Future Trends in
Robotics
Commercial Vehicle Megatrends India 2012
Raj Singh Rathee
KUKA Robotics (India) Pvt. Ltd.
www.kuka.in
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 3
Introduction
Automotive Industry faces right now the
largest period of growth in history:
REE’s (Rapidly Emerging Markets):
• China
• India
• Brazil
• Russia
• Malaysia
• Mexico
• Indonesia
China has already replaced the US as largest
automotive market in the world
In the “Rapidly Emerging Markets” the
sales volume will be six times larger in
2018
370 Mio. new cars up to 2013
715 Mio. New cars up to 2018
Increasing industrialization and per-capital-
income will dramatically increase the car
sales volume in general
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 4
Introduction
Actual production in India
0
100,000
200,000
300,000
400,000
500,000
600,000
700,000
800,000
2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11
Commercial Vehicles
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 5
Introduction
To meet the requirements of a cost-effective mass-
production the automotive industry worldwide will
have to develop new body shop and production line
concepts:
shorter production lines with higher robot density to
minimize the required floor space
shorter cycle time and faster cell-to-cell transport to
increase the required through-put
higher availability to guarantee the daily output of the
body shop
cost-efficient and multi-functional equipment to reduce the
overall investment costs
cost-efficient solutions for standard processes and
integration of new processes for light weight bodies
lower life time costs specially in respect to energy
consumption
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 6
Content
Compact Production Lines
New Robot Generation for Future Body Shops
Lean and Cost Effective Cell Concepts
Multi-Functional Robot Controller
Energy-Efficient Production Lines
Sustainable and Energy-Efficient Robot Systems
Reduction of Floor Space, Cycle Time and Enhanced Safety
Safe Robot Technology
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 7
Compact Production
QUANTEC – The New Robot Generation
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 8
Compact Production: QUANTEC - Compact, Fast and Accurate Robots
The KUKA QUANTEC Series was especially designed
for the future requirements of a compact body shop
with highest output and shortest cycle time:
extremely compact design with 25 % less volume
intelligent material selection and latest casting technology
12 % weight reduction
30% reduced energy consumption
minimized interference contours for enhanced accessibility
very small foot print for maximum robot density
reduced weight, highest stiffness of the structural elements
and new control algorithms guarantee:
maximum dynamic and speed 25 % faster
highest repeatability ± 0.06 mm
highest path accuracy ± 0.15 mm
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 9
Compact Production: QUANTEC - Minimized Life Cycle Costs
The intelligent design and highly reliable components
used for the KUKA robot system reduce the operating
costs and the maintenance requirements drastically:
up to 30% less energy consumption during production
and stand-by
robust and wear free drive chain in axis 3 with straight
shafts and without belts
well proven durable SIEMENS motors and sophisticated
drive technology
oil change after 20.000 hours of operating time within 30
minutes
exchange of buffer batteries after 4 years
self-explanatory electronic mastering of all six robot
axes within 10 minutes
easily accessible mechanical interfaces for wrist
exchange within 30 minutes
very fast exchange of media supply without removing
the connectors through the 150mm hollow shaft
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 10
Compact Spot Robot – Increasing Robot Density
A significant reduction of the production area inside
a body-in-white requires an increased robot density
that can only be achieved with new robot concepts:
a new generation of extremely compact spot-welding
robots with a low overall height
these robots will be installed in front and between
standard or shelf-mounted robots
the reduction of the production area leads to:
increased energy-efficiency regarding the building
increased number of process jobs per m2 and
shorter throughput-time
reduction of non-value-adding transportation time
the KUKA CSR family
Reach approx. 1800mm
Height approx. 1300mm
Weight approx. 800kg
Payloads 180kg, 150kg, 120kg, 90kg
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 11
Compact Production: QUANTEC - Productivity Benchmark
0 200 400 600 800 1000 1200 1400 1600
Productivity / Cycles per hour
Po
wer
Co
nsu
mp
tio
n [
Wh
]
1000
2000
3000
4000
5000
6000
7000
Competitor
QUANTEC Productivity is a measure of the efficiency of a
production process and is measured as a ratio
of output per hour and costs per part:
the energy-efficient design of the KUKA robot
reduces the required energy per production cycle
compared to our competitors significantly
Reduction of costs per part at the
same production volume
Significant increase of production
volume without effects on the part
costs
Lower investment costs for a
cost-effective production
the unmatched speed and acceleration of the KUKA
robot allow shorter cycle times without a significant
increase in power consumption
0 200 400 600 800 1000 1200 1400 1600
Productivity / Cycles per hour
Part
Co
sts
/ E
nerg
y p
er
Part
[W
]
1
2
3
4
5
6
7
Competitor
QUANTEC
15%
20%
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 12
Compact Production: QUANTEC - Productivity Benchmark
Due to fluctuation in demand the production
volume often has to be adapted to meet the
market requirement immediately:
installing the new KUKA robot system guarantees
shorter cycle times and higher part throughput in
comparison to our competitors
Scalable productivity buffer due
to different robot models
Increased production capacities
for the same investment costs
Highest volume flexibility to react
on market fluctuations
flexible adaptation of the production volume
without adding additional robots and almost no
adverse effects on the part costs
Production Benchmark Program Automotive
45 55 65 75 85 95 105
Productivity / Parts per hour
Po
wer
Co
nsu
mp
tio
n [
Wh
]
500
1000
1500
2000
2500
3000
3500
Competitor
QUANTEC
QUANTEC
PRIME
+ 32%QUANTEC
EXTRA
+ 18%Competitors
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 13
Lean and Cost-Effective Production Concepts
Multi-Functional Robot Controller
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 14
SW-based
Closed Loop ControlDSE
SW-based
Safety PLC ESCSRDW
SW-based
ProfiNet / ProfiSafe CP1616 ET200S/F
KR C4 Controller: Software Replaces Hardware-Components
SW-based
Master-Stack MFC
SW-based
Main Contactor K1/2SW-based
Visualization VGA
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 15
KR C4 Controller: Software Replaces Hardware-Components
SW-based
Closed Loop ControlSW-based
Closed Loop ControlDSE
SW-based
Safety PLC SW-based
Safety PLC ESCSRDW
SW-based
ProfiNet / ProfiSafeSW-based
ProfiNet / ProfiSafe CP1616 ET200S/F
SW-based
Master-Stack SW-based
Master-Stack MFC
SW-based
Main ContactorSW-based
Main Contactor K1/2
SW-based
VisualizationSW-based
Visualization VGA
SW-based
Closed Loop ControlSW-based
Closed Loop ControlDSE
SW-based
Closed Loop ControlSW-based
Closed Loop ControlDSEDSE
SW-based
Safety PLC SW-based
Safety PLC ESCSRDW
SW-based
Safety PLC SW-based
Safety PLC ESCESCSRDWSRDW
SW-based
ProfiNet / ProfiSafeSW-based
ProfiNet / ProfiSafe CP1616 ET200S/F
SW-based
ProfiNet / ProfiSafeSW-based
ProfiNet / ProfiSafe CP1616CP1616 ET200S/FET200S/F
SW-based
Master-Stack SW-based
Master-Stack MFC
SW-based
Master-Stack SW-based
Master-Stack MFCMFC
SW-based
Main ContactorSW-based
Main Contactor K1/2
SW-based
Main ContactorSW-based
Main Contactor K1/2K1/2
SW-based
VisualizationSW-based
Visualization VGA
SW-based
VisualizationSW-based
Visualization VGAVGA
A powerful multi-core processor allows
the general replacement of formerly
hardware-based functionalities with
software-based tasks:
increase of system availability
smaller spare part stock
higher adaptability to customer’s requirements
30% more compact controller
35% reduction of controller hardware
components
50% reduction of controller cables and
connectors
The reduction of controller hardware
components results in a significant
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 16
Energy-efficient production
Sustainable and energy-efficient robot systems
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 17
Energy Efficiency: Development of energy prices
Development of Energy Prices (approx. 6% Inflation)
End Customer
Stock Exchange Price
Development of Energy Prices (approx. 6% Inflation)
End Customer
Stock Exchange Price
Source:
www.stromvergleich.de
Energy prices will definitely rise during the
coming years – it is only the exact magnitude
of this increase that cannot be predicted:
Within the service life of a robot system, the
energy price for the automotive industry will more
than double from €0.10 to €0.20 for 1 kWh.
As natural resources become scarcer, this will
affect energy prices. This is because the
development of competitive renewable energy
sources has only just begun.
Saving energy by installing energy-efficient robot
systems will be one new “source of energy”.
Incalculable energy costs as a corporate risk
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 18
Requirements for an energy management system that will
allow companies to reduce their energy consumption
systematically and continuously:
Reduced costs – Up to 10% of energy costs could be saved in
the first few years after implementation of an energy
management system.
Environmental protection – Efficient energy management is an
important element, as it can make a major contribution to the
reduction of greenhouse gas emissions.
Sustainable industry – New energy concepts and innovative
energy technologies are the key to operating successfully in the
market in the coming years.
Improved image – Ecological requirements are tending to play
a greater role in public image.
Energy Efficiency: Energy management systems in acc. with DIN EN 16001:2009
Energy-intensive companies can benefit
from legislative relief
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 19
Sustainable Product Development
Energy Efficiency: The Consequences
The Energy-Efficient Robot System
Involves all steps during planning, engineering and final design of the
robot system including materials and production processes
Supports the energy-efficient use of the robot system during the
complete life span by online condition monitoring
Considers the possibilities of recycling parts of the robot system or
the reuse of the complete system
Reduced power consumption during motion
Reduced power consumption during stand-by
Online monitoring of energy consumption during production
Report of energy consumption data to energy management
Strategies for an energy-efficient programming
Recuperation of brake energy
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 20
Engineering and design
12% weight reduction
30% reduction of volume
Sustainable materials
Supply chain logistics:
Innovative logistics concept
60% reduction of CO2 emissions
Robust robot systems:
Service life of more than 15 years
Repurchase of used systems
Energy efficiency: Sustainability throughout the entire life cycle
Energy efficiency on the shop floor
Up to 30% less energy consumption
in motion
Up to 80% less energy consumption
in standby mode
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 21
Energy Efficiency: Energy consumption in a car plant
Energy Consumption Plant
Paint Shop
Body Shop
Final Assembly
Press Shop
Components
Air Conditioning
Light
Water-cooling
Energy Consumption Body Shop
With an average share of 22 % less than one third
of the energy required in an automotive plant is
consumed in the body shop:
in the body shop approx. 50% of the energy is
consumed by the building including light, air
conditioning and water cooling
the other 50 % are consumed by robot
systems, process equipment, transportation systems
etc.
at an average only 5% of the plant-wide energy
demand is consumed by the robot systems
next to the possible energy savings that are possible
with the new generation robot systems the building
itself has the biggest potential for energy conservation
concepts
shorter and more compact production lines with
significantly increased robot density
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 22
In a typical tree-shift-production with a production
stop over the weekend the robot systems show
different levels of energy consumption:
Robot in Motion
19 % robot system is moving with an average
energy consumption of 2,5 kW to 3,5 kW
Robot is stopped 2sec to 20sec
10 % brakes are not activated with an average
energy consumption of 650 W to 800 W
Robot is stopped 20sec to 10min
26 % brakes are activated with an average energy
consumption of 220 W
Robot is stopped 10min to 3h
17 % brakes are activated with an average energy
consumption of 220 W
Robot is stopped over the weekend
28 % brakes are activated with an average energy
consumption of 220 W
Energy Efficiency: Energetic States of a Robot in Production
Energy consumption states of a robot
system in a three-shift-production
19%
10%
26%
17%
28%
Robot in Motion
Wait 2sec - 20sec
Wait 20sec - 10min
Wait 10min - 3h
Wait Weekend
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 23
- 80 %- 30 %- 15 %- 60 %- 30 %
Robot in
Motion
Wait
20sec – 10minWait
2sec – 20sec
Wait
10min – 3h
Ble
nd
ed
Bre
akin
g
Tem
pera
tur
Co
ntr
olled
Fan
Wait
Weekend
KR
C4 a
nd
QU
AN
TE
C
Sta
nd
by-M
od
e 2
Sta
nd
by-M
od
e 3
Energy Efficiency: KUKA Energy-Efficiency Functions
19 %26 %
10 %
17 %
28 %
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 24
Energy consumption of a robot system in a three-
shift-production with production break over the
weekend:
Assumption:
Energy consumption in motion 3.0 kW
5.000.000 brake cycles
32 h Robot in Motion
16,8 h Wait 2sec – 20 sec
43,7 h Wait 20sec – 10min
28,5 h Wait 10min – 3h
47 h Wait Weekend
168 h per Week
Energetic State Energy Consumption Energy Consumption
96 kWh → 9,60 €
11,8 kWh → 1,18 €
9,6 kWh → 0,96 €
6,3 kWh → 0,63 €
10,6 kWh → 1,06 €
134,3 kWh → 13,43 €
67,2 kWh → 6,72 €
4,7 kWh → 0,47 €
8,1 kWh → 0,81 €
4,4 kWh → 0,44 €
2.2 kWh → 0,22 €
86,6 kWh → 8,66 €
KR C4 and
QUANTEC
- 30%
- 60%
- 15%
- 30%
- 80%
- 36%
- 2480 kWh per Year
- 1426 kg CO2 per Year
- 248 € per Year
CO2 – Emission related to Energy 2009: 575 g CO2 / kWh
Energy Efficiency: KUKA Sustainability in Numbers
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 25
Energy
consumption
The KR C4 and QUANTEC series are market
leaders in terms of speed and energy efficiency
Energy efficiency – Reduced energy consumption in the production motion
– 30% 15% reduction in weld gun weight by means of
robot-based gun compensation
12% reduction in weight of robot structure
Optimized gear units with minimized friction
Energy-efficient motor and drive technology
Model-based closed loop control for energy-efficient
motion and positioning
Intelligent brake control system
Temperature-controlled cabinet fan
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 26
KR C4 supports the PROFIenergy profile for reducing
energy consumption in standby mode and for efficient
energy management
The standard was defined by the German automotive
industry together with SIEMENS and KUKA
During breaks in production, the robot controller
automatically reduces energy consumption
The breaks in production are initiated by the line PLC using
standardized PROFInet services
The KR C4 supports two different standby modes which are
activated according to the length of the break
The KR C4 supports, by means of configurable
measurement points, all necessary information for a future
plant-wide energy management system.
Standby 2
Standby 3
– 30%
– 80%
Energy efficiency – Virtual main switch in standby mode
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 27
Robot
simulation
Model-based
energy
consumption
forecast
Analysis
Checking
Settings
Payload category of the robot
Tooling – Weight – Center of gravity
Adaptation of velocity and acceleration
Energy-optimized motion profiles
Energy-optimized robot paths
Optimized robot selection
Cycle time and energy-optimized paths
Energy efficiency must be taken into consideration
as early as the planning phase:
The expected energy consumption of the application must
be forecast on the basis of a robot path programmed
offline.
The energy efficiency is improved by adapting the payload
category, the tool parameters and the velocity.
Optimization of robot and tool selection, as well as the path and
velocity, ensures maximum energy efficiency.
Energy efficiency – Consumption forecasts during planning
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 28
Reduction of Floor Space, Cycle Time and Enhanced Safety
Safe Robot Technology
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 29
In the case of manual loading/unloading stations, additional
measures must be taken to protect the operator:
• separation of operator and robot and intermediate supports
(additional tools and increased space requirements)
• if parts are loaded directly into the gripper, the robot drives
must be safely deactivated (cycle time losses due to restarting)
Safe Robot Technology: Simplification of Manual Loading Station
Safe Robot Technology:
the safe operational stop greatly simplifies direct loading of
parts into the robot gripper
the velocity of the robot moving in and out the loading area is
safely monitored and the drives remain activated during loading
• Reduced space and shorter cycle times
• No costs for additional positioning systems
• Lower costs for additional safety components
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 30
Until now, the workspaces of the operator and the robot were
strictly separated – assembly tasks were either fully manual or fully
automated:
complex sensor systems are required for automation
cost-optimized partial automation was not possible
Safe Robot Technology: Partial Automation of Manual Tasks
Safe Robot Technology:
robot tasks are optimally broken down into autonomous and
operator-guided sequences
utilizes the high-availability sensory capabilities of the operator
Reduces costs by means of scalable
automation
Implements cost-effective intermediate
steps on the way to full automation
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 31
Until now, the workspaces of the operator and the robot were
strictly separated – robots were always surrounded by safety
fences that hampered production flow and the flow of materials:
safety fences increase the space requirements and make an
unobstructed production flow more difficult
very low degree of automation in final assembly
100%60%40%20%20%40%60%80% 80%100%
sicherer Betriebshalt
Arbeitsbereich 1 mit 20% Geschwindigkeit
Arbeitsbereich 2 mit 40% Geschwindigkeit
Arbeitsbereich 3 mit 60% Geschwindigkeit
Arbeitsbereich 4 mit 80% Geschwindigkeit
100%60%40%20%20%40%60%80% 80%100%
sicherer Betriebshalt
Arbeitsbereich 1 mit 20% Geschwindigkeit
Arbeitsbereich 2 mit 40% Geschwindigkeit
Arbeitsbereich 3 mit 60% Geschwindigkeit
Arbeitsbereich 4 mit 80% Geschwindigkeit
Sensor unit
Space
with restricted
detection capability
6.4 x 4.8 m
9.8 x 7.4 m
(maximum
field of vision)
1.5
m
5.0
m
7.5
m r
ea
ch
Safe Robot Technology: Cooperation of Robot and Worker
Safe Robot Technology:
robot and operator work next to one another without physical
safeguards
if the operator gets closer to the robot, the velocity of the robot
is gradually reduced and failsafe monitored
Reduction of costs for access control and
access protection (roll doors, light curtains
and laser scanners)
Unimpeded flow of materials and production
flow combined with low space requirements
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 32
KUKA Robots in CV production in India
Ashok Leyland
Bharat Benz
M&M
TATA
www.kuka-robotics.com
Future Trends in RoboticsKUKA Robotics (India) Pvt. Ltd. | Raj Singh Rathee | 26.4.2012 | Slide 33
Thank You