The diploma thesis is focused on Industry 4.0, where all essential elements of Industry 4.0 are gradually being discussed. This thesis presents the collaborative robots and their specifications are described and then the market for these robots is depicted. Subsequently, the robot cell is designed with collaborative robots ABB Yumi to serve the educational purposes. This created robotic cell is displayed exemplary role. In the last part of the thesis a risk analysis is created for this robotized workplace. This entire Risk Analysis Protocol is attached.

The aim of this thesis was to describe how a manual assembly process of polycarbonate sheets for heat exchangers can be automated with an industrial robot. The objectives were to design suitable robot cell concepts and simulate them to describe how the automated process could be done and to present which machines and equipment that could be used. Additionally, productivity rates and investment costs was to be calculated.The project started with a situation assessment and a literature review. Experts and suppliers of robotic equipment were consulted, and the results served as a basis for the concept generation process. Several concept ideas were evaluated, and three ideas using adhesive for the assembly were chosen for further studies and simulation. Existing products and machines were used in the designs when possible. By modeling and simulating the cells in simulation software, feasible cell designs was created, and cycle times were measured.The three proposed solutions all utilize an industrial robot, a vacuum gripper and adhesive as the assembly method. Two of the concepts has the robot attending different adhesive dispensing machines; one gantry and one conveyor. In the third concept, the robot applies the adhesive. The cell design that achieved the lowest cycle time in the simulations was the conveyor concept, with a cycle time of 21 seconds per sheet. The conclusion of the study is that investing in a robot cell would increase productivity. / Syftet med detta arbete var att designa en robotcell anpassad för tillverkning av värmeväxlarpaket i moduler. Målet var att besvara hur tillverkningen av värmeväxlare kan automatiseras samt vilken robot och övriga verktyg och maskiner som kan användas. Vidare skulle den möjliga produktionstakten och investeringskostnaden för designförslagen beräknas. Arbetet inleddes med en nulägesanalys och en litteraturstudie. Ett flertal experter och leverantörer inom automationsområdet konsulterades. Resultaten från detta låg till grund för en konceptgenereringsprocess i vilken ett flertal designidéer togs fram. Tre av dessa designförslag valdes ut för vidare studier och simulering. Genom att modellera och simulera robotcellerna kunde de utformas realistiskt och möjliga cykeltider beräknas. De tre designförslagen använder alla en robotarm, ett vakuumgripdon samt lim som metod för monteringen. Två av koncepten består av en medelstor robotarm som betjänar en limappliceringsmaskin. I ena konceptet är det en kartesisk robot med limbord som används för limappliceringen, i det andra är det ett transportband som för plastskivan under ett antal limpistoler. Det tredje designförslaget låter en större robot, utrustad med verktygsväxlare, utföra alla moment i processen genom att den byter verktyg mellan vakuumgripdon och limpistol. Det koncept som uppnådde den lägsta cykeltiden i simuleringarna var lösningen med rullbandet, med en cykeltid på 21 sekunder per skiva. Studiens slutsats är att en investering i en robotcell skulle leda till ökad produktivitet jämfört med manuell produktion.

In order to test an automation code for a production cell it is necessary to have access to the physical model. Therefore, the automation code is validated in the end of the design process. Finding and correcting faults in the code takes time and changes late in the design process tend to be expensive. Having a virtual model of a production cell with the same features as a physical model enables to test automation code and evaluate different features in an early stage of development. The process of having a virtual model to validate code and try out new features is called Virtual Commissioning (VC). The ability to detect errors in the code and identify problems early in the process can lower the lead time for the project and reduce the overall cost. Virtual Commissioning is a relative new process step in the industry and have so far mainly used in larger enterprises. This project has been done at a company named NPB Automation AB, located in Jönköping, Sweden. NPB is a smaller company that designs and produces robot cells that are fully automated. This project is an investigate to see if a software that can perform a Virtual Commissioning should be added to their lineup of tools. This task has been managed by empirically finding how a Virtual Commissioning can be set up. To find out how Virtual Commissioning can affect different fields at the company interviews were held with personnel from different working fields. To get practical knowledge and verifying that Virtual Commissioning can be performed on a robot cell produced at the company, a Virtual Commissioning were set up of a subsystem of a robot cell. The Virtual Commissioning in this project was set up with the software Emulate3D connected to a Rockwell PLC model 1769- L33ERMS, the PLC code used were written in Studio 5000 Logix Designer. The conclusion of his project is that Virtual Commissioning can reduce time to market by reducing the commissioning time. The tasks where Virtual Commissioning will benefit the most is in new projects or when validating changes.