Making Haptical Product Features Measurable and

Transcription

1 ROBOTIC measuring ROBOTIC measuring Battenberg Robotic GmbH & Co. KG Zum Stemel 11 D Marburg Phone: +49 (0) fax: +49 (0) Making Hatical Product Features Measurable and Dulicable Battenberg Robotic GmbH & Co. KG Design: Designbüro Schönfelder, Essen Photograhy: Martin Kreutter, Marburg Background of the title age, other ages and images of the robots on all ages:

2 Battenberg Pioneers of Our Success Story The challenge, thirty years ago, was to develo a robot that could measure quality attributes. We took u the challenge and succeeded. This signalled the beginning of robotic measuring which we have exanded and erfected over the years. Battenberg robotic measuring uses a combination of hardware (robot, robotic cell, robot arm with griers), software and sensors to measure, test, analyse and assess quality attributes of roducts along the whole value chain. Your Exectations Successful roducts require continuous quality reviews and assessment during their creation and develoment. Systematic and recise measurements that rovide verifiable results are crucial to the rocess. These quality tests results must be transarent, dulicable and above all correctly. Furthermore, the measurement setting must be relicated anywhere at any time. Battenberg robotic measuring rovides a trustworthy base for safe, correct and effective quality measurements to answer following questions and tasks: We would like our customers to areciate our high brand value and the quality of our interior right from our vehicle s cockit harmony. How can we find out how our customers like and judge the oerating elements in the cockit? How can the subjective and objective characteristics of the oerating controls be systematically harmonized? How can we align and secure the value and functionality of our roducts in our global customer s eyes? Globally alicable measurement technology with robots, sensors and software 2 3

3 Flexible Solutions for Precise Quality Tests Battenberg With our standard robotic measuring system you can measure, analyse and assess simle and comlex tactile attributes fast and effectively. The system can be exanded as required to include visual, acoustic and geometric functions. Our standard system is made u of following comonents: a robot arm with controller unit robotic measuring sensors robotic measuring software ROBFLOW a mobile work-station with integrated controller and c base latform with testing stations The recise and verifiable results, the system s flexibility and the longevity and faithfulness of our customer relationshis seak for themselves. Battenberg robotic measurement systems are used across the globe and internationally they are considered to be the benchmark for measurement robotics systems. 3D-Vision Force and Torque Sensors Sectrometer Luminance Laser-Triangulation Multi-touch ForceFeedback ROBFLOW ROBPOINT ROBREPORT ROBVISU ROBCOMMAND Flexible Software for Any Tye of Test Our core exertise is develoing software solutions for robotic measurement engineering including all analysis and assessment functions. Our systems offer not only basic robotic movements, but by using intelligent algorithms our robots move in comlex and sensor-guided sequences. Easy to Use The robot is rogrammed via a grahic rogramming interface. The use of flow charts allows our customers to adjust or develo comlex robot rogrammes without any secial knowledge of rogramming languages. The system can also be directly rogrammed by the testing engineer. Adjustments and additions can be added at any time as more sensors, hardware and functions can be easily integrated into the modular lug-in system. Mitsubishi Stäubli Kuka ROBMTC ROBNORM Reference bodies Hatic tools Casings 4 5

4 Keeing an Eye on Added Value The Value Added Chain by Product research and develoment, manufacturing and any subsequent roduct evolution require sohisticated measurement systems able to generate deendable quality assessments. Battenberg robotic measuring can be used in all levels of the value chain. We develo and roduce comlete robotic measuring systems for: quality and functionality tests for otimal roduct analysis and quality assurance functionality tests for trials, research and develoment Research and Develoment functionality tests under extreme climate conditions in climate test chambers in-line and end-of-line tests on the roduction line cockit and interior measurements Quality Assurance BEnchmarks hatic, acoustic, visual and geometric qualities of the oerating controls human ercetion of roduct quality, via sychohysics to measure subjective criteria like look and feel of a roduct We guarantee verifiable, dulicable and reliable test results and a reliable customer service to suort you. Tests in Production Lines Vehicle Analysis A reliable quality assessment base 6 7

5 Globally Alicable Reliable Quality Assessments at all your Comany Sites How can mandatory quality tests be reliable and consistent across different locations all over the globe? CAD Data Requirement Secifications Generalised Test Sequences and Assessment Tree Our solution is the Q-Box. The rules and the deviation ermissible for each test as described in the requirement secifications are translated mathematically into test sequences and assessment functions. These are then saved centrally in the Q-Box (Quality Safebox) and accessible for all users. An authorised user imlements the Q-Box in the local robotic system. Robotic Measuring Order All tests run automatically and the results are saved in the Q-Box ready to be sent to a central quality assurance. Q-BOX Global Robotic Measuring System Global Robotic Measuring System Global Robotic Measuring System Q-Box Solution for Quality Assessment Sanning your Global Enterrise 8 9

6 Comrehensive Quality Assessment for Successful Brand and Quality Politics Differentiated Assessments for Global Products Modern roducts are generally develoed and roduced for the global market. A re-requisite of international success is intensive roduct quality testing. Battenberg robotic measuring offers technology to ensure objective test results to rovide a solid global quality strategy base. Globalisation has added a further dimension to roducts: the subjective human judgement. A US customer reaction to a roduct can be significantly different to that of a German customer. Integrating these differing human ercetions and judgements into roduct tests resents comletely new challenges. It oses new questions in roduct develoment and assessment: ROBQ Objective Gradual Assessment What are the individual customer s exectations from different regions and cultural sheres? Are these exectations measurable? How can subjective feelings be objectified? How does the relationshi between the objective assessment and subjective imression influence the roduct develoment? Are subjective ercetions related to objective measurable quality roerties? Is it ossible to redict the human ercetion and judgement of known quality roerties? Robotic Measuring Objective Physical Quality Assessment Psychohysics Subjective Araisal This new comrehensive quality assessment method has been develoed by Battenberg robotic measuring which links the subjective sychical exerience to quantitative and measurable triggers. This aroach is based on sychohysics research and has the otential to create a aradigm shift in quality assessment. It oens new ossibilities in develoment, roduction and sales. A Global Quality Strategy Base 10 11

7 Comrehensive Quality Assessment for Successful Brand and Quality Politics and Psychohysics Is there a significant and rovable relationshi between the subjective feeling of a car driver and the objective and technical secifications of the vehicle? Customers more often decide to urchase a roduct based on its visual, tactile and acoustic feel than on its actual measurable technical arameters. The better the functionality and the smaller the erceivable functional differences are between roducts, the more imortant the subjective judgements become. Finally they are the only features that allow any kind of differentiation and subsequently influence the customer s choice signifi cantly. We use sychohysics and exerimental sychology to collect the subjective judgements in comrehensive quality assessments. Secific values created by these methods are related to hysical attributes. When incororating these results into the assessment, the multidimensional nature of subjective oinions has to be recognised. We use a method well-known in market research called connected associations with the so called semantic differential. The results show that it is ossible to connect subjective judgements and objective hysical attributes foreseeably and systematically, and so to be able to make redictions based on the hysical attributes about the subjective imressions. This new method oens u new areas in the quality assessment. It allows otimisation in the following areas: the rocess chain the roduct quality the roduct differentiation the brand rofile and the customer satisfaction New Otions in Quality Assessment 12 13

8 ROBQ Objective Gradual Quality Assessment Objective Gradual Assessment with ROBQ In the reviously described comrehensive quality assessments, Battenberg robotic measuring uses its own ROBQ software. The conviction that the measurable quality of all attributes can be combined into one single quality figure led to ROBQ s develoment. After that, the question was how subjective human ercetion and objective measurable criteria are related to each other and if human ercetion could be redicted out of objective measurement results. Ideally, a single figure can be used to ensure consistent roduct quality across manufacturing locations. Our solution ROBQ is an assessment and decision-making software system. The central decision tree in the software reflects that human judgement is multi-layered and more comlicated than binary yes/no decisions. A fundamental art of the oerator flow chart is that objectively measured criteria can be added, adjusted and otimised so the system can simulate a human exert. The Quality Figure between 0 and 1 describes the Product Quality The roduct quality figure describes the objective quality of the criteria between 0% and 100%. ROBQ aggregates the results of all criteria tested with a selectable function (deviation boundaries) and fuzzy oerators in a decision tree to generate a figure between 0 and 1. The roduct quality figure describes your roduct quality transarently. You know the exact quality standard of your roduct. When all of your roduct s comonents have the same standard and are assembled at a central location, then you can be sure your targeted value and imression can be obtained across roduction facilities. ROBQ can be locked in the Q-Box. With this Q-Box, quality measurements across the globe can be assessed and sent back to central quality assurance. ROBQ is an assessment and decision software system 14 15

9 Scalable for Many Alications Universal, scalable, flexible and effective Our robotic measuring systems are more than machines that measure, their very recise robot kinematics, sensitive sensors, measurement technologies, transarent test methods and algorithms all offer you the strategic requirements to reach your global quality objectives. Robotic measuring has a wide alication sectrum. The choice of robot, sensors and software are defined by the customer s tests secification requirements and the environmental conditions under which they are carried out. Seat Tests A generalised software for rogrammable test sequences and comonents guarantees fast imlementation of new or adjusted tests. The first test comonents are tested at room temerature. Products can be tested under extreme climatic conditions in the climate chamber, where acclimatised robotic measuring is used. For testing either 100% or random samles on the roduction line, robotic measuring is used at the end of line in a comlete robotic cell. Final quality tests in the vehicle s interior mark the end of the value chain. Robotic measuring can be used to create benchmarks from other manufacturers vehicles enabling you to rank the quality and value of your own vehicles against theirs. Robotic measuring enables an automated work flow and reduces the overall amount of work. Cockit Tests Climate Chamber Tests Door Tests End of Line Tests Enables an automated work flow and a general reduction in the overall amount of work 16 17

10 Cockit Test: Hatics Otics Acoustics Measurements in the Car Interior The look and feel, the value and the functionality of the cockit are very imortant quality criteria that influence a vehicle s emotional aeal. This significantly influences the decision to buy a car. The quality assurance measurements of all integrated comonents taken in the vehicle interior are the final milestone in the value chain right before the customer can make a decision to buy or not. Battenberg robotic measuring can be used to comrehensively test the interior quality. If the results match the exectations, then quality assessments have been fulfilled. If not, a com arison with the sulier s end-of-line assessment is made. Transarent results from the robotic measuring systems allow an informed rofessional discussion on the cause and solutions to meet the quality goals. A collaborative robot with seven axle kinematics carries out defined measurement tasks in secific ositions even in the vehicle s interior. Mix and Match The comlete range of hatic, visual, acoustic and geometric criteria can be tested in one sequence by a modular multi-sensor robot. The multi-adater on the robotic hand can accommodate u to seven sensors with following functions: Luminance camera to identify and measure symbols Sectrometer for surface colour tests Force and torque sensors to measure the hatics and tactile qualities Laser line sensor to measure rofiles, gas and slots Acoustics sensor to measure activity acoustics Only with Battenberg robotic measuring systems the robots can osition themselves by using their own force and torque sensor in the robot s hand. A key figure for successful robotic measuring is the ability to dulicate the erendicular robot osition towards the surface at any time. With the hel of a laser ointer an otical sensor determines the normal vector across the surface and the recise orthogonal alignment and distance to the object. All following tests can then be ositioned exactly ixel by ixel as rocessed in the first re ference test. 7 axle kinematics to erfectly osition the robot for recise tests 18 19

11 Cockit Test: Hatics Otics Acoustics ROBTOUCH Verification of the Pixel Position and the Panel Reactions This robotic measuring system offers menu, functionality and signal tests for resistive, caacitive and infra-red touch anels. After the anel surface has been automatically located, the robot touches the desired ixel ositions on the dislay or follows defined aths. The dislay reactions can be measured while the touch ositions can be filtered from the CAN messages simultaneously. POLYLINE Comlex touch aths and corresonding touch can be generated to test the touch anel reactions. During the test information from the CAN messages about the anel osition x, y as well as the size of the finger on the area touched are used. ROBPROXIMITY For infra-red controlled dislays, Battenberg rovides a measurement set u with a test hand. The hand comes from different ositions and the infra-red sensor of the dislay reacts when the hand is registered for the first time. All coordination oints are stored in the CAN message and visualised as 3D cloud. Touch screen with hatic feedback The touch screen technology is increasingly becoming standard for the controls and cockit dislay. Touch sensitive surfaces with hatic feedback feel like real buttons. A combination that allows modern dislays both the advantages of hard buttons and flexible touch screens. Atmoshere and Night Design The luminance camera LMK was develoed by Technoteam to measure luminance and colours in the interior atmoshere and night design. Combined with further sensors and integrated into the Robflow-software, the robot is hatically and intuitively rogrammable. The robot uses a new tye of visual test to autonomously find and osition the oints to measure on the surface. The user no longer has to manually rogramme the measurement oints and it guarantees a redefined LMK test is rocessed securely

12 Seat Tests Enabling Safety and Comfort to be measured Safety and Comfort The seats influence the comfort and erceived safety like almost no other vehicle element. A good seat holds a assenger erfectly when driving fast and is comfortable on a long drive. The seat osition can be adjusted easily to suit the assenger by integrated controls. At the same time, the shae of the seat rotects the assenger from ossible injury on collision. To guarantee these demanding requirements, a range of tests with redetermined rules are necessary. These include: control mechanisms functionality seat comfort shae (articularly for assenger safety) longevity of the seat to the elements The set u rovided by Battenberg robotic measuring for seat tests are robots with high ayloads and robotic hands with three axis force and torque sensors. Deending uon the test, secial tools and/or dummies can be adated to fit the requirements and measure further characteristics. A further otion for many of the tests is to be carried out under extreme climatic conditions in a climate chamber. Safety Feature Headrest The atented Battenberg robotic measuring tests for back set (head rest) measurements that comly to comulsory US Regulation FMVSS 202a measure the distance between the back of the head and the headrest with a test dummy. It has been roven that a small distance between the two on vehicle collision significantly reduces the risk of whi lash. Seat Comfort and Durability The definition of seat hardness, i.e. how hard the seat is in chosen test ositions (raster measurements) is an imortant criterion for seat comfort. Marked ositions on the seat surface are measured and visualised to see how disersion energy and indentation aths behave. Robotic measuring uses a new tye of visual test to autonomously find and osition the oints to measure on the seat surface. The user no longer has to manually rogramme the oints. Seat adjustment functionality tests are carried out by the robot with comlex movements and adatable measurements. During ingress/egress tests the durability of the seat covering over a eriod of time is measured. Changes in seat shae during the test are counterbalanced by the adatable movements and measurements of the robot. Patented Battenberg Robotic Measuring Testing Methods for Back Set Measurements 22 23

13 Door Tests in Laboratory and in Manufacturing Do the Doors Shut Proerly? With Battenberg robotic measuring, a robot can test the door functionality by closing it with a dulicable defined movement whilst various results are monitored by intelligent sensors. These tests are done both in the roduct develoment as well as at the end of the roduction line. Closing Energy and Closing Seed The adatable force and torque sensors allow the robot to close the door with a defined amount of force at a certain seed and directly measure the force. Whilst oening or closing the door, the robot can measure the comlete force-door angle-curve. Door Tests at the End of the Production Line Otimise the Final Test An interesting alication on the roduction line is a slam door test with a redefined energy and osition, e.g. the door is shut from the first detent osition to verify it has shut roerly. Furthermore, the sensors can measure the seed-door angle-curve indeendently from the whole door movement. This is of articular interest in develoment when it is not about the door closing curves, but the minimum energy needed to shut the door at a redefined seed. Automated Programming in Laboratories Instead of having to rogramme elaborate robotic movement curves, the system can be equied with intelligent sensors, which learn to relicate a secific door closing movement. This is reducing door testing to a fast and simle rocess. The osition from which the robot should shut the door is marked. The sensors can see the marker within their field of vision and calculate the coordinates in the robot s coordinate system. This is done for three different door ositions. The angle for the robot to shut the door can be defined automatically and directly. The whole rocess only takes minutes. Door Tests with Battenberg Robotic measuring Suort 24 25

14 Reaching Zero Defects with an End-of-Line Test How Good is the Manufactured Product? Zero defects and fulfilled quality objectives are the absolute goals for every comonent manufactured. All comonents need to reach the highest quality standards to eliminate ossible comlaints and failures. One milestone is the test and assessment of all quality criteria within a secure robotic cell at the end of the roduction line. In the Battenberg robotic measuring cell all hatic, visual and acoustic comonents are tested at the seed level of the roduction line. The manufactured roduct can be either manually moved by the emloyee or automatically brought to the cell. All tests are documented and visualised in a rotocol. If a comonent fails the test, an error log is created, that comonent is removed from the roduction line or is blocked from use. A detailed error analysis of the comonent is generated enabling the error to be accurately identified and the cause removed. The results from robotic cells at all international sites can be made available to the central quality assurance. End of Line Tests and Assessment within a comlete Cell 26 27

15 Tests under Extreme Conditions The Simulation of Extreme Environments to Ensure Functionality Reliability and quality tests under extreme climatic conditions are an imortant art of roduct develoment. Battenberg robotic measuring can be used in a climate chamber to give transarent and reliable results about the reliability and quality of the functions even under extreme environmental conditions. Visualisation in the Climate Chamber The robot has its own air conditioning and is covered in an oaque, but im erishable cover to rotect it from the extreme temeratures in the climate chamber. This rotection renders it imossible to visually record the exact ositions of the robot. This makes lanning and carrying out the test sequences in the climate chamber more difficult. To over come this when rogramming the robot visualisation software RobViSu shows the hinge osition in 3D and allows movement simulation. Often many comonents have to be ositioned in the climate chamber and all have to be reachable during one test. RobViSu allows the user to incororate own test equiment and records into the visualisation (wave format). Comarable Results in Differing Conditions To be able to comare the results from room temerature and the climate chamber, the test sequences have to be identical. This is another advantage of the robots. The test sequences are exchangeable and via a secial calibration osition deviations can be eliminated, to ensure that the measurement osition of both tests is exactly the same. Battenberg Robotic measuring in Extreme Conditions 28 29

16 Further Alications Infotainment Particularly devices that inform and entertain consumers oerate on a high degree of user interaction. These devices demand otimal tests for functionality and user comfort. Our robots can be used for hatic tests as well as to recognise the visual, electronic and other roerties of radio/sound systems, navigations systems, board comuters and the com bination of these. Our end of line solution RobEOL is ideal for this. Communication Technology For most eole mobile communication devices are indisensable, both rivately and in business. Smart hones and tablets articularly require objective and recise measurements to ensure otimal quality. Robotic measuring offers a multitude of tests including in extreme climatic conditions in the climate chamber. Medical Technology Medical technology is subject to strict criteria concerning functional, hatical and visual quality. Our robotic measuring systems are used to rovide exact measurements of the oerating forces required and visual roerties on equiment (syringe ums, infusion ums and insulin alicators). Aviation and Aerosace Alongside tests to rove adherence to strict regulations concerning safety relevant comonents, other tests are becoming increasingly imortant in civil aviation. This includes the quality of elements that are used and oerated by assengers. Our robots rovide exact readings of oerating forces required and other roerties for the in-flight audio and video systems, assenger seats and overhead comartments. Otics The quality demands on otical equiment s adjustment and release mechanisms have become increasingly imortant. In both sorts and camera otics recise and simultaneously leasant tactile handling are obligatory. Our robotic measuring systems can offer to measure recisely all oerating forces and other roerties for menu buttons and dials, shutter release and lenses on (hotograhic) cameras and otical sights