APAS assistant Product scope
APAS assistant Table of contents Non-contact human-robot collaboration for the Smart Factory Robots have improved the working world in the past years in many ways. Above and beyond the protective fencing, they usually take over tasks which are dangerous or non-ergonomic for us humans, or if we cannot keep up with speed and precision, respectively. However, the fact is evident that humans and robots together form an unbeatable team. Robots leave their shelter and support their human counterparts in their direct work environment. Human-Robot-Collaboration combines the strengths of the robot with those of humans. Both together achieve more than each on its own does. This smart collaboration between both partners allows new forms of cooperation, allows optimization of existing process structures and leads to efficiency increase. In the long term, the overall productivity improves. APAS assistant mobile 2 Product scope 3-4 APAS assistant inline 5 Product scope 6-7 inline plus 8-9 APAS safety concept 10 Sensor skin monitoring 11 Automatic speed adjustment 12 Example of laser scanner 13 Periphery 14 End effectors 15 Pneumatic kit 16 Installation 17 Bottom & Backside Connector 18 1
01 APAS ASSISTANT MOBILE
APAS assistant mobile Product scope The APAS assistant mobile is a collaborative and movable robot for flexible applications in the Smart Factory. It can be used independently of the location and in different tasks. As an intelligent robot-based assistant, it is primarily aimed at end users who benefit from rapid and cost-efficient realization applications for new product variants, high robustness, easy handling and intuitive operation. GENERAL Dimensions (W x H x D) Height (robot outstreched) Height (transport position) Weight Power supply Interfaces 775 mm x 1.600 mm x 730 mm 1.900 mm 1.600 mm ca. 230 kg AC 230 V Ethernet, EtherCat, E/A non-isolated ROBOT Model Pick & Place cycle duration Reach TCP speed Repeatability Payload Safety Sensor reliable safety distance Fanuc LR Mate 200 id/7l application-specific 911 mm safe speed with sensor skin monitoring in close range 0.5m/s opt. high speed with remote range monitoring 2.3m/s +/- 0,03 mm max. 5,5 kg non-contact (capacitive) typical 50 mm 3
APAS assistant mobile Product scope Equipped with an integrated 3D image processing system and a standardized three-finger gripper, the APAS assistant mobile becomes a flexible and versatile automation solution. While the image processing system allows the robot to perceive the environment, detect parts to be gripped and to distinguish them from one another, the sensitive three-finger gripper of the APAS assistant makes it possible to use the force-form-fitting gripping of components and products. This makes it fast and easy cost-effective to new activities and is suitable for the takeover various tasks in production. THREE-FINGER-GRIPPER Principle Force control Position control Payload universal three-finger gripper adjustable in gripping direction 40-120 N 0-130 mm opening diameter max. 2 kg VISION Overview camera Positioning camera Field of view Integrated lighting 2D monochrom 3D, calibrated stereo cameras 250 mm x 250 mm 1x Infrared 4
02 APAS ASSISTANT INLINE
APAS assistant inline Product scope The APAS assistant inline is a protective fence-free, MRK-compatible robot for the Smart Factory. As an automation component, it is suitable for system set-up or system addition, and is therefore primarily aimed at system integrators and machine builders who want to expand their solution space without having to change existing structures. Equipped with a Fanuc LR Mate 200 id / 7L the programming in this standard version takes place via the standard Fanuc control. In doing so, existing know-how can be used, which accelerates the entry into human-robot collaboration and attractiveness. ROBOT Model Fanuc LR Mate 200 id/7l Pick & Place cycle duration application-specific Robot controller FANUC R30iB Safety module Reach TCP speed 911 mm safe speed with sensor skin monitoring in close range 0.5 m/s opt. high speed with remote range monitoring 2.3 m/s Weight ca. 35 kg Repeatability +/- 0,03 mm Customer interface Payload Safety sensor max. 5,5 kg Contact free (capacitive) Customer interface Reliable safety distance typical 50 mm SPS (Siemens, Beckhoff,...) Safety SPS Application 6
APAS assistant inline Product scope Eqquiped with KR Agilus, KR10 R1100-2, this version of the APAS assistant inline is primarily aimed at system integrators and machine builders who want to expand their solution space by intelligent automation components without having to change existing structures. Thanks to the familiar KUKA programming and the teach pendant KUKA smartpad, handling tasks can be programmed directly and without additional training, which accelerates the entry into human-robot collaboration and attractiveness. Especially the high load capacity and the long reach make this version of the APAS assistant inline a valuable production assistant for monotonous or ergonomically unfavorable tasks. ROBOT Model KUKA Agilus, KR 10 R1100-2 Pick & Place cycle duration application-specific Reach 1.100 mm Robot controller (e. g. KUKA KR C4 smallsize-2) Safety module TCP speed Weight safe speed with sensor skin monitoring in close range 0.5 m/s opt. high speed with remote range monitoring 2.3 m/s ca. 60 kg Repeatability +/- 0,01 mm Payload max. 10 kg Customer interface Safety sensor Reliable safety distance Contact free (capacitive) typical 50 mm Customer interface SPS Safety SPS Application 7
APAS assistant inline plus Product scope In this inline plus version, the robot is delivered with the Bosch-own control platform. This is a comprehensive control system with a comprehensive functional library as well as numerous apps and software services, which use the latest technologies. All processes can be bundled in a modern, object-oriented development environment and easily be implemented in a structured manner. All functions are tested, the interfaces implemented in the shortest possible time, and connected systems or machines are immediately ready for use. The machine is operated via the Bosch control panel (mpad). ROBOT Model Fanuc LR Mate 200 id/7l Pick & Place cycle duration application-specific Reach 911 mm Control cabinet Safety module TCP speed safe speed with sensor skin monitoring in close range 0.5m/s opt. high speed with remote range monitoring 2.3m/s Weight ca. 35kg Repeatability +/- 0,03 mm Payload max. 5,5 kg Safety sensor Contact free (capacitive) Reliable safety distance typical 50 mm Safety PLC Robot controller FANUC R30iB Control plus automation system HMI Application 8
APAS assistant inline plus Product scope SWITCH CABINET Dimensions (W x H x D) 550 mm x 600 mm x 600 mm Weight ca. 120 kg Ambient temperature max. 32 C Length of the connecting cable to the robot arm ca. 3 m Length of the connecting cable to the touch pad ca. 4,5 m Electric feeding 1 / N / PE AC 230 V 50 Hz Control voltage DC 24 V Full load / short-circuit current 7,4 A / 10 ka Min. supply line 3 x 2,5 mm² / 1 x 10 mm² PE Control cabinet Safety module Max. fuse 16 A gg Protection class IP54 Recommended wire size 16 mm² Safety PLC Robot controller FANUC R30iB Control plus automation system HMI Application 9
03 SAFETY CONCEPT
Sensor skin monitoring (short range) Detection in short range: TCP speed = 0 m/s Collaborating robots (Cobots) work hand in hand with their human colleagues. Therefore, the reliable recognition of the employees and the avoidance of a collision at the MRK are the first priority. Unlike most robots on the market, our robotic solutions stop automatically and completely contact-frees in case a human comes too close. This is due to our unique capacitive sensor skin, which surrounds the robot arm and monitors the close range around the sensor skin for the presence and absence of people. Even before a collision occurs, the robot automatically detects its human colleagues at a safe path speed of 0.5 m/s and stops with a safe switching distance of typical 50 mm. Only when the human being has left this close-up area, the APAS assistant resumes his work immediately from where he previously has stopped. Our sensor skin is a key technology for human-robot collaboration. Therefore, we guarantee the safe detection of employees at performance level d, category 3 (two-channel safety). Certification short range ca. 50 mm Our systems are certified by the German Berufsgenossenschaft and can work directly and safely alongside people without the need for safety guard. 11
fig. 1: As long as the human being is outside the defined long range, the robot operates at an 4,6-increased speed of 2,3 m/s. Automatic speed adjustment (long range) Workspace of robot (930 mm) Adjustable long range Via the APAS assistant interface for automatic speed adjustment, the so-called far range of the robot can be monitored in addition to the close range. The interface automatically regulates the speed and adapts it flexibly to the environment. As long as no human is in the work area of the robot, the robot operates at a speed of 2.3 m/s. If a human misses the distance, the APAS assistant automatically switches to a safe speed of 0.5 m/s. If the robot arm is less than 50 mm, the sensor arm monitors the sensor and stops the system. In concrete terms, this means higher productivity without reducing work safety. Means for remote area monitoring Various means are available for remote area monitoring, e.g. laser scanners, foot mats, light barriers, etc. We would be glad to advise you on the selection. fig. 2: Man enters the monitored area and is recognized, robot automatically switches to a safe speed of 0,5 m/s. Workspace of robot (930 mm) Detection in long range short range long range 12
Remote area monitoring: example of laser scanner Coverage area laser scanner 2 Regulates the working speed of the APAS assistant depending on the presence or absence of people. The remote field monitoring allows higher process speeds and a reduction of cycle times by 4.6 times the robot speed. The robot stops contactless as soon as the sensor skin detects an approach. The far range can be set up to a minimum distance of 1.2 m to the working range. EXPAMPLE LASER SCANNER Model Protective field range Standard safe area laser scanner e.g. SICK S-30B-3011BA 3 m Scan angle 270 Coverage area laser scanner 1 Example: Use of two laser scanners on an APAS assistant mobile; possible cover 360 (view from above) scanner 13
04 PERIPHERY
End effectors Gripper systems Extend the functions of the robots with our additional offer. With our end effectors, we offer you individual solutions for your tasks. They enable the high-precision gripping of different parts and also allow the handling of different tools. Customer-specific grippers can also be easily adapted. We would be pleased to advise you on the selection. Three-finger-gripper Three-finger-gripper with integrated camera system Safety element for attachment of own grippers Safety element for attachment of own grippers 15
Pneumatic Kit With the components of the pneumatic kit, the pneumatic lines are detachably attached to the piping of the sensor skin using clips. Depending on the diameter of the pneumatic line, the following connection possibilities can be implemented: CONNECTION OPTIONS Max. 4 lines (with hose spout) Max. 2 lines (with hose spout) max. 1 line Ø 4 mm Ø 6 mm Ø 8 mm Available mounting clips 3 x Ø 4 mm 4 x Ø 4 mm 2 x Ø 6 mm Cable routing via small clip or via hose nozzle in large clip 16
05 INSTALLATION
Backside Connector Standard version available for APAS assistant mobile and inline. Bottom Connector Optional available for APAS assistant inline. 18
Robert Bosch Manufacturing Solutions GmbH Bosch Connected Industry Postfach 30 02 20 70442 Stuttgart Deutschland 0711 811-0 APAS@de.bosch.com bosch.com bosch-apas.com Robert Bosch Manufacturing Solutions GmbH June 2018 Printed in Germany Bosch and the device mark are registered trademarks of Robert Bosch GmbH, Germany. This document is a schematic representation and not an operating manual. Occasional differences of the images to the operating manual are possible. Please refer to the operating manual with regard to the proper use of the system.