Planning Operator Support in Cyber-Physical Assembly Systems

Abstract

Abstract:Due to the complexity of assembly processes, a high ratio of tasks is still performed by human workers.Short-cyclically changing work contents due to smaller lot sizes, especially in the varied series assembly, increases both the need for information support as well as the risk of rising physical and psychological stress. The use of technical and digital assistance systems can counter these challenges. Through the integration of information and communication technology as well as collaborative assembly technologies, hybrid cyber-physical assembly systems will emerge. Widely established assembly planning procedures only facilitate the design of purely manual work system. In this paper, two new planning approaches for digital and technical support systems in cyber physical assembly systems will be outlined and discussed with regard to synergies and delimitations of planning perspectives. CYBER PHYSICAL ASSEMBLY SYTEMSAssembly systems especially in high-wage countries are faced with the challenge of tackling rising product and process complexity in terms of individualized customer needs and an aging society by demanding preservation of efficiency as well as productivity at the same time. Assembly systems, as they are established in the industry, are reaching their limits increasingly when encountering these challenges. By networking digital data and modern forms of information and communication technology with physical production and assembly processes, altered forms of assembly processes will be possible (Dombrowski et al. (2013)). Assembly processes will be upgraded in this way to adapt economically to requirements of costumer-individual products (Schlund and Gerlach (2013)). Cyber-physical systems (CPS) realize a connection between the physical and the digital world. CPS are composed of a surrounding physical object and an embedded computational system, which collects and processes digital data and interacts with physical processes via actuators. These systems are linked through digital networks and use available data and services globally. CPS are not (technically) closed units. They are defined as open socio-technical systems, which are characterized by a high degree of cross-linking of the physical, social and virtual world as well as by the intelligent use of information and communication systems (Geisberger et al. (2012)). By integrating assembly equipment with CPS-characteristics into assembly environments, so called cyber-physical assembly systems (CPAS) will emerge. Existing examples for such equipment are fastening tools that identify product variants through ICT and parameterize automatically in accordance or small parts containers which are able to determine their fill level and communicate with the parts supplier to assure accurate replenishment.In addition to cost pressure in global competition and the need for age-appropriate work environments, more frequent changes of work contents as a result of higher product variance, reduced lot sizes and shortened product life-cycles make it more di...

From a literature review to a conceptual framework of enablers for smart manufacturing control

“…This category reviews the main technologies which allow the integration of humans into CPPS. To support humans, CPS need human machine interaction (HMI) methods, as explored in [116,117]. In their works, they describe how HMI methods have evolved from indicator lights, buttons and levers through to every day graphical user interfaces (GUI), keyboards, mouse and touchscreens, before arriving to the concept of multimodal interfaces [118], where the voice, hands, and entire body become a communication channel.…”

Assessment Based Information Needs in Manual Assembly

“…As the initiatives as the digitalization and industry 4.0 will continue to receive much focus, it is important to incorporate the industrial requirements in such initiatives. In such a way, the suggested performance improvements in cyber-physical assembly systems [27] can be achieved.…”

“…As researchers suggest that cyberphysical assembly systems can provide improved production performance [27], there are new possibilities of implementing new technology to support operators in manual assembly. Already a decade ago, industry started to implement smart sensors in their production to improve traceability which in earlier research has been suggested to increase the collaborative, flexible and responsive characteristics of manufacturing systems which continuously become more complex every day [28].…”

A Decision-Making Framework for Implementing Digitalisation in the South African Tooling Industry

“…User-centered approaches have been successfully implemented to develop assistance systems in the domains of transportation systems [82], healthcare systems [83], and environmental monitoring systems [84]. Since they employ human factor engineering principles, the acceptance and implementation of the final solution is enhanced [85]. Furthermore, human factors like safety and ergonomic needs are catered for in the early stages of the development process.…”

“…The interaction model guides the developer in deriving required user experience with the new technologies. The optimal technologies that fit the derived specification can therefore be selected, tested, and implemented [85].…”