ReApp

Brief description

ReApp defines standardised interfaces for integrating hardware and software from different manufacturers for robot systems. Together with a catalogue of reusable smart services (robot apps) and a model-driven development environment, robot systems are to be adapted faster and at less cost to the specific requirements of small and medium-sized enterprises (SMEs). In this way, SMEs are to be able to make flexible and economic use of robot systems production, assembly and logistics.

The challenge

Robot-supported automation systems are becoming increasingly complex. The time and money needed to program these systems, their integration, maintenance and adaptation are much higher than the actual cost of the components. This means that the use of robot-based automation systems in small numbers, as is often the case at SMEs, is often not economically feasible. Although software architectures that distinguish between programming individual components and programming the overall system already exist in research and consumer-based service robotics, these software architectures do not meet with the high quality and reliability standards required by industry. There is also a large number of components that cover almost the entire range of (robotic) functionalities, algorithms and control models. However, these are usually tailored to a specific application and hardware configuration. This is all set to change. The open-source ROS Industrial project is currently working on adapting the open Robot Operating System (ROS) software architecture to facilitate industrial demands while at the same time establishing standards for interfaces and the quality of ROS components.

Aim

The ReApp project takes up the concepts of the ROS Industrial project in order to define standardised interfaces and create software and hardware libraries that permit real plug-and-play for the most varied components. Together with a catalogue of reusable smart services and a model-driven development environment, robot systems are to be adapted faster and at less expense to specific requirements and especially those of small and medium-sized enterprises (SMEs).

Technologies

An innovative, smart programming assistant is an integral part of the development environment. Without the need for special expertise, the assistant enables the user to set up his robot system for his application by identifying the hardware and software components in the library that are needed for the application and then automatically configuring the application once connected to the integration platform (another part of the development environment). Cloud-based simulation environments will also be provided for automated testing of components and applications and in order to meet high quality and reliability demands. The simulation tool ensures that virtual robot cells, for instance, or even entire production plants, can be tested and optimised before they are actually installed. ReApp will hence make it possible, especially for small and medium-sized enterprises, to boost their efficiency with flexible and reliable automation solutions. At the same time, the market for system integrators as well as robot and component manufacturers is growing.

Use case

The ReApp concepts will be tested in three scenarios: two in the automotive sector and one in the electronics industry. In light of the growing number of vehicle models, automotive suppliers are finding it increasingly difficult to maintain the quality and delivery speed demanded with strong fluctuations in quantity. Workpieces for picking and assembly, as well as packaging of finished parts, are often carried out manually because these operations are (still) difficult to automate. ReApp will develop a demonstration system for this case where a robot can be easily and quickly fitted with different grabbing tools and sensors, depending on the product. The robot will primarily perform monotonous sub-tasks, such as counting, weighing and arranging different parts. Plug-and-play capability enables fast retooling for new orders and the programming assistant means simple adaptation of robot behaviour directly by the worker at the factory.

Flexibility and simple reconfiguration are becoming increasingly important for car manufacturers too. The technologies developed by ReApp will be demonstrated on the basis of door pre-assembly, gluing, optical quality inspection and bolting jobs which up to now could only be automated to a limited degree at a reasonable cost. Tailored solutions are also in demand in the niche market of circuit board assembly. The production of very small quantities is currently carried out by SMEs for the most part for whom today's automation solutions are not commercially viable due to high hardware, software and integration costs. 

Partners: Fraunhofer IPA (consortium leader), BMW AG, Dresden Elektronik Ingenieurtechnik GmbH, Fischer IMF GmbH & Co. KG, Fluid Operations AG, fortiss GmbH, FZI Forschungszentrum Informatik, InSystems Automation GmbH, ISG Industrielle Steuerungstechnik GmbH, Karlsruher Institut für Technologie (KIT) – Institut für Prozessrechentechnik, Automation und Robotik, Ruhrbotics GmbH, SICK AG