ZF Friedrichshafen uses industrial robots from various manufacturers for production. Uwe Wachter is Head of the Production Tech Center Robotics and Vision (PTCRV). He reports: "We founded the PTCRV, based in Schweinfurt, about three and a half years ago. We are the division within the ZF Group that deals with new technologies such as lightweight robots, camera systems and software solutions for production." This is how he became aware of the Robot Programming Suite (RPS) from ArtiMinds. Once a robot application has been developed, it can be run on different robot systems at any time. Wachter explains: "If we develop an application for robot manufacturer A in Schweinfurt, for example, we can then generate the executable program for robot manufacturer B from this source code and send this program by e-mail to our plant in Portugal. Then our colleagues in Portugal can run the same production as we do in Schweinfurt."

First simulate, then realize

One area of application for which Jonas Arnold, engineer for collaborative robots and Wachter's colleague, regularly uses the RPS is simulations. "We are often confronted with the task of estimating whether a robot can fulfill a certain cycle time in a given situation." In the past, ZF had to install the robot system on site at great expense, develop the appropriate application and then test whether the system could meet the specified cycle time.

With the RPS, ZF can now not only program applications, but also simulate them. Special standards must also be observed when using collaborative robots.

Arnold explains: "For example, we have to evaluate in advance where collisions between humans and robots are possible. Can the robot arm reach head height? Are there any potential pinch points? To ensure safety, we have to comply with force and pressure values and limit the robot's speed of movement. We have to allow for inaccuracies in the gripping process that cause time delays. Simulation makes it easier for us to assess all of this." On this basis, ZF is then also able to estimate whether the use of robots is financially worthwhile for the task in question. Wachter explains: "Ultimately, it's always about whether we can meet a certain target. A lightweight robot that is to work with a cycle time of 20 to 30 seconds must not exceed a defined price for hardware, programming and installation. With the help of a simulation, we can quickly estimate at an early stage whether we can meet this target."

Minimize maintenance effort and downtime

ZF is currently evaluating the Learning & Analytics for Robots (LAR) tool. Arnold already knows how this feature can help him: "The cost of maintaining robot systems is a major problem for us. We have some applications where the entire system changes over time due to changes in material properties. The LAR could help us to intervene at an early stage and make corrections with just a few clicks or even allow the robot to adapt autonomously."

Avoid failures

For larger systems, re-teaching can take several days, during which the system is at a standstill. This is exactly where LAR comes in. It continuously collects data on every movement carried out during operation. Based on this data collection, the software can detect and warn at an early stage if there are inaccuracies in the gripping movement, for example. Costly maintenance work is avoided. Arnold sums up: "By using ArtiMinds RPS, we have been able to reduce the costs of developing robot applications. With LAR, we will also be able to reduce maintenance costs in the future."

The author: Matthias Lohrer, freelance editor, Silke Glasstetter, Head of Marketing at ArtiMinds Robotics.

This article first appeared in our sister magazine INDUSTRIAL Production.