Periodic Reporting for period 1 - MASTERLY (Nimble Artificial Intelligence driven robotic solutions for efficient and self-determined handling and assembly operations)
Reporting period: 2023-01-01 to 2024-06-30
Over the last years, production has been shifted from mass production to customization. The conventional production lines, traditionally focused on one product variant or one family of products, do show their limitations to cope with the new needs. Moreover, unprecedented worldwide events, such as the recent pandemic crisis, indicated even more the need for flexible production systems that can rapidly switch production to a totally different one. It was revealed though that current production paradigms present drawbacks that limit the flexibility in production switch.
MASTERLY project pioneers technological advancements that facilitate a seamless transition from mass production to customization. It aims to develop flexible robotic solutions comprised of modular grippers and cutting-edge technologies. These include mobile and stationary industrial robots with varying payloads, collaborative robots, and smart cranes, all enhanced with AI-driven control and perception capabilities. This allows them to autonomously handle a wide variety of parts, differing in size, shape, and material, and ensures usability across all workforce genders.
In order to meet this challenge, MASTERLY consortium aims to work based on the following five objectives:
• Innovative, efficient and low consumption systems for storage, retrieval, conveying and pick-and-place using a multi-disciplinary approach combining technologies
• Robust handling devices and systems, with integrated –AI driven– advanced control
• User-friendly interfaces for robot/machine control and programming
• Interoperable S/W and H/W interfaces
• Industrial Pilot Cases for work piece handling in full production line
The proposed technologies will be tested for flexibility, efficiency and user acceptance in three use cases from different productions sectors, aiming to demonstrate production line and cross sector applicability, scalability and adaptability:
• Elevators manufacturing, focusing on the assembly of electrical cabinets of lifts,
• Sportswear, focusing on warehouse logistics and packaging and
• Aeronautics production, focusing on production of large composite panels of aircraft wings.
MASTERLY project pioneers technological advancements that facilitate a seamless transition from mass production to customization. It aims to develop flexible robotic solutions comprised of modular grippers and cutting-edge technologies. These include mobile and stationary industrial robots with varying payloads, collaborative robots, and smart cranes, all enhanced with AI-driven control and perception capabilities. This allows them to autonomously handle a wide variety of parts, differing in size, shape, and material, and ensures usability across all workforce genders.
In order to meet this challenge, MASTERLY consortium aims to work based on the following five objectives:
• Innovative, efficient and low consumption systems for storage, retrieval, conveying and pick-and-place using a multi-disciplinary approach combining technologies
• Robust handling devices and systems, with integrated –AI driven– advanced control
• User-friendly interfaces for robot/machine control and programming
• Interoperable S/W and H/W interfaces
• Industrial Pilot Cases for work piece handling in full production line
The proposed technologies will be tested for flexibility, efficiency and user acceptance in three use cases from different productions sectors, aiming to demonstrate production line and cross sector applicability, scalability and adaptability:
• Elevators manufacturing, focusing on the assembly of electrical cabinets of lifts,
• Sportswear, focusing on warehouse logistics and packaging and
• Aeronautics production, focusing on production of large composite panels of aircraft wings.
The initial actions performed by MASTERLY’s consortium during the first period of the project are summarized into the following points:
• Definition of the pilot case scenarios:
o The Elevators Manufacturing pilot is focused on assembling an electrical cabinet designed for lifts. This pilot includes the use of mobile manipulators for intra-shopfloor logistics and timely delivery of electrical components as well as features collaborative solutions for installing these components inside the cabinet. The process also integrates a modular gripper, automatic programming of robot behaviour, and adaptation to various product variants.
o The Sportswear pilot explores the use of robotics in logistics operations. It employs a stationary, low-payload collaborative robot for automated material sorting and packaging, equipped with a modular gripper. This automation aims to reduce the cognitive load on operators, minimize repetitive human actions, and improve ergonomics.
o The Aeronautics pilot focuses on the production of large composite panels for aircraft wings. It features the use of smart cranes equipped with modular grippers for transporting components between stations and advanced control systems to handle the delicate, large composite panels. Additionally, smart fixtures are utilized for precise positioning of elements. Operators concentrate on the installation of smaller components.
• Definition of the requirements and specifications for the execution of pilot cases.
• Design of the MASTERLY architecture and the communication between s/w and h/w modules.
• Design and implementation of the MASTERLY web internal and public portal.
• Development of the initial version of technology prototypes.
• Definition of the pilot case scenarios:
o The Elevators Manufacturing pilot is focused on assembling an electrical cabinet designed for lifts. This pilot includes the use of mobile manipulators for intra-shopfloor logistics and timely delivery of electrical components as well as features collaborative solutions for installing these components inside the cabinet. The process also integrates a modular gripper, automatic programming of robot behaviour, and adaptation to various product variants.
o The Sportswear pilot explores the use of robotics in logistics operations. It employs a stationary, low-payload collaborative robot for automated material sorting and packaging, equipped with a modular gripper. This automation aims to reduce the cognitive load on operators, minimize repetitive human actions, and improve ergonomics.
o The Aeronautics pilot focuses on the production of large composite panels for aircraft wings. It features the use of smart cranes equipped with modular grippers for transporting components between stations and advanced control systems to handle the delicate, large composite panels. Additionally, smart fixtures are utilized for precise positioning of elements. Operators concentrate on the installation of smaller components.
• Definition of the requirements and specifications for the execution of pilot cases.
• Design of the MASTERLY architecture and the communication between s/w and h/w modules.
• Design and implementation of the MASTERLY web internal and public portal.
• Development of the initial version of technology prototypes.
The concept of MASTERLY is built around a number of building blocks, consisting of several modules. The goal is to develop a solution that can easily adapt to various scenarios, both in terms of hardware as well as software. More specifically, the five building blocks are focused on collaborative robots, adaptable & modular grippers, AI-driven modules for advanced control, programming and interaction tools, and integration platform for seamless communication. The development and the integration of all these technologies will result in flexible and reconfigurable robotized solutions able to advance the research and manufacturing beyond the state of the art, focusing on the following results:
• Development and customization of serial robotic arm: “Racer 5 Cobot”
• Development and customization of AGV:
• “Agile 1500 AGV”
• ROS2-based library for programming COMAU robots and facilitate the communication with other s/w modules
• Dexterous gripper prototype for handling flexible objects
• Modular gripper prototype for handling rigid objects
• Intelligent fixtures for automatic placing of large parts
• Smart crane for autonomous transportation
• Force control module for sensitive and smooth robot movements (impedance controller)
• AI-driven CAD-less approach vision systems
• Digital twin at cell and process level
• Digital twin for visualization and prediction through simulation
• Dynamic tasks and actions planning tool
• AR interfaces for operator support
• Motion planning and collision avoidance for serial robotic arms
• Robot programming based on AI-driven CAD-based approach vision systems
• Motion planning and collision avoidance for AGVs
• Human tracking and collision avoidance
• Manual robot and machine control
• ROS2-based communication and integration platform (workflow controller)
• Development and customization of serial robotic arm: “Racer 5 Cobot”
• Development and customization of AGV:
• “Agile 1500 AGV”
• ROS2-based library for programming COMAU robots and facilitate the communication with other s/w modules
• Dexterous gripper prototype for handling flexible objects
• Modular gripper prototype for handling rigid objects
• Intelligent fixtures for automatic placing of large parts
• Smart crane for autonomous transportation
• Force control module for sensitive and smooth robot movements (impedance controller)
• AI-driven CAD-less approach vision systems
• Digital twin at cell and process level
• Digital twin for visualization and prediction through simulation
• Dynamic tasks and actions planning tool
• AR interfaces for operator support
• Motion planning and collision avoidance for serial robotic arms
• Robot programming based on AI-driven CAD-based approach vision systems
• Motion planning and collision avoidance for AGVs
• Human tracking and collision avoidance
• Manual robot and machine control
• ROS2-based communication and integration platform (workflow controller)