The team’s task is to utilise the FlexFELLOW mobile robot unit, supplied by KUKA Systems UK, as part of an autonomous robotic system that can solve a series of shop floor logistics and manipulation challenges. The contest’s aim is to further exploit human-robot collaboration technology so that advanced manufacturing processes and applications can be developed for European industry.

KUKA’s new FlexFELLOW, which comprises a lightweight, streamlined robot arm mounted on a compact, portable workstation, was chosen for the challenge as it’s specially designed to allow users to share the same workspace without safety guards. It has integrated, sensitive torque sensors on all 7 axes, which not only ensure a range of safety functions such as safe collision and force detection, but also mean the operator can influence and control the sequence of an application just by touching the robot.

“We’re solving this challenge by working together in a series of code camps at the host site in Germany as well as here at the MTC, which is where our partnership with KUKA Systems UK has been key,” explained Matt Rayment, MTC senior automation programme manager. “They have been able to support the team by providing the FlexFELLOW mobile robot unit so that we’re able to test code, make examples and conduct trial runs.”

Visit the KUKA Systems website for more information.

See all stories for KUKA Systems

The cell comprises a 6-axis KUKA robot, mounted on a 3-axis, 5m high gantry, and a 2-axis manipulator with 3.5m diameter turntable. The robot arm is equipped with a TOP TIG arc welding system that integrates the wire feed into a welding torch.

The robot works directly from a CAD model to lay down weld material to create 3D geometries and add non-critical structural features to structures such as large pump and valve casings or pressure vessels. In addition, the robot can carry a variety of end effectors, which enable the research team not only to potentially deploy a range of welding techniques using metal powder and wire, but also inspect and finish parts in a single set-up.

The project, funded by the High Value Manufacturing Catapult, is designed to show how additive manufacturing can be more easily introduced into existing production lines. It stemmed from KUKA’s previous involvement in building a small shaped metal deposition cell that was originally supplied to Rolls-Royce and later moved to the Nuclear AMRC facility.

Dave Burns, KSUK’s project sales engineer, explained: “The research team asked KUKA to tender for a bigger cell based on the same technology so that they could work on larger components. A new design was evolved and the new cell was built and installed over a six-month period.”

He added that discussions were now underway with the Nuclear AMRC team on how to upgrade the cell and further expand its capabilities and flexibility.

KUKA Systems UK, based in Halesowen, West Midlands, produces automated production solutions for a wide range of industry sectors including aerospace, automotive and nuclear decommissioning.

Visit the KUKA Systems website for more information.

See all stories for KUKA Systems