Digital planning of ability-appropriate and productive human-robot interactions in production

Hybrid work systems, which enable interaction between humans and robots, offer high economic and ergonomic potential. This paper demonstrates how workplaces can be designed with regard to human-robot-interaction (HRI) using the process simulation tool ema Work Designer (emaWD). A method for simulation-aided planning of HRI tasks is introduced and applied to a real-world use case of handling and assembling turbochargers onto an engine. In planning process the work processes are simulated and assessed regarding automation, ergonomic and economic potential. Furthermore, a capability-oriented task allocation including workers with different abilities (anthropometrics, flexibility, strength related to aging) as well as the technical feasibility of different robots are considered and evaluated using the HRI-simulation approach. In the result a new HRI-workplace is developed in which the UR10e robot take over manual load handling tasks and acting as a third hand to ensure a worker-specific favorable working position. These measures reduce the ergonomic risk according to the EAWS-method from high risk to a low risk level for all workers. Also, person with limitations can be included into the work process. The execution time of the HRI system is 41.3s, which is within the allowed cycle time. By using a collaborative robot, no additional space is required. Due to the integrated safety technology, the robot can work directly in the work area of the workers.