Inside the Autonomous Robotic Manipulation (ARM) Lab, massive KUKA robotic arms select and delicately transfer the correct beanbag from a pile of random objects. Photo: Robert Coelius

It’s one thing for a robot to sort through a pile of rigid objects like blocks, but what about softer stuff?

The beanbag test

Flexible endoscopes can snake through narrow passages to treat difficult to reach areas of the body. However, once they arrive at their target, these devices rely on rigid surgical tools to manipulate or remove tissue. These tools offer surgeons reduced dexterity and sensing, limiting the current therapeutic capabilities of the endoscope.Now, researchers from the&nbsp;<a href="http://seas.harvard.edu/" target="_blank">Harvard John A. Paulson School of Engineering and Applied Sciences</a> and&nbsp;<a href="http://wyss.harvard.edu/" target="_blank">the Wyss Institute for Biologically Inspired Engineering</a> at Harvard University have developed a hybrid rigid-soft robotic arm for endoscopes with integrated sensing, flexibility, and multiple degrees of freedom. This arm &mdash; built using a manufacturing paradigm based on pop-up fabrication and soft lithography &mdash; lies flat on an endoscope until it arrives at the desired spot, then pops up to assist in surgical proceduresThe research is described in <a href="http://onlinelibrary.wiley.com/doi/10.1002/admt.201700135/full" target="_blank">Advanced Materials Technologies</a>.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1569906785018-ArmwithWritingWeb.jpg" style="width: 766px;" class="fr-fic fr-dib">Multi-articulated soft pop-up robotic arm. Concept of the system (left): An endoscope navigating in the GI tract and detail of the arm mounted at the tip of the endoscope. Soft pop-up arm (right) performing tissue counter-traction during an ex-vivo test on a porcine stomach (Image courtesy of Harvard University)Soft robots are so promising for surgical applications because they can match the stiffness of the body, meaning they won&rsquo;t accidentally puncture or tear tissue. However, at small scales, soft materials cannot generate enough force to perform surgical tasks.&ldquo;At the millimeter scale, a soft device becomes so soft that it can&rsquo;t damage tissue but it also can&rsquo;t manipulate the tissue in any meaningful way,&rdquo; said Tommaso Ranzani, a postdoctoral fellow at SEAS and the Wyss Institute and coauthor of the paper. &nbsp;&ldquo;That limits the application of soft microsystems for performing therapy. The question is, how can we develop soft robots that are still able to generate the necessary forces without compromising safety.&rdquo;Inspired by biology, the team developed a hybrid model that used a rigid skeleton surrounded by soft materials. The manufacturing method drew on previous work in origami-inspired, pop-up fabrication, developed by Robert Wood, the Charles River Professor of Engineering and Applied Sciences.Wood coauthored the paper and is a Core Faculty Member of the Wyss Institute. &nbsp;Previous pop-up manufacturing techniques &mdash; such as those used with the&nbsp;<a href="http://micro.seas.harvard.edu/research.html#flapping" target="_blank">Robobees</a> &mdash; rely on actuation methods that require high voltages or temperatures to operate, something that wouldn&rsquo;t be safe in a surgical tool directly manipulating biological tissues and organs.So, the team integrated soft actuators into the pop-up system.&nbsp;&ldquo;We found that by integrating soft fluidic microactuators into the rigid pop-up structures, we could create soft pop-up mechanisms that increased the performance of the actuators in terms of the force output and the predictability and controllability of the motion,&rdquo; said Sheila Russo, postdoctoral fellow at SEAS and Wyss and lead author of the paper. &ldquo;The idea behind this technology is basically to obtain the best of both worlds by combining soft robotic technologies with origami-inspired rigid structures. Using this fabrication method, we were able to design a device that can lie flat when the endoscope is navigating to the surgical area, and when the surgeon reaches the area they want to operate on, they can deploy a soft system that can safely and effectively interact with tissue.&rdquo;The soft actuators are powered by water. They are connected to the rigid components with an irreversible chemical bond, without the need of any adhesive. The team demonstrated the integration of simple capacitive sensing that can be used to measure forces applied to the tissue and to give the surgeon a sense of where the arm is and how it&rsquo;s moving. The fabrication method allows for bulk manufacturing, which is important for medical devices, and allows for increased levels of complexity for more sensing or actuation. Furthermore, all materials used are biocompatible. &nbsp;The arm is also equipped with a suction cup &mdash; inspired by octopus tentacles &mdash; to safely interact with tissue. The team tested the device ex vivo, simulating a complicated endoscopic procedure on pig tissue. The arm successfully manipulated the tissue safely.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1569906823020-ArmPigWeb.jpg" style="width: 688px;" class="fr-fic fr-dib"><div class="inline-image">Soft pop-up arm performing tissue counter-traction during an ex-vivo test on a porcine stomach (Image courtesy of Harvard University)</div>&ldquo;The ability to seamlessly integrate gentle yet effective actuation into millimeter-scale deployable mechanisms fits naturally with a host of surgical procedures,&rdquo; said Wood. &ldquo;We are focused on some of the more challenging endoscopic techniques where tool dexterity and sensor feedback are at a premium and can potentially make the difference between success and failure.&rdquo;The researchers demonstrated that the device could be scaled down to 1 millimeter, which would allow it to be used in even tighter endoscopic procedures, such as in lungs or the brain.Next, the researchers hope to test the device&nbsp;in vivo.&ldquo;Our technology paves the way to design and develop smaller, smarter, softer robots for biomedical applications,&rdquo; said Russo.

SEM images of the hybrid soft pop-up actuators. The image has been colored in post processing to differentiate between the soft (in yellow) and the rigid structure (in blue) (Image courtesy of the Wyss Institute at Harvard University)

Bioinspired approach combines pop-up fabrication with soft robotics

Smaller, smarter, softer robotic arm for endoscopic surgery

One key element of the future production landscape is highly flexible Human-Robot Collaboration (HRC). This article describes 3 case studies which illustrate how collaborative robots change the way people will manufacture. KUKA, one of the world&#39;s largest suppliers of industrial robots, has written a free, downloadable white paper called &quot;<a href="http://bit.ly/kuka-whitepaper-US" rel="noopener noreferrer" target="_blank">Shaping future production landscapes</a>.&quot; The white paper describes &#39;megatrends&#39; that impact manufacturing and 3 key factors to designing production infrastructures that can meet the requirements of the future.&nbsp;<hr><h1>Intro</h1><h2>Human-robot collaboration&nbsp;</h2>In human-robot collaboration, the robot assists the human operator. This means: The machine does not replace the human, but complements his capabilities and relieves him of arduous tasks. These can include overhead work, for example, or the lifting of heavy loads. Autonomous, collaborative robots are also used to supply production workstations.In the ideal &#39;factory of the future&#39; there is no separation between automated and manual workstations. Humans and robots collaborate optimally &ndash; without separation and without safety fencing.<h2>Human-robot collaboration: the advantages</h2>HRC-capable robots (often labeled &#39;Collaborative Robots&#39; or &#39;Cobots&#39;) are rendered mobile and capable of performing different tasks flexibly using mobile platforms. They can thus be individually deployed at whatever location and for whatever purpose corresponds to production requirements &ndash; dependent on the required batch size, for example. Furthermore, these types of robots offer maximum flexibility by means of so-called spontaneous automation: They support a user as an assistant in the case of workload peaks and resource bottlenecks in production operations.Human-robot collaboration changes industrial production and manufacturing and can bring a number of advantages over traditional automation or manual labor:<ul><li>Increased flexibility in production</li><li>Relief of employees by performing ergonomically unfavorable work steps that could not previously be automated</li><li>Reduced risk of injuries and infections</li><li>High-quality performance of reproducible processes &ndash; without requiring type-specific or component-relevant investment.</li><li>Increased productivity and improved system complexity thanks to integrated sensors</li></ul> <h1>HRC Case Studies</h1>To give you an idea of the impact of collaborative robots in the workspace we&#39;ve gathered 3 case studies to show you the impact of these robots and the challenges they overcome. <h2>Case Study 1: Lightweight robots supporting operators in adhesive bonding processes.</h2><h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1566292124494-KUKA+LBR+iiwa+Duerr.jpg" class="fr-fic fr-dib" style="width: 766px;"></h2>All images courtesy KUKASystem and machine builder <a href="https://www.durr.com/en/" rel="noopener noreferrer" target="_blank">D&uuml;rr</a> uses two sensitive LBR iiwa robots in final assembly. Without a safety fence, they perform key tasks in the application of adhesive beads. This improves quality, saves time and lowers unit costs.<div data-ignore="true">At the company, humans and robots work together in final assembly without the need for physical safeguards. Sensitive lightweight robots are used for the adhesive bonding of GPS antenna covers and tanks in the vehicle body. The solutions improve the quality of the adhesive bonding result, save time and lower unit costs.&nbsp;</div>The LBR iiwa detects any fault that arises when the GPS antenna cover is loadedFor application of adhesive to the GPS antenna cover, the assembly worker places the workpiece into the robot gripper manually. The gripper sucks onto it and moves it to the adhesive nozzle on the application tower. The robot slowly moves the GPS antenna cover upwards to the application nozzle. If it encounters an obstacle, it moves back a little thanks to its collision detection ability and starts the motion over from the beginning. Only after three attempts does it move back into the starting position. Otherwise, the adhesive application process starts and the adhesive bead is applied carefully while the robot executes the path. Finally, back at the starting point, the assembly worker removes the GPS antenna cover and mounts it on the vehicle. &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;&nbsp;<iframe src="https://www.youtube.com/embed/PdAXCNtXabc?&wmode=opaque" allowfullscreen="" class="fr-draggable" style="width: 767px; height: 429px;" frameborder="0"></iframe>Precise adhesive beads thanks to the seventh axis of the LBR iiwaFor the automated process of gluing the tank into place in final assembly, the skilled worker guides the tank to a turntable with the aid of a manipulator. There he cleans it, moves it into the correct position and transfers it directly to the robot for further processing. When the starting point is reached on the stationary tank, the nozzle opens under pressure so that no air bubbles are created. The robot then applies the adhesive bead onto the tank very evenly. Sensors on the application head monitor the accurate height of the bead. Thanks to its seventh rotating axis, the robot glues in a radius of 360 degrees &ndash; without re-orienting or having to interrupt the bead. As soon as the robot has completed its task, the skilled worker fits the tank into the vehicle body at the specified position.<a href="http://www.durr.com/" target="_blank">D&uuml;rr</a> has already sold ten systems in the field of adhesive bonding, and is working on HRC solutions for the robot-based adhesive bonding of small washers and other components. <h2>Case Study 2: Human-robot collaboration during the adjustment of headlights.</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1566292345359-Fahrassistenzsystemprfstnden_Drr.jpg" style="width: 766px;" class="fr-fic fr-dib">To reduce the strain on the workers, two KUKA LBR iiwa cobots perform the unergonomic task of adjusting fog lights at Ford. Parallel to this, human colleagues can adjust the main headlights.<article data-ignore="true">The initial situationIn the automotive industry, vehicle fog lights have previously been adjusted manually by human operators. While stooped over, the human operator searches for the hard-to-reach opening for the adjusting screws in the bumper area. Once he has found the adjusting screw, he positions the tool on it extremely carefully without damaging the adjustment opening on the bumper.</article><article data-ignore="true">The solutionTo provide relief for the human worker during this ergonomically unfavorable work and simultaneously achieve improved of the adjustment, Ford VOME (Vehicle Operation Manufacturing Engineering), D&uuml;rr Assembly Products and KUKA have jointly developed an innovative alternative concept for the conventional process as part of a feasibility study. The solution called for the use of the KUKA LBR iiwa cobot. The sensitive robot adjusts the fog lights fully automatically. In doing so, humans and robots work on the same vehicle without additional safety equipment.</article><iframe src="https://www.youtube.com/embed/9HWY-CLR3Co?&wmode=opaque" allowfullscreen="" class="fr-draggable" style="width: 766px; height: 419px;" frameborder="0"></iframe>TeamworkWhile the human operator adjusts the conventional headlights, the cobot adjusts the hard-to-reach fog lights. Two lightweight robots are already in use in four headlight/driver assistance system test stands for the new Ford Focus C519 at the Ford plant in Saarlouis. &nbsp; &nbsp; &nbsp; &nbsp;The secret of the HRC conceptWith its size and joint torque sensors, the robot detects contact immediately and reduces its level of force and speed instantly. These characteristics make it possible to work with human operators in confined spaces. Furthermore, with its high-performance servo control, the cobot detects contours quickly under force control. In combination with an end effector specially developed by D&uuml;rr (consisting of a camera system and an adjustment screwdriver), the robot positions the adjustment screwdriver according to the hole coordinates acquired by the camera system. The adjusting screw itself is located approximately 80 mm behind the hole in the bumper. Thanks to sensitive movements, the cobot optimally positions the adjustment tool into the screw head.Redundant safety is provided by the HRC-capable, heavy-duty aluminum gantry from D&uuml;rr Assembly Products &ndash; on which the KUKA LBR iiwa is positioned in a ride-on installation above the light collecting box directly in front of the headlight to be adjusted. The advantage here: additional robot positioning can be dispensed with. <h2>Case Study 3: Using a cobot to install pump wells. </h2><h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1566292578317-KUKAflexFellow_Platzierung_im_Arbeitsbereich_IMG_3628.jpg" style="width: 766px;" class="fr-fic fr-dib"></h2>In the future, BSH Hausger&auml;te GmbH will be using a <a href="https://www.kuka.com/en-us/products/mobility/mobile-robot-systems/kuka-flexfellow" rel="noopener noreferrer" target="_blank">KUKA flexFELLOW</a> to carry out the installation of pump wells on the dishwasher production line.&nbsp;<article data-ignore="true">The initial situationThe <a href="https://www.bsh-group.com/us/" rel="noopener noreferrer" target="_blank">BSH Hausger&auml;te</a> GmbH factory in Dillingen, Germany is Europe&rsquo;s largest and most modern factory for dishwashers. Around 10,000 machines leave the production line every day in two-shift operation. There are a total of seven production lines for manufacturing dishwashers.Screw fastening of the pump covers in the dishwasher is an ergonomically inconvenient task as the employee has to lean into the dishwasher housing to perform the task. The mechanical assistant now takes on this monotonous step in the process.&nbsp;The task &nbsp; &nbsp;&nbsp;&nbsp; &nbsp;Its contribution has already been tested successfully over several months as part of a pilot system. In addition to relieving the human operator of a cumbersome task, the robot also contributes by documenting its work and indicating whether the screws have been tightened correctly or not.The solution &nbsp; &nbsp; &nbsp; &nbsp;The key challenge when designing the system was to ensure that the manual workstation remained unchanged and that the automation solution could be integrated into the existing assembly line. Its sensitive and responsive capabilities enable it to recognize if, for example, a pump well component is not positioned correctly and then presses it into place.&nbsp;<iframe src="https://www.youtube.com/embed/jtkJQJXO7AQ?&wmode=opaque" allowfullscreen="" class="fr-draggable" style="width: 767px; height: 413px;" frameborder="0"></iframe>The advantages of using a cobot:<ul><li>Reduction of the manual workload in an ergonomically inconvenient task</li><li>Automated documentation of work steps</li><li>Indication of correct screw fastening operation</li></ul>Using its responsive capabilities, the cobot can then calibrate itself independently at its workstation, use a search run mode to find the screw positions, re-apply pressure to the component if it is not correctly positioned and finally tighten the four screws. <hr><h1> </h1><h1>Further Reading</h1><ul><li>Specifications of the <a href="https://www.wevolver.com/wevolver.staff/kuka.lbr.iiwa/" rel="noopener noreferrer" target="_blank">KUKA LBR iiwa</a></li><li>&quot;<a href="http://bit.ly/kuka-future" rel="noopener noreferrer" target="_blank"></a><a href="http://bit.ly/kuka-whitepaper-US" rel="noopener noreferrer" target="_blank">Shaping future production landscapes,</a>&quot; KUKA&#39;s white paper describing the &#39;megatrends&#39; that impact manufacturing and 3 key factors (people, technology and adaptation) to designing production infrastructures that can meet the requirements of the future.</li></ul> </article>

In human-robot collaboration, human and machine work hand in hand. The human operator controls and monitors production, the robots perform the physically strenuous work. Both contribute their specific capabilities.

robotic arms

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The beanbag test

Smaller, smarter, softer robotic arm for endoscopic surgery

Human-robot collaboration: 3 Case Studies

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