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The paper aims to deliver an approach of how lightweight robot systems can be used to automate manual processes for higher efficiency, increased process capability and enhanced ergonomics. To show how these systems can be utilized in practice, a new collaborative testing system for an automated water leak test was designed using an image processing system utilized by the robot.

The “water leak test” in an automotive final assembly line is often a significant cost factor due to its labour-intensive nature. This is particularly the case for premium car manufacturers as each vehicle is watered and manually inspected for leakage. This paper delivers an approach that optimizes the efficiency and capability of the test process by using a new automated in-line inspection system whereby thermographic images are taken by a lightweight robot system and then processed to locate the leak. Such optimization allows the collaboration of robots and manual labour which, in turn, enhances the capability of the process station.

This paper examines the development of novel applications for lightweight robotic systems and provides a suitable process whereby the systems are optimized in technical, ergonomic and safety-related aspects.

A new automated testing process in combination with a processing algorithm was developed.

To optimize and validate the system, it was set up in a true to reality model factory and brought to a prototypical status. Several original equipment manufacturers showed great interest in implementing the system in their assembly line.

The direct human–robot collaboration allows humans and robots to share the same workspace without strict separation measures which is a great advantage compared with traditional industrial robots. The workers benefit from a more ergonomic workflow and are relieved from unpleasant, repetitive and burdensome tasks.

A lightweight robotic system was implemented in a continuous assembly line as a new area of application for these systems. The automated water leak test gives a practical example of how to enrich the assembly and commissioning lines, which are currently dominated by manual labour, with new technologies. This is necessary to reach a higher efficiency and process capability while maintaining a higher flexibility potential than fully automated systems.

This study aims to deliver an approach of how lightweight robot systems can be used to automate manual processes for higher efficiency, increased process capability and enhanced ergonomics. As a use case, a new collaborative testing system for an automated water leak test was designed using an image processing system utilized by the robot.

The “water leak test” in an automotive final assembly line is often a significant cost factor due to its labour-intensive nature. This is particularly the case for premium car manufacturers as each vehicle is watered and manually inspected for leakage. This paper delivers an approach that optimizes the efficiency and capability of the test process by using a new automated in-line inspection system whereby thermographic images are taken by a lightweight robot system and then processed to locate the leak. Such optimization allows the collaboration of robots and manual labour, which in turn enhances the capability of the process station.

This paper examines the development of a new application for lightweight robotic systems and provides a suitable process whereby the system was optimized regarding technical, ergonomic and safety-related aspects.

A new automated testing process in combination with a processing algorithm was developed. A modular system suitable for the integration of human–robot collaboration into the assembly line is presented as well.

To optimize and validate the system, it was set up in a true to reality model factory and brought to a prototypical status. Several original equipment manufacturers showed great interest in the system. Feasibility studies for a practical implementation are running at the moment.

The direct human–robot collaboration allows humans and robots to share the same workspace without strict separation measures, which is a great advantage compared with traditional industrial robots. The workers benefit from a more ergonomic workflow and are relieved from unpleasant, repetitive and burdensome tasks.

A lightweight robotic system was implemented in a continuous assembly line as a new area of application for these systems. The automated water leak test gives a practical example of how to enrich the assembly and commissioning lines, which are currently dominated by manual labour, with new technologies. This is necessary to reach a higher efficiency and process capability while maintaining a higher flexibility potential than fully automated systems.

This paper aims to provide a European perspective on the collaborative robot business and to consider the factors governing future market development.

Following an introduction, this first describes the collaborative robots launched recently by European manufacturers and their applications. It then discusses major European research activities and finally considers the factors stimulating the market.

This article shows that collaborative robots are being commercialised by the major European robot manufacturers as well as by several smaller specialists. Although most have low payload capacities they are inexpensive and offer a number of operational benefits, making them well suited to a range of existing and emerging applications. Europe has a strong research base and several EU-funded programmes aim to stimulate collaborative robot development and use. Rapid market development is anticipated, driven in the main by applications in electronic product manufacture and assembly; new applications in the automotive industry; uses by small to medium-sized manufacturers; and companies seeking robots to support agile production methods.

This paper provides a timely review of the rapidly developing European collaborative robot industry.

A review of safety‐technology, applicable safety‐related standards and the impact on the use of robots in industrial environments.

Technological developments are presented in safety‐related control technology, including programmable safety controllers, configurable safety controllers, safety networking and robotic safety in human environments. The technological developments are related to new and emerging safety standards.

The development of safety‐related technology and new international and European standards have fundamentally changed the way in which safety is now being engineered in industry. The introduction of new standards and revision of others have allowed safety‐related systems to utilise “state of the art” electronic, programmable, and network based technologies. New international standards are likely to include collaborative working with humans in the robotic workspace. This is set to change how robots are utilised in manufacturing environments.

The review of applicable standards and technical developments: with examples from current research and new technologies, demonstrating engineering solutions that embody the principles of the new standards.

Automotive robotics R&D and application developments concentrate on methods, tools, and procedures, that enable industry leaders to reduce cost, whilst simultaneously increase quality and productivity. Furthermore, in particular in the USA, manufacturing and assembly system, plant security, safety and reliability, and real‐time performance evaluation and control became key too. The focus is appropriate, since downtime in automotive robotics can mount to typically US$5‐10K, and even to $20K loss per production minute. Introduces some key trends and methods, as well as some implementation examples, showing quality solutions.

Describes an automated laser cutting cell used in the automotive industry. The cell has the benefits of fast throughput because of high cutting speeds, adaptability of height sensing, safety of crash protection and flexibility of part modifications via robot path and program modifications. Outlines the feature of the cell which consists of two Nd:YAG lasers with fibre‐optic delivery and two five‐axis robots with trepanning heads, and describes their performance characteristics. Concludes with a summary of the advantages of using a laser cutting cell.

Collaborative robotics and autonomous driving are fairly new disciplines, still with a long way to go to achieve goals, set by the research community, manufacturers and users. For technologies like collaborative robotics and autonomous driving, which focus on closing the gap between humans and machines, the physical, psychological and emotional needs of human individuals becoming increasingly important in order to ensure effective and safe human–machine interaction. The authors' goal was to conceptualize ways to combine experience from both fields and transfer artificial intelligence knowledge from one to another. By identifying transferable meta-knowledge, the authors will increase quality of artificial intelligence applications and raise safety and contextual awareness for users and environment in both fields.

First, the authors presented autonomous driving and collaborative robotics and autonomous driving and collaborative robotics' connection to artificial intelligence. The authors continued with advantages and challenges of both fields and identified potential topics for transferrable practices. Topics were divided into three time slots according to expected research timeline.

The identified research opportunities seem manageable in the presented timeline. The authors' expectation was that autonomous driving and collaborative robotics will start moving closer in the following years and even merging in some areas like driverless and humanless transport and logistics.

The authors' findings confirm the latest trends in autonomous driving and collaborative robotics and expand them into new research and collaboration opportunities for the next few years. The authors' research proposal focuses on those that should have the most positive impact to safety, complement, optimize and evolve human capabilities and increase productivity in line with social expectations. Transferring meta-knowledge between fields will increase progress and, in some cases, cut some shortcuts in achieving the aforementioned goals.

The automotive industry has been the principal driver in the development of robotics; however, as car design becomes more sophisticated, demands on robot makers will continue undiminished.

Outlines the background of robotized waterjet cutting and its advantages over traditional punching and manual cutting methods. Discusses the development of the modular cutting box which can be adapted to the customer’s requirements covering the water pressure, the size and speed of the jet, the reduction of sound emissions and a safety zone to protect personnel. Examines the programming of the robot arm and the creation of cutting programs. Concludes that waterjet cutting has enormous potential in the automotive industry.