ett gripverktyg har konstruerats och gått igenom olika utvecklingsfaser, från att konceptgenerera idéer på designen till att välja material och göra FEM-analyser. Resultat antyder att val av design och material på gripverktyget gör att den är godkänd för tillverkning och kommer att klara av belastningarna gripverktyget kommer att utsättas för vid utförandet av arbetsuppgiften. / This work is performed to use a collaborative robot in a mounting process with the aim of solving a type of hidden assembly, in which gear wheels should be synchronized. Because the parts are fragile and heavy, they become difficult for the assembler to handle, which can lead to damage to material or even worse the assembler. A gripping tool should therefore be designed to be used with a collaborative robot in this type of assembly. A comparison of collaborative robots is performed, based on two necessary requirements, where the robot's lifting capacity must be at least 10 kg and that the robots meet safety standards in a safety manner. Where the cobot KUKA LBR IIWA 14 meets these requirements and is considered to be most appropriate for carrying out the task. The robot has a lifting capacity of 14 kg, which means it can handle the gripping tool and the gearbox housing mass, the robot is also considered to be very easy to program. LBR iiwa is a very versatile robot and has no major deficits and therefore the choice of robot is considered to be well completed. A gripping tool has been designed and gone through different stages of development, from concept-generating ideas to design and choosing materials and making FEM analyses. Results suggest that selection of designs and materials on the gripping tool makes it approved for manufacturing and will handle the various loads the gripping tool will be exposed to in carrying out the task.

Au cours des dernières années, nous avons assisté à un changement de paradigme, passant de la fabrication de robots rigides à des robots compliants. Ceci est dû à plusieurs raisons telles que l'amélioration de l'efficacité des robots dans la réalisation des mouvements explosifs ou cycliques. En fait, l'une des premières motivations à l'origine de ce changement est la sécurité. Parlant de la sécurité à la fois du sujet humain et du robot, tout en s'engageant dans des tâches collaboratives. Ainsi la désignation des cobots. Les cobots peuvent aider un opérateur humain expérimenté dans plusieurs domaines où la précision est essentielle, comme les applications industrielles ou les tâches médicales. Jusqu'à présent, les cobots présentent toujours des problèmes de sécurité, même avec des recommandations réglementaires telles que ISO / TS 15066 et ISO 10218-1 et 2 qui limitent leurs avantages économiques. Dans cette vue, plusieurs projets de recherche ont été lancés dans le monde entier pour améliorer la dynamique des cobots par rapport à la sécurité, ANR-SISCob (Safety Intelligent Sensor for cobots) étant l'un de ces projets. Les travaux menés au cours de cette thèse ont pour but de concevoir des dispositifs de sécurité qui sécuriseront les robots en y introduisant l’aspect de compliance. En effet, nous avons développé deux dispositifs dans lesquels l'aspect sécurité est atteint avec deux approches différentes :- Prismatic Compliant Joint (PCJ) : qui vise à la mise en œuvre dans les articulations linéaires, car peu de travaux ont traité de tels systèmes d'actionnement. Ici, la sécurité est atteinte biomimétiquement tout en faisant face à d'autres critères de sécurité liés aux propriétés mécaniques du corps humain.- Variable Stiffness Safety Oriented Mechanism (V2SOM) : Contrairement au premier dispositif d'inspiration biomimétique qui sert aux systèmes d'actionnement linéaires, le profil de sécurité du V2SOM est axé sur la sécurité selon deux critères de sécurité: force d’impact et HIC. L'aspect ‘orienté sécurité’ est dû à ce que nous appelons la capacité de découplage d'inertie de son profil de rigidité. V2SOM est actuellement dans ses dernières étapes de brevetage.Ces deux appareils seront intégrés dans un robot sériel réalisé dans notre laboratoire. / In the recent years, we witnessed a paradigm shift from making stiff robots toward compliant ones. This is due to several reasons such as enhancing the efficiency of robots in making explosive or cyclic motion. In fact, one of the earliest motivations from which this change stems are safety. Speaking of safety of both the human subject and the robot alike, while engaging in a collaborative task. Thus, the designation of cobots. Cobots may assist well-experienced human operator in several domains where precision is a must, such as industrial applications or medical tasks. Until now cobots still display safety concerns, even with regulatory recommendations such as ISO/TS 15066 and ISO 10218-1 et 2 that limits their economic benefits. In this view, several research projects were launched worldwide to enhance the cobot’s dynamics vs safety, ANR-SISCob (Safety Intelligent Sensor for cobots) is one of these projects. The works conducted during this thesis aims at making safety devices that will make robots safe by introducing compliance aspect in them. Indeed, we developed two devices in which safety aspect is achieved with two different approaches: - Prismatic Compliant Joint (PCJ): is aimed at prismatic joint’s implementation, as few works have dealt with such actuation systems. Herein, safety is biomimetically attained while coping with other safety criteria related to the mechanical properties of human body. - Variable Stiffness Safety Oriented Mechanism (V2SOM): Unlike the first device that’s biomimetically inspired and serves at linear actuation systems, V2SOM’s safety profile is safety oriented according to two safety criteria Impact force and HIC, and is designed for rotary actuation. The safety oriented aspect is due to what we call inertia decoupling capacity of its stiffness profile. V2SOM is currently in its final patenting process.Both devices will be integrated in serial robot built in our lab.

Projektet gick ut på att utveckla ett antal koncept för att automatisera limningen av ett kullager som monteras i underdelen med hjälp av en kollaborativ robot. De ser detta som vägen framåt mot en mer effektiv produktion. Målet var att ta fram tre koncept för hur detta kan ske samtidigt som kraven upprätthålls. Projektet handlade endast om limningen av lagret och inte andra delar av sammanställningen av underdelen. Robotens gripdon som används vid sammanställningen fick dock inte modifieras på ett sätt som påverkar andra steg i processen. Underdelen är den komponent som fäster mätinstrumentet vid ett stativ. Den består av två huvuddelar som monteras vid varandra via ett lagerpar för att minimera oönskat spel. Utrymmet som finns tillgängligt begränsas huvudsakligen av robotens räckvidd och de andra stationerna i produktionslinan som roboten arbetar i. Tester av robotens förmåga att utföra de nödvändiga stegen genomfördes genom att stegvis testa dess egenskaper. Resultatet av dessa tester visade att roboten kunde utföra de nödvändiga stegen. De tre koncepten som togs fram byggde på varandras styrkor och svagheter med olika filosofier som grund. När dessa koncept var färdigställda utvärderades de och ställdes mot varandra i en beslutsmatris där det vinnande konceptet vidareutvecklades i CAD. Denna CAD-sammanställning omvandlades sedan med hjälp av 3D-utskrifter i PETG till en 1:1-skalig modell. Det koncept som valdes för vidareutveckling var det som bygger på att använda robotens rotationsförmåga och på så vis inte behöva några extra motorer. Resultatet blev då en station som uppfyller målen och går att använda för utveckling av produktionslinan. / The project aimed to develop several concepts for automating the bonding of a ball bearing that is mounted in the adapter housing with the help of a collaborative robot. They see this as the way forward to a more efficient production. The goal was to develop three concepts for how this can be done while maintaining the requirements. The project only dealt with the bonding of the ball bearing and not other parts of the assembly of the lower part. However, the robot's tongs used in the assembly could not be modified in a way that affects other steps in the process. The adapter housing is the component that attaches the measuring instrument to a tripod. It consists of two main parts that are mounted together through a pair of ball bearings to minimize unwanted play in the construction. The space available is mainly limited by the robot's reach and the other stations in the production line where the robot acts. Tests of the robot's ability to perform the necessary steps were carried out by systematically testing its features. The results of these tests showed that the robot could perform the necessary steps. Three concepts were developed that built on each other's strengths and weaknesses with different philosophies as a basis. When these concepts were completed, they were evaluated and compared in a decision matrix, where the winning concept was further developed in CAD. This CAD assembly was then converted using 3D printing in PETG to a 1:1 scale model. The concept chosen for further development was the one based on utilizing the robot's rotational capability, thus eliminating the need for any additional motors. The result was a station that meets the objectives and can be used for the development of the production line.

This thesis discusses adaptive control of cooperative robotic manipulator. It deals with gathering and processing of data from six degrees of freedom tensometer and their use in adaptive control.

Background: For several decades companies have had their focus on automation and to make the processes more effective. Today's companies are thinking about how to streamline and automate processes with upcoming new technology. A new way to automate processes is to use automation in combination with employees, this can be done with the help of HRC. At the moment HRC is something that Scania CV AB would like to have in order to be able to automate and improve its working methods. Scania CV AB want to investigate how HRC can be used most effectively as a step in their automation and digitization roadmap. Research questions: 1. What are the advantages, limitations and requirements for human robot collaboration to be able to be implemented in line feeding in the automotive industry's assembly process? 2. In which activity at Scania CV AB Oskarshamn truck cab assembly factory in line feeding could human robot collaboration be implemented and why? 3. What can an implementation process look like for human robot collaboration in the selected activity at Scania Oskarshamn's truck cab assembly factory? Purpose: The purpose of the work has been to discuss the advantages limitations and requirements of implementing human robot collaboration in line feeding in the automotive industry. Furthermore, a decision basis has been produced in the work to implement human robot collaboration as a step in that Scania CV AB wants to automate and improve its working methods. With the help of the decision basis, a suitable activity has emerged. An implementation model has been created for the selected activity at Scania CV AB Oskarshamn.  Implementation: This work is a case study at Scania CV AB in Oskarshamn. The authors have used goal-directed selection and snowball selection where semi-structured and unstructured interviews have been conducted. The work has used the deductive approach and used the qualitative research as method Conclusion: In this case study, three research questions have been analyzed. The first research question is aimed at the entire automotive industry, while the other two are aimed at Scania CV AB, however, all three research questions can provide value to stakeholders both internally at Scania CV AB and externally. The first research question has discussed the advantages, limitations and requirements for implementing HRC. Furthermore, in connection with the work’s second research question, a decision basis has been produced for the classification of suitable articles to be handled by HRC. Finally, the third research question has led to the development of an implementation model for activity for the selected article. Contributions/value: This work has contributed to both theoretical and contributions in the form of the authors having developed an implementation model that can be used by both Scania CV AB and other companies in the automotive industry. It also contributes by giving stakeholders a broader perspective, including benefits, limitations and requirements that should be borne in mind when implementing HRC.

Volvo CE i Arvika vill utöka sin kunskap kring automation på monteringsavdelningen för att skapa en mer ergonomisk, säker och effektiv tillverkningsprocess. Arbetet utförs i ett projekt där två examensarbeten arbetar parallellt med syftet att undersöka möjligheten att använda en kollaborativ robot för äntring av komponenter och på så vis avlasta personalen från de icke ergonomiska arbetsmomenten.  De två examensarbeten är separerade där “allt som inte rör på sig” såsom fixturer och layout utvecklas i det parallella examensarbetet och “allt som rör på sig” såsom kollaborativ robot, gripdon och verktyg utvecklas i detta examensarbete. Arbetet är avgränsat till att äntra samtliga komponenter till ett anslutningsblock med användning av en kollaborativ robot, UR10e från Universal Robots och gripdonet Hand-E från Robotiq. Genom laborationer, rapid prototyping, konceptutveckling kombinerat med en teoretisk fördjupning inom kollaborativa robotar, gripdon, human robot collaboration, ergonomi och dess roll i industri 4.0 har möjligheten att använda en kollaborativ robot inom montering undersökts samt hur arbetsplatsen påverkas ergonomiskt av denna typ av implementering. Arbetet resulterade i två användbara prototyper. Ett par självcentrerande gripfingrar och ett magnetverktyg. Med dessa två prototyper, fixturer från det parallella examensarbetet, den kollaborativa roboten UR10e samt gripdonet Hand-E kan samtliga komponenter äntras i anslutningsblocket. Processen är dock inte helt komplett. Magnetverktyget är utformat för att fixera en insexplugg men fixeringen är inte helt pålitlig, varför verktyget behöver vidareutvecklas. Utöver detta anses den kollaborativa robot som har använts under laborationerna överdimensionerad och funktionsanalysen visar att en mindre kollaborativ robot, UR3e, uppfyller de krav och önskemål bättre. / Volvo CE in Arvika wants to expand their knowledge in automation on the medium line to create a more ergonomic, safe and efficient manufacturing. This task is performed in a project where two bachelor theses are working parallel. The purpose with this work is to find out if a collaborative robot can enter the different components into a connection block thus relieving the personnel from those un-ergonomic tasks. The two theses are separated in “things that don’t move” and “things that move” where the thesis that have the parts that don’t move include fixtures and layout. The other thesis includes development within the collaborative robot, gripper and special tools for the collaborative robot. The work is limited to entering all the components to a connection block with a collaborative robot, UR10e from Universal Robots and a gripper HAND-E from Robotiq. Through laboratory work, rapid prototyping, concept development, and theoretical exploration of collaborative robots, grippers, human-robot collaboration, ergonomics, and their role in Industry 4.0, the feasibility of using a collaborative robot in assembly operations has been investigated, along with the ergonomic impact of such an implementation on the intended workplace. The work resulted in two useful prototypes. A pair of self-centering grippers and a magnetic tool. With these two prototypes, fixtures from the parallel thesis project, the collaborative robot UR10e, and the gripper Hand-E, all components can be assembled in the connection block. However, the process is not flawless. The magnetic tool is designed to secure an Allen plug, but the fixation is not entirely reliable why further development is needed. In addition to this, the collaborative robot used in the experiments is considered oversized, and a smaller collaborative robot, UR3e, is recommended, as it better fulfills the requirements and preferences stated in the functional analysis.