Feasibility Study on the

Introduction of

Automation in the

Assembly Process

Degree Project

Author: Osama Ziada, Konstantina Tzivleri

Supervisor: Gunnar Bolmsjö, Jetro Pocorni

Examiner: Martin Kroon

Supervisor, Company: Albin Nilsson, Volvo

Construction Equipment AB

Date: 23-05-2021

Department of Mechanical Engineering

Faculty of Technology

Abstract

The assembly process in Volvo Construction Equipment, in Braås, is fully

hand-operated. The aim of this Master thesis project is to develop and evaluate

different concepts of how the automation level could be increased. This study

aims to find reliable technology/automation solutions that could be used in one

or more operations in the assembly process and identify the benefits for Volvo

Construction Equipment. The work will end up in concepts and

recommendations on what areas of the assembly process would be most

beneficial to automate first.

Conversations, observations, and interviews took place in the assembly

department to help in the selection of the station in which automation can be

most easily introduced. Automated procedures at this station will have

advantages since they will include robots. The robot can take over some of the

assembly procedures, while the worker can be occupied with others. From an

ergonomic perspective, these procedures will be improved; thus, the efficiency

and the quality will be better, and this will be achieved because the human will

focus on procedures where creativity and human hands are needed, and the

robot will take over the most un-ergonomic and difficult operations.

Keywords

Automation, Assembly, Human-Robot Collaboration, HRC, HIRC,

Simulation, RobotStudio, Sensors, Safety

Acknowledgments

We would like to thank our supervisors in Volvo CE, Albin Nilsson and Sara

Torså, that gave us the opportunity to be part of this research study. We would

also like to thank our supervisors at Linnaeus University, Gunnar Bolmsjö and

Jetro Kenneth Pocorni, for all the guidance and support during this research

project.

Konstantina Tzivleri, Osama Ziada, Växjö, June 2021

Contents 1 Introduction ...................................................................................................... 1

1.1 Problem Description/Background .............................................................. 1

1.2 Purpose and Objectives .............................................................................. 2

1.2.1 Research Questions ............................................................................ 3

1.3 Limitations .................................................................................................. 3

2 Research Method .............................................................................................. 4

2.1 Literature Study .......................................................................................... 5

2.2 Study Case .................................................................................................. 5

2.2.1 Validity and reliability of a study case ............................................... 5

2.2.2 Interviews, Observations, Data Collection ......................................... 6

2.3 Robot Simulation ........................................................................................ 7

2.3.1 RobotStudio ........................................................................................ 7

3 Theory ............................................................................................................... 9

3.1 Robot Applications ..................................................................................... 9

3.2 Human-Robot Interaction ........................................................................ 10

3.3 Human-Industrial Robot Collaboration ................................................... 13

3.4 Safety Sensors ........................................................................................... 14

4 Methodological Approach ............................................................................. 16

4.1 Analysis .................................................................................................... 16

4.1.1 SWOT Analysis ................................................................................ 16

4.1.2 Current Assembly Process (Manual) ................................................ 17

4.1.3 Automation Solution ........................................................................ 17

4.2 Study Case Selection Method ................................................................... 18

4.2.1 Funnel ............................................................................................... 18

4.2.2 Concept Classification Tree ............................................................. 18

4.3 Morphological Chart................................................................................ 20

4.4 Weight Scored Matrix............................................................................... 21

4.5 Data collection ......................................................................................... 22

4.5.1 Interviews ......................................................................................... 22

4.5.2 Observations and Document Analysis ............................................. 23

5 Results and Discussion ................................................................................... 24

5.1 Selection of Assembly Station ................................................................... 24

5.2 Selection of the Study Case ...................................................................... 26

5.2.1 Not selected assembly stations ......................................................... 26

5.2.2 Selected assembly station ................................................................. 27

5.3 Study Case ................................................................................................ 28

5.3.1 Description of the study case............................................................ 28

5.4 Robot Selection ......................................................................................... 31

5.4.1 Gripper and Clamping ...................................................................... 32

5.4.2 Safety Sensors .................................................................................. 32

5.5 Functions of the robot station .................................................................. 33

5.5.1 Benefits of this Automated Application ........................................... 39

6 Conclusions ..................................................................................................... 40

7 Future Work and Recommendations ........................................................... 42

7.1 Recommendations for future research ..................................................... 42

7.2 Recommendations for Volvo ..................................................................... 42

7.2.1 Simulation Software ......................................................................... 42

7.2.2 Tools ................................................................................................. 42

7.2.3 Change in the design ........................................................................ 43

8 References ......................................................................................................... 1

Appendix 1 ................................................................................................................ 1

Appendix 2 ................................................................................................................ 3

Appendix 3 ................................................................................................................ 4

Figures Figure 1: Volvo Articulated Hauler [2] ............................................................... 2

Figure 2: Human-Robot Interaction [16] [25] [26] ........................................... 10

Figure 3: Coexistence operation [50] ................................................................. 11

Figure 4: Synchronized operation [50] .............................................................. 11

Figure 5: Co-operated operation [50] ................................................................ 12

Figure 6: Collaborative operation [50] .............................................................. 12

Figure 7: Human-Robot Collaboration (YUMI) [16] ........................................ 13

Figure 8: Industrial Robots from ABB [16] ...................................................... 14

Figure 9: Safety sensors from Sick [39] ............................................................. 15

Figure 10: Methodology followed ..................................................................... 16

Figure 11: Assembly Procedure ........................................................................ 24

Figure 12: Rear Frame ..................................................................................... 26

Figure 13: Axles ............................................................................................... 26

Figure 14: Assembled Component (Rear Frame + Axles) .................................. 26

Figure 15: Fender ............................................................................................ 27

Figure 16: Air Block (Selected Study Case) ....................................................... 27

Figure 17: Air Blocks (Not Selected Study Case) .............................................. 28

Figure 18: Current state of the Air Block .......................................................... 29

Figure 19: Future State of the Air Block .......................................................... 31

Figure 20: Industrial ABB robot IRB 4600_45 [47] .......................................... 32

Figure 21: Safety laser scanner microScan3 Pro-PROFINET, Type: MICS3-

CCAZ90PZ1P01 ............................................................................................... 32

Figure 22: Yellow and red area ......................................................................... 33

Figure 23: Arrange the fittings (Function a) ..................................................... 35

Figure 24: Fixing the main block on the rotation table (Function b) ................. 35

Figure 25: Push the button (Function b) .......................................................... 35

Figure 26: After rotation (Function c) .............................................................. 36

Figure 27: Fix the nipples and the bolt of 16mm (Function d) .......................... 36

Figure 28: Fixing the nipple of 22mm (Function e) ........................................... 36

Figure 29: Storing table (Function g) ............................................................... 36

Figure 30: Assembled Air block (Function g) .................................................... 36

Figure 31: Robot station with fences (Side view) .............................................. 37

Figure 32: Robot station with fences (Top view) .............................................. 37

Figure 33: Robot station with fences only in the front side (Side view) ............. 38

Figure 34: Robot station with fences only in the front side (Top view) .............. 38

Tables Table 1: Features of different human-robot relationships [29] .......................... 13

Table 2: SWOT Analysis for the current situation ............................................ 17

Table 3: SWOT Analysis for automation solution ............................................. 17

Table 4: Morphological Chart ........................................................................... 20

Table 5: Weight Scored Matrix ........................................................................ 22

Table 6: Interview details ................................................................................ 23

Table 7: Details of each component of the Air Block (Current State) ................ 29

Table 8: Functions of the robot station ............................................................ 34

Graphs

Graph 1: Different steps of the research ............................................................. 4

Graph 2: Funnel Concept Selection .................................................................. 18

Graph 3: Concept Classification Tree (Phase one) ............................................. 19

Graph 4: Concept Classification Tree (Phase two) ............................................. 19

List of Abbreviations

HRC: Human-Robot Collaboration

HIRC: Human-Industrial Robot Collaboration

ERM: Electric Rotary Module

SDK: System Development Kit

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1 Introduction

This chapter will present the problem that this project is examining. It will give

a background of this thesis and the purpose of it. The goals, the research

questions and the limitations are also going to be stated.

1.1 Problem Description/Background In Volvo Construction Equipment AB, the assembly area is divided into two

processes: the main-assembly and sub-assembly processes. There are limited

automated procedures in the assembly section, so both the main-assembly and

sub-assembly processes depend entirely on manpower. This is common in

assembly lines since the assembly is one of the most demanding and intense

manufacturing processes and it is difficult to automate with robots. [1]

The limited automation level in these assembly processes, besides the

advantage that it provides, which is the occupation for many workers, also

causes a variety of challenges. The first challenge is related to productivity,

i.e., the delay of the assembly process. In some of the sub-assembly and main-

assembly stations, workers finish faster than in other stations; this is because

some assembly procedures need less time to complete than others, and that

may cause a delay for the whole assembly procedure. The second type of

challenge is related to ergonomics. In the assembly area, the workers often

perform procedures in unsuitable and uncomfortable positions. These kinds of

procedures can cause pain problems or even injuries, either to their wrists or

their backs. Some of these injuries can lead to surgeries. This is one reason

that this project will introduce automated solutions, including robots, that can

help in the assembly procedure.

Besides all these issues, there are procedures in the assembly process where

the human interaction is needed. Some of these procedures can be places that

need the flexibility of the human hand to reach or procedures that include

connecting wires and hoses, which are complicated. These kinds of procedures

are hard to achieve with a robot itself.

This project will examine the assembly process of an Articulated Hauler at

Volvo CE, as we can see in Figure 1. It will conclude, where is the best place

to install automated procedures that will include robots, and what kind of

reliable technology/automation solutions can be found in order to achieve

collaboration between worker and robot, in a way that it will be valuable,

functional and safe.

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Figure 1: Volvo Articulated Hauler [2]

These automation solutions will be beneficial for the company and the workers

since they will work together with the robots and assemble everything faster

and safer.

In this project, simulations were made to see how everything can be

implemented and how the station could look like. These simulations were

made with the help of ABB RobotStudio software.

1.2 Purpose and Objectives The purpose of this Master thesis is to develop and evaluate different concepts

of how the automation level, for the assembly process, at Volvo CE could be

increased in order to reduce the assembly time and the workers' injuries.

Finding solutions to increase the automation and the efficiency of the assembly

area and the workers' ergonomics, is the aim of this thesis.

The collaborative applications, and specifically the robots that will be

introduced, as possible solutions, in this project, could be completely

automated, or they can also work closely with the workers due to the installed

sensors. To achieve the collaboration between robot and worker, the robot’s

processes and speed can be slowed down when the worker comes closer to it,

with the help of sensors. As stated before, some procedures could be done

entirely by robots, and in this case, the extra workers can be placed in a

different assembly station that needs more time to be assembled. In this way,

the time of the assembly procedure can be reduced. The worker can also

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collaborate with the robot if needed; in this case, the worker will be in their

position helping with the procedure.

The goal is not to vanquish the entire manual work done by humans; this

project is trying to accomplish the collaboration between worker and robot so

the assembly process will be faster and safer.

This project will have as a result, the suggestion of introducing automation

inside the assembly section, and it will increase the interest in using

automation in the future. Additionally, it will show what kind of benefits this

technology could have for the company and how they can derivate these

applications for future use.

1.2.1 Research Questions

To aid the fulfillment of the purpose, research questions and sub-questions

were created:

1. What kind of applications would be suitable to introduce in the

assembly section?

a. In which assembly station is better to present these

applications?

b. Will this be functional for the company and the workers?

c. What are the possible derivatives that could be applied in

these applications for future demands?

2. What benefits these applications will have for the company?

3. Will these applications be applicable for possible changes in the

design of the product?

1.3 Limitations The project will not suggest a new layout of the assembly station. The station

inside the simulation is a concept of how the robot will appear and work with

the worker.

The research will be done with the already existing design of the part.

Industrial and collaborative robots will be considered as a solution for this

assembly process.

Safety sensors will be recommended to make the industrial robot able to

interact with the workers safely.

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2 Research Method

Here, the literature study is going to be described. Also, the research steps

that this project is based on will be introduced as well.

In Graph 1, all the different steps followed to complete this project are shown.

To better understand what this project is dealing with, studies that include

papers and books about robotics and robotic safety aspects, safety sensors,

applications of Human-Robot Collaboration (HRC) and Human Industrial-

Robot Collaboration (HIRC), and manuals for the simulation software used,

took place. Additional steps had to be followed in order to narrow down to the

study case of this project.

Graph 1: Different steps of the research

Research

Literature Study

RoboticsHRC

Application

HIRC Application

Robotic Safety Aspects

Safety Sensors Cells

Study Case

Interviews with Workers

Interviews with

Engineers

ObservationsData

Collection

Ergonomic Evaluation

Contact with Companies

Simulation

RobotStudioHuman

Modeling

Robotics

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2.1 Literature Study A literature study had to be made to help gather all the knowledge and all the

information that will be used to reach this project’s goals and answer all the

research questions and sub-questions. Literature study helped to understand

better every theory that this project is dealing with and how to integrate

everything for the best result [3].

For articles and papers that have to do with technology it was important to

search for recent published ones. Nevertheless, some articles that have been

used as references in recent researches have been taken into consideration as

well. This kind of articles can include studies for e.g., the study case selection

[4].

2.2 Study Case An investigation for selecting a study case was made. Since there is no

automation and no robots in the assembly section, it was valuable to choose a

station that would be easy to introduce automation solutions and robots.

For selecting the study case of this project, it was critical to narrow down all

the different options. All the advantages and disadvantages of every possible

study case were written down and discussed to conclude with the best one. The

benefits of the study case should be that it is possible to analyze it in a good

way and will not be that complicated to simulate it. There will be

disadvantages as well, including that the simulations' results could not be

applied well in the real world [5]. Either way, a reasonable estimation of how

everything is going to work will be done, and ways will be found of how this

technology can be applied.

2.2.1 Validity and reliability of a study case

Validity of a study case is about describing this study case and resulting in

how valid the result can be [6]. Validity is also about explaining how the

methodology that has been followed is answering the research questions, and

that follows the purpose of the project.

There are two types of validity, internal and external.

Internal validity is about how good the explanations of the findings are and

about the reliability of the conclusions. It is good when a causal relationship

between the findings has been made by the researcher. To make sure that this

relationship is real the researcher should have a good study planning, good

data collection and data analysis [7].

External validity is about when a finding and the causal relationship are

general and can be used in additional situations than in the study case. If only

one study case has been used, it is essential e.g., for a company to discuss with

the researcher why they think that their results can be used by others [7].

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The reliability in a case study describes how big the chances are that someone

else, using the same method or the same research, found the same results. It is

also about the good documentation of the methods and the processes that have

been followed. To increase the reliability of a study case it is good for multiple

sources to be used. Another way would be to do many interviews and

observations on different days and times [7].

For the study case done at Volvo CE to be more valid and reliable, several

methods have been used and will be described in the subsections below [6]

[7].

2.2.2 Interviews, Observations, Data Collection

2.2.2.1 Interviews

Interviews help in gathering good data regarding a specific topic and give a

straightforward view of what the researcher is dealing with. Interviews are

mostly being made face to face, through telephone and online calls if the

distance is an obstacle [8].

For an unstructured interview, it is common to generate a single question with

the interviewer and continue the interview with questions that will be

generated after the first discussion [8].

For this project´s case, interviews took place with the workers to better

understand their needs and problems. These interviews aimed to figure out

where the workers have more difficulty to assemble a part and which kind of

difficulties they are facing. These interviews took place inside the assembly

area, and they were unstructured, and came out as discussions with the

workers.

Additional interviews with the engineers of the department and the managers

of each station were made to understand better how everything is working and

whom to address for further questions and information if needed.

2.2.2.2 Observations

Observations were performed to understand the whole assembly procedure.

Understanding how everything is being assembled will help to the conclusion

of the study case and the analysis of the entire process.

Observations are a way to collect information without spending too much time,

as it would happen if we interviewed every single worker in the assembly area.

They can help understand better, and in more detail, the tasks and the

procedures that are impossible to understand only with an explanation of the

worker [9]. The data that can be collected from observations can help to learn

a lot of information [10]. These observations give an understanding of the

tasks, and they are helping to narrow down the different options.

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2.2.2.3 Data Collection

To have accurate results and truthful collections a data collection is required.

Data collection is about gathering all the information that are needed to answer

the research questions and estimate the results and is a research stage that is

more than important for a research. The reason for collecting these data is to

gather good documents and translate them into convincing and trustworthy

resources to answer the questions [11].

Data collection will start by researching what kind of data a researcher wants

to obtain [11]. For this project data collection can help collect the timesheets

and some documents about the assembly parts, for a better understanding of

the time that it takes for each station to finish and to look at the steps of the

assembly processes. These data can also be used to analyze un-ergonomic

procedures that exist in the assembly area.

Every work task in the assembly area takes some time to be assembled.

Frequency study is a helpful tool to understand the distribution of a work task

without using a stopwatch to monitor each process. For this project, a

frequency study was done to determine the time that needs for some work tasks

to be assembled and how often they are being assembled [4].

Document Analysis

To understand better the assembly processes, document analysis was an

excellent tool to gather all the sketches and data with not that much effort [12].

Collecting and examining these industry documents is a crucial step that must

be followed in a research. Using all these existing documents by the company

can make the research easier [13].

Ergonomic Evaluation

Ergonomics is one of the factors that a company must consider for the worker

to be safe. It is a study about the relationship between the worker and the

environment that they are working in. It is crucial for a worker to understand

and realize the ergonomic risks around the area that they are working to

because the consequences can be fatal like death and disability. The absence

of awareness by the workers about the existence of these potential accidents

on their workspace can lead to threaten their safety [14, 15].

2.3 Robot Simulation

2.3.1 RobotStudio

In order to see if the application will work or not, a simulation has to be made.

RobotStudio is an offline software that anyone can use for programming

robots, modeling and simulating, from their own computer. The robot can be

programmed without stopping the production e.g., in a factory. Anyone can

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use RobotStudio as a tool to simulate and understand how the robot and all the

processes will be run after applying everything to the actual robot in the

production [16].

RobotStudio allows the user to add off-line controllers, also called as Virtual

Controllers. Virtual Controllers allow programming in offline mode [16].

This software makes the simulation realistic since it runs a copy of the actual

software that is installed on the robot in the production. Another application

that someone can use in RobotStudio is that it allows the user to import files

of the actual geometries that they are dealing with; in this way, they can have

accurate simulations [16].

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3 Theory

In this chapter all the information about the investigation that has been done

for all the areas of this study will be presented.

3.1 Robot Applications Robot applications can vary, but the focused areas that can be categorize these

applications are:

▪ for assembly operations

▪ for process operations

▪ for material handling operations

In this project, the assembly operations are going to be presented [17].

Every operation that is dealing with assembling parts needs different robots

that can grip different components that need physical connection between

them, and collect them in a specific area or a tray so they can be in correct

positions for another robot or worker to work with them [18].

Assembly procedures with robots needs physical contact between the robot

and the environment that it is working in [19]. Assembly procedures can be

characterized as different kind of parts/components, that are connected all

together to create a system or a bigger part/component that is more

complicated. In total 80% of the entire cost of product manufacturing, is

coming from the assembly process, this is why it allows it to have a

competitive advantage in this field [20].

A new way of programming robot is human guidance. Between every

command that a robot can be programmed to do, there are applications that

allowed a robot to learn from the operator. The robot observes and start doing

operations and that leads to start learning all the necessary movements that

needed in a specific operation. The robot also monitors the human´s motions

and muscle activities in order to take over the demanding aspects of the task

[21].

In order to perform well, industrial robots usually require a very structured and

predictable working environment; clear programming is also something that is

needed. The cost and the time needed are a big obstacle for an engineer to

intermediate the tasks to a robot; there are methods that can reduce the work

needed to program a robot and improve the ability of the robot to handle

unexpected events. The benefits of this are that the programming of the robot

can be faster and easier since it is not that complicated for an unexperienced

engineer to do it. These methods can be used in different robot applications

like assembly tasks [22].

Robots can be a good solution for assembly operations, and they are used in

the industrial production because of their efficiency and the better quality of

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the product. Nevertheless, an assembly robot is not able yet to replace the

human assembly because there are still challenges that must be solved first.

These challenges can be the high assembly environment requirements, the low

sensing ability, bad assembly adaptability, low assembly efficiency, and

incapability to complete complicated assembly procedures in a demanding

environment [23].

3.2 Human-Robot Interaction Human-Robot Interaction (HRI) is about how a robot can be made in order to

increase the interaction with the human and how this interaction can be

beneficial; the human can be occupied by less operations and the robot will

take over more tasks and that will lead to a better task performance. For this

collaboration to be effective and safe, the robot should be able to understand

the mechanisms and movements that are similar to those that a human can do

with another human [24].

Figure 2: Human-Robot Interaction [16] [25] [26]

Nowadays, robots have already been introduced in modern factories; a lot of

these factories ‘procedures include robots. The human knowledge and

intelligence allow the operations that have been taken over by the robots, to

run smooth and as a result to have better quality of the production.

Collaborative robots are easy to program and work with the worker, they can

directly be installed in any production. The robots can take over positions and

operations that are repeatable and maybe boring for a human to do, and they

can be occupied by ergonomically unsuitable tasks for the human.

Collaborative robots do not need that much floor space since they are small

and that makes it easy to fit almost everywhere [27].

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More and more intelligent robots are being introduced to the working

environment or even the houses of humans. Robots and human can collaborate

for different applications; these interactions with the human allows the robot

to understand better the human actions and learn from them. Representation

learning is coming from the researches about artificial intelligence, and it

extents different fields and applications like speech, object and emotion

recognition, language processing and emergence [28].

Humans and robots can work together with varying degrees of proximity.

There are four different definitions for the relationship between humans and

robots. These definitions are going to be described below [27] [29].

Human-Robot Coexistence

In Human-Robot Coexistence, robots and

humans work together in the same area without

the robot being in a cell and without overlapping

the workspace of each other. The workspace of

the worker differs from the robot’s workspace

and they work on different parts in parallel and

they may exchange the work object in between

the process (see Figure 3). The process itself is

completed independently [29].

Human-Robot Interaction/Synchronization

Human-Robot Interaction is when the human

and the robot interact physically in the same

working environment but with no direct

contact. The robot works on a different task

from the human and the whole process is

completed sequentially. The communication

between the worker and the robot is needed and

will be possible to achieve it taking into

consideration all the necessary aspects needed

including safety (see Figure 4). The worker can

control the robot either locally or remotely and

the Human-Robot Interaction can happen in the

same workspace [29].

Figure 4: Synchronized operation [50]

Figure 3: Coexistence operation [50]

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Human-Robot Cooperation

In Human-Robot Cooperation, robots and

humans are working in the same workspace

but still the worker does not have any contact

with the robot. The worker and the robot have

the same goal to achieve but they work

separately by turns on different tasks within

the same process (see Figure 5). Cooperation

is the communicating relationship that

combines the knowledge of the worker and the

capabilities of the robot to reach the same

target or goal [29].

Human-Robot Collaboration

Collaborative robots have developed into one of

the main driving forces of Industry 4.0 and have

made a lot of progress in the past few decades.

HRC is more available outside of manufacturing

and has a broader application area than

industrial robots, they have more flexibility,

they can offer better productivity and they are

safer (see Figure 6) [30].

Human-Robot Collaboration is the study of the collaborative process in which

humans and robots can work together without fences and barriers to stop them.

Lots of new applications allow robots to work with people. These kinds of

robots can include robots that can be used in homes and offices, in hospitals,

for space exploration and in manufacturing. Human-Robot Collaboration

(HRC) is a research field that beside classical robotics also includes human-

computer interaction, artificial intelligence (AI), design, science and

psychology [31].

Figure 5: Co-operated operation [50]

Figure 6: Collaborative operation

[50]

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Figure 7: Human-Robot Collaboration (YUMI) [16]

As in cooperation, robots and human in collaboration, are working in the same

workspace. Human and robot can share the same activity in the same working

space to complete the same working task. The physical contact and interaction

are allowed, and that makes the human-robot interaction collaborative (see

Figure 7). The two parties are sharing their tasks, their capabilities and all their

resources to achieve a common goal [29].

Coexistence Interaction Cooperation Collaboration

Workspace

Direct Contact

Working Task

Resource

Simultaneous

Process

Sequential

Process

Table 1: Features of different human-robot relationships [29]

3.3 Human-Industrial Robot Collaboration In the last century, the industrial application of robotics has become crucial.

According to the current definition, the origin of "industrial robots" can be

traced back to the 1950s. However, some automation in the industrial

environment has begun to appear since the Industrial Revolution [32].

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Industrial robots can increase the automation levels and flexibility in an

industry. This technology deals with the subsystems of industrial robots like

their mechanics and control systems [17].

Cause of their size and the forces that are creating, industrial robots ‘systems

have to support sensors' usage. The safety in these robotic systems is the most

crucial factor that must been taking care of, especially when the specific robot

system has a high degree of flexibility [17]. They can be equipped with

different kinds of safety sensors depending on the application where this

industrial robot will be used for [33].

In the past 30 years, industrial robots have been a booming field of research,

and they already made significant progress within these years [34, 35]. These

robots were used in industries, and they have been positioned there to replace

the humans or help them with various tasks that might be dangerous, repetitive,

or monotonous for them (see Figure 8) [36]. Industrial robots are being

installed in cells, in a different workspace from the workers and away from

them. As the technology capabilities are evolving in this field, humans will be

able to work in the same workspace with the robots and use them as

collaborators to help them with their tasks [37]. In the figure below, an

example of some industrial robots in a production line is shown.

Figure 8: Industrial Robots from ABB [16]

3.4 Safety Sensors For the human to be safe and protected, in an environment that robots exist,

the usage of safety sensors is crucial. Safety sensors can be activated by the

human´s motions [38].

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Figure 9: Safety sensors from Sick [39]

Before the introduction of the safety sensors, the robots were in different

workspaces and inside cells, traditional safety standards stipulate that only an

authorized person can enter the cell and only when the robot is in a non-

automatic mode. This situation leads to inflexibility and ineffective

workspaces; this becomes a problem because as the industries are developing,

higher demands are place on aspects related to flexibility and efficiency. In

order to accomplish all these things, safety systems need to be introduced to

avoid collisions between robot and worker, to help calculate the level of pain

and injury by a collision and minimize injuries [40].

Collaborative robots, on the other hand, already have safety sensors integrated

into them, and it easier to introduce them for automated collaborative

applications. In the case when the human will accidentally touch the robot

while the robot is moving, a stop will be triggered so the robot will stop its

tasks immediately, or the robot will reduce its speed sufficiently to prevent the

risk of injury on the human. The human and the robot can work in the same

workspace without any barriers and fences to separate them, and this can be

done with safety and without any concerns [27].

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4 Methodological Approach

In this chapter, the methodology that the project followed will be presented.

The methodological approach helped to evaluate all the concepts and

conclude to the final study case and the automated application that will be

suggested. The overall structure of the processes will be described.

A good way for analyzing, evaluating and finding the best solution would be

by using physical robots in Epic Technology Center that is located in Linnaeus

University in Växjö, or realistic virtual simulations. The challenge to do this

physical experiment is to find the right tools to apply on the existing robot.

The methodology of this thesis is shown in Figure 10.

Figure 10: Methodology followed

4.1 Analysis

4.1.1 SWOT Analysis

The SWOT (strengths, weakness, opportunities, and threats) analysis is a tool

that is used for situation analysis, mostly in business analysis. This tool is

considered a powerful tool that can be applied for any situation analysis. It

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helps to identify the strengths of any process and use them; at the same time

can also identify the weaknesses of a process and so the researcher can have a

clearer view, additionally the opportunities and threats can be identified. In

this case threats will be considered as challenges [41].

4.1.2 Current Assembly Process (Manual)

The current assembly prosses is totally manual as mentioned in Chapter 1, and

the SWOT observation for the current state of the assembly process is shown

below:

STRENGTHS WEAKNESS

• Easy to assemble

• Flexible workstation

• Analyze and troubleshoot

problems on time

• Worker injuries due to

improper ergonomics

• Imbalance in production line

• Increase of manual workers to

reduce the assembly time

OPPORTUNITIES THREATS (CHALLENGES)

• Change the worker´s position

if needed

• No threats (challenges)

Table 2: SWOT Analysis for the current situation

4.1.3 Automation Solution

The strengths, weaknesses and opportunities for an automation solution in the

assembly area should adhere the following criteria:

STRENGTHS WEAKNESS

• Easy for assemble

• Better ergonomics for the

worker

• Cost and time saving for mass

production

• Standardized work

• Costly for the short-term

production

• Possible change in the product

design must adapt to the

current stations´ layout

OPPORTUNITIES THREATS (CHALLENGES)

• Easy to adapt process of the

robot in case of a change in the

product design (flexible

manufacturing)

• Easy to change tasks

• New job opportunities for

workers

• In case of adding a new

product in the assembly line,

the design of the product will

need to be changed

• System may crash

Table 3: SWOT Analysis for automation solution

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4.2 Study Case Selection Method The selection of the study case will be passed through a funnel [42] and from

a concept classification tree, and that will result to narrow down to the final

concept.

4.2.1 Funnel

The funnel method is describing the steps that this project followed to answer

the general questions and thoughts and helped in achieving the requirements

of Volvo CE.

The general thoughts in the beginning of this research are stated in Graph 2, as

well as the steps followed to the final concept selection.

Graph 2: Funnel Concept Selection

4.2.2 Concept Classification Tree

The assembly area in Volvo CE is divided into different main and sub

assembly stations. The concept classification tree method (see Graph 3) helped

in narrowing down to the final selection of the station for this project.

The general view of the assembly department including the main and sub

assembly lines are shown in the figure below. In the first phase of selection,

after observations and discussions, the possible stations that will include the

study case were selected.

The main-assembly section was directly canceled from the beginning and the

project focused on the sub-assembly section. After further research and

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interviews inside the department, the conclusion was to select something from

the small assembled components from one of the sub-assembly areas.

Graph 3: Concept Classification Tree (Phase one)

In phase two the final study case was decided (see Graph 4). Initially, physical

robot experiments in Epic Technology Center were planned. Because of this,

the capabilities of the robots played an important role in selecting the study

case. The conclusion was that the robots ‘payload is not more than 10 kg [43]

so a smaller component would be best to automate by simulations and/or

physical experiments. Additionally, the selected study case based on reducing

the ergonomic issues.

Graph 4: Concept Classification Tree (Phase two)

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4.3 Morphological Chart Morphological chart is based on product function analysis and provides the

conceived design function during the idea generation process. In this case, it

helps to identify the sub-solution of each sub-function in the design of the

station. It combines different solution ideas for each sub-function and creates

possible options for the future assembly station [44, 45].

Option I Option II Option III

Options

Sub-

functions

steps A B C D

1

Prepare the

fittings (nipples

16,22 mm, bolt

16 mm)

Manual

(worker)

Feeding

Machine GoFa [46]

2

Fix the main

block

Manual

(Clamp)

Rotational

table Conveyor GoFa [46]

3

Add the fittings

to the main

block and torque

Substation

(torque

machine)

Manual

(worker)

IRB 4600

[47]

Change

tools

IRB 4600

[47]

ERM

4 Fix the plastic

parts

Manual

(worker) GoFa [46]

Table 4: Morphological Chart

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A more detailed explanation of the morphological chart is written below.

First Option

For the first option (yellow line), the worker will prepare the fittings on a fixed

tray. After that, the robot (GoFa) will fix the main block to the clamping area

in a station that torque will be applied on it. After fixing the first bolt (16 mm),

the robot will take the block and guide it to the next tool to fix the three nipples

(16 mm). Lastly, the robot will guide the block to the third tool to fix the fourth

nipple (22 mm). After fixing every part on the main block, the worker can fix

the plastic fittings at the end of the procedure.

Second Option

In the second option (pink line), the operator will fix the fittings to a fixed tray

and also fix the main block on a rotating table in a clamp. After that, the

operator will push a button and the table will rotate 180 degrees. Then the

robot (IRB 4600) will start taking the fittings from the tray and assembled

them on the main block; after fixing the bolt (16 mm) and the three nipples (16

mm), it will change its tool to fix the fourth nipple (22 mm). The operator will

again press the button so the table will rotate 180 degrees, and now they can

take the already assembled blocks to store them.

Third Option

In the third option (green line), a robot (GoFa) will fix the fittings to a fixed

tray, and the same robot (GoFa) will fix the block to a clamping area. After

that, a robot (IRB 4600) with a multi-tool (see Appendix 1) installed on it, will

take the fittings from the tray and torque them on the main block; the robot's

tool will rotate to change when it needs to assemble the big nipple (22 mm).

After the assembly procedure finishes, the robot (GoFa) will take the blocks

and store them in a box.

The selected study case and the final station will be described in more detail

in Chapter 5.

4.4 Weight Scored Matrix To select which of the options (see Table 4) could be the best solution for the

station, every option was put in a weight scored matrix (see Table 5). Some

criteria have been taken into consideration to conclude to the best option. The

criteria where selected after discussions with the supervisors, interviews and

papers found online; also, the customer´s needs. The baseline is the current

situation in the assembly procedure. The rating for it is 5; if the criteria is better

for one of the other options are rating with a higher number, and anything less

good than the baseline is rating with a number below 5.

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Criteria W

eig

ht

(%)

Options

Baseline I II III

Rating Weight

Score Rating

Weight

Score Rating

Weight

Score Rating

Weight

Score

Ergonomic 20% 5 1 8 1.6 8 1.6 10 2

Accuracy 15% 5 0.75 5 0.75 5 0.75 4 0.6

Safety 10% 5 0.5 5 0.5 5 0.5 5 0.5

Cost 10% 5 0.5 2 0.2 4 0.4 1 0.1

Collaboration 10% 5 0.5 6 0.6 7 0.7 6 0.6

Efficiency 10% 5 0.5 7 0.7 7 0.7 5 0.5

Flexibility 10% 5 0.5 4 0.4 5 0.5 3 0.3

Automation

level 5% 5 0.25 7 0.35 7 0.35 10 0.5

Size of

station 5% 5 0.25 4 0.2 6 0.3 1 0.05

Speed/Time 5% 5 0.25 3 0.15 4 0.2 2 0.1

Total score 100 5 5.55 6 5.25

Rank 4 2 1 3

Table 5: Weight Scored Matrix

4.5 Data collection

4.5.1 Interviews

One of the important data-gathering method is to review the current situation

of the assembly process with the production manager and the supervisors who

are responsible for each station. At this point it was critical to do some good

quality interview (see Table 6).

The interviews were arranged in an unstructured type. In this way, the

interviewers can express their work experience and knowledge with the

opportunity to share ideas to improve the product or to find the best way to

add automation to the assembly process [8].

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Position Type of

interview Carried

Number of

interviewers

Time

(Approximately)

Production, project

Manager Unstructured

On site 2 6 hours

Section worker Unstructured On site

4 2 hours

Section Manager Unstructured On site

2 1 hour

Companies’ sales

representative Unstructured Zoom 4 4 hours

Companies’ sales

representative Unstructured On site 2 2 hours

Companies’

technical manager Unstructured

Phone

call 1 1 hour

Other, for valuable

information and

data

Email

Table 6: Interview details

4.5.2 Observations and Document Analysis

To have a clear and accurate understanding of the assembly at Volvo CE, in

Braås, the authors had the chance to be stationed at the company for three

months. This made it easier to have access to the company´s data and all the

important relevant information for the assembly area. Documentation

(drawings, assembly data) was obtained through the company’s sharing

network Volvo Faros. Additionally, information and best practices with

respect to the automation level at other departments within Volvo CE were

gathered. These observations helped to narrow down the choice of the study

case.

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5 Results and Discussion

The results of this project are going to be introduced in this chapter as well

as the discussion that will help to understand better how the results were

found.

5.1 Selection of Assembly Station The first step was to observe the entire assembly area, main-assembly stations

and sub-assembly stations. The authors took some tours with the assembly

engineering manager of Volvo CE and the supervisor, to observe and get

explanations of how everything is working.

There are four assembly sections, D1, D2, D3, D4 (see Figure 11). From these

assembly stations, an evaluation was made to choose the study case from a

sub-assembly procedure. The goal was to select a study case that would be a

good start to introduce automation.

Figure 11: Assembly Procedure

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Observations were not enough to decide from which assembly station the study

case will be selected. Further interviews and discussions with the managers of

each assembly station took place.

None of the main-assembly stations were selected since most of the

components there are big and heavy, as well as a lot of hydraulic work and

further procedures that needs cable ties to add all the wires together are being

done and these kind of procedures needs hand work.

A list of the criteria that the assembly station needs to fulfil to be selected was

created. This list helped in the selection of the assembly station and point

toward to the study case.

The assembly station that requires an automated solution should fulfil all the

criteria below:

▪ Unergonomic positions for the workers that an automated solution can

reduce.

▪ Beneficial for the company for future usage.

▪ Will not be complicated to introduce automation.

▪ A solution that includes human-robot interaction or collaboration is

possible.

▪ There is enough space for the robot and the human to work together at

the assembly station.

▪ Some tasks require human interaction because they need more

flexibility to assemble.

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5.2 Selection of the Study Case

5.2.1 Not selected assembly stations

In the third and fourth assembly section (D3, D4), the findings did not fulfill

the list above due to the complexity of the station. In this station mostly big

components are being assembled (see Figure 12, Figure 13, Figure 14) and

after further observations and discussions, the conclusion was that the whole

design of this station has to be change in order to be able to automate it. So,

the study case will not be selected from this assembly station.

Figure 12: Rear Frame

Figure 13: Axles

Figure 14: Assembled Component (Rear Frame + Axles)

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In the second station (D2), a possible study case was found. This study case is

about one of the fenders of the truck (see Figure 15). After some research,

observations, and discussions with the engineers, the conclusion was that these

kinds of parts of the truck might change design occasionally, so it is not a

priority for now to automate this assembly procedure, but there are good

possibilities to automate this station in the future.

Figure 15: Fender

5.2.2 Selected assembly station

In the first assembly section (D1), three possible study cases were found in the

sub-assembly procedure (see Figure 16, Figure 17). These possible study cases

are air blocks and their pictures are shown below.

Figure 16: Air Block (Selected Study Case)

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Figure 17: Air Blocks (Not Selected Study Case)

5.3 Study Case Here, a more detailed description of the study case will be presented, how

everything works in the specific assembly procedure, and the improvements

that could be made in order to successfully introduce automation in the

assembly area.

5.3.1 Description of the study case

The study case that was selected to be automated for this project is an air block.

The assembly selected as a study case is a part of the articulated hauler air

system. It is a distribution block, and its function is to distribute compressed

air from compressor/tank to different air-controlled functions of the machine.

Examples of these functions are differential locks, the signal horn and exhaust

aftertreatment system.

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Current State

Figure 18: Current state of the Air Block

# Quantity Air Block (Current State)

1 1 Piece Block

2,3 1 Set Plug and Gasket

4 1 Piece Elbow Nipple 22 mm

5,6 2 Pieces Elbow Nipples 16 mm

7 1 Piece Nipple, Swivel 22 mm

8,9,10 1 Set Plastic T-Nipple + 2 Plastic Nipples

Table 7: Details of each component of the Air Block (Current State)

At this point one worker is assembling this air block and place it on a table, so

when the main assembly line needs this air block, they will take it from there.

The average time needed for the worker to assemble this air block is 2-3

minutes and in average, around 10 of these are being assembled daily.

It is a complicated geometry since all the fittings that are located on the upper

part of the main block are so close to each other that needs more flexibility

from the worker to torque them correctly. Because of this hand intensive work,

injuries could appear in the worker´s wrists. This will happen over time if they

keep doing the same procedure every day.

An interview took place with the worker who was assembling this air block at

that current moment. Some of the questions and answers of this interview are

listed below:

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Question: Is this component hard or complicated to assemble?

Answer: No, it is not hard but because the bolts are too close to each other,

apply the correct torque on the components is a little bit complicated though.

Question: How much time it takes from you to assemble this air block?

Answer: Takes around 2-3 minutes to finish the assembly of this block.

Question: How many air blocks do you assemble every day?

Answer: It is required to assemble 12 air blocks every day.

Question: Is there anything dangerous about this procedure?

Answer: I would not say that it is dangerous, but if someone is occupied with

this assembly procedure for a long time, wrist pain may appear.

Future State

After a lot of interviews and discussions with the engineers of the assembly

department (see Appendix 3), the conclusion was that a change in the elbow

nipples was needed in order for the components to be easier to assemble using

automation.

Because the elbow nipples needed more space to rotate and the robot´s tool is

not able to assemble them. For that reason, a change in the nipples was needed.

The first option was to change the design of the main block so the nipples will

be far from each other. The second option was to keep the same design of the

main block and replace the elbow nipples to be nipples, swivel, all of them 16

mm; on them, plastic elbow nipples will be assembled (see Figure 19).

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Figure 19: Future State of the Air Block

5.4 Robot Selection A suitable robot must be selected that has the capabilities and the

specifications needed to be able to lift the entire tool mechanism that weights

approximately 25-28 kg. This is because the torque for these components to

be assembled is 15-35 Nm. This torque is too big and an ERM unit with

servomotor is weighting approximately 21 kg. The gripper, PGN-plus-P 160

and the adapter plats are 13kg more, physically much too large, and heavy for

this application.

A suitable robot for this application will be an industrial robot, and more

specifically the IRB 4600 of a 45 kg load, from ABB (see Figure 20). This

robot also used for the simulation part of this project.

# Air Block (Future State)

1 Block

2,3 Plug and Gasket

4,5,6 Nipples, Swivel 16mm

7 Nipple, Swivel 22 mm

8,9,10 Plastic T-Nipple + 2 Plastic Nipples

11,12,13 Plastic Elbow-Nipples

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Figure 20: Industrial ABB robot IRB 4600_45 [47]

5.4.1 Gripper and Clamping

The grippers and the clamping system need to be designed from the company

so there is not a specific gripper or clamp mechanism at this time, so the

gripper used in the simulation is a smart gripper from RobotStudio library.

5.4.2 Safety Sensors

Because IRB 4600 is an industrial robot, safety sensors must be installed to

ensure the safety of the operator. These sensors can be from SICK (see Figure

21) [39], and the best selection of a sensor system would be one that would be

able to detect human motions so when the human walks closer to the area of

the robot the robot will reduce its speed or even terminate it if the operator

comes closer to the red area (see Figure 22).

Figure 21: Safety laser scanner microScan3 Pro-PROFINET, Type: MICS3-CCAZ90PZ1P01

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Figure 22: Yellow and red area

5.5 Functions of the robot station After selecting the study case the robot, and the robot station and the functions

of it had to be selected as well. Morphological chart (see Table 4) and weight

scored matrix (see Table 5) helped in the selection of the robot station that will

be used in the simulation. Further research, discussions with the engineers and

call sessions with different companies also helped in narrowing down all the

possible solutions. The final station was decided and is presented below.

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Table 8: Functions of the robot station

Rotational

table

Rotational

table

Arrange the fittings on

the tray

Fix the main parts to

the Clamp on the

rotational table

Press the button

Rorate to the work

position

Pick the nipples

(16mm) from the table

and fix them on the

main body

Pick the bolt (16mm)

from the table and fix

it on the main body

Robot

IRB 4600

Change the tool, pick

the nipple (22mm)

from the table and fix

it on the main body

Rorate to home

position

Collect the assembled

blocks and store them

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A more detailed explanation of the functions of the robot station is stated

below:

a. The operator will be standing outside the area the robot will work in, and

he will arrange the fittings on a fixed tray (see Figure 23).

b. The operator will be standing outside the area that the robot will work, and

he will fix the main blocks on the rotating table in the clamping locations

(see Figure 24). After that he will press the button (see Figure 25).

c. When the button is pressed the table will rotate 180 degrees. Now the table

with the main blocks on it, is inside the robot station (see Figure 26).

d. The robot will start fixing the fittings one by one. First it will assemble the

three nipples (16 mm), after that the robot will fix the bolt (16 mm) (see

Figure 27).

e. After the robot change the tool, it will fix the last nipple, swivel 22 mm

(see Figure 28).

f. When the robot finishes the procedure, the operator will again push the

button and the table will rotate 180 degrees. Now the assembled blocks are

ready to be stored.

g. The operator will take the assembled parts and store them on a table (see

h. Figure 29). When the air block is needed from the assembly line, a worker

will fix the plastic parts and then the air block will be ready to be used (see

Figure 30).

Figure 23: Arrange the fittings (Function a)

Figure 24: Fixing the main block on the rotation

table (Function b)

Figure 25: Push the button (Function b)

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Figure 26: After rotation (Function c)

Figure 27: Fix the nipples and the bolt of 16mm

(Function d)

Figure 28: Fixing the nipple of 22mm (Function e)

Figure 29: Storing table (Function g)

Figure 30: Assembled Air block (Function g)

Final design of the robot station

Two options were designed for the robot station. The first option includes

fences that are installed all around the robot station (see Figure 31 and Figure

32). The second robot station has less fences than the first one. These fences

are located in the front side of the station, where the operator will be standing

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(see Figure 33 and Figure 34). In the option that there are no fences around the

robot, safety sensors must be installed for the safety of the operator.

Figure 31: Robot station with fences (Side view)

Figure 32: Robot station with fences (Top view)

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Figure 33: Robot station with fences only in the front side (Side view)

Figure 34: Robot station with fences only in the front side (Top view)

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5.5.1 Benefits of this Automated Application

The benefits of this automated application are stated below:

▪ Improve the ergonomics for the workers since they will no longer apply

the torque on the fittings by hand.

▪ Possible damage on the product will be reduced since no tools will touch

the product and the torque will be applied by the standardized work of a

robot.

▪ Since the robot will do this assembly procedure, the time of a new worker

searching and learning how to assemble the product will be reduced.

▪ The worker now can focus on other sections that need more hand work.

▪ The standardized work of the robot will have positive effects on the quality

of the product.

▪ The functions of the robot can be programmed in the offline software, if

there is a need of changing the design or the product, without stopping the

production, then the changes can be applied on the physical robot.

▪ The workers will have the possibility to become operators of this procedure

and learn new things.

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6 Conclusions

In this chapter the answers of the research questions and sub-questions will

be stated. A summary and reflection of the research will be included as well.

The Human-industrial robot collaboration is an early stage technology. This

technology has many potential applications, but it has not yet undergone any

major testing. The purpose of this thesis is to better understand the

prerequisites, functions, and advantages of these applications. Below the

research questions and sub-questions are being answered.

Research Question 1: What kind of applications would be suitable to

introduce in the assembly section?

Answer: The challenge for this project was to use the existing robot from ABB

or YASKAWA in Epic Technology Center, but due to the unavailability of the

tools needed it was not possible to do the experiment there so only a simulation

have been done to have a view of the robot station and how it might work.

At first, a collaborative robot came as a good idea to use for this operation.

This robot is GoFa from ABB [46]. After further research, the authors found

out that the load of the robots in Epic Technology Center and GoFa could not

handle to carry the weight of the customize tool (ERM, Servo, Gripper, see

Appendix 1, Appendix 2) that came as one of the solutions for this study case.

The reason that this tool is that heavy is because of the torque needed for the

nipples to be assembled correctly. The ERM´s weight will change depending

on the torque needed, more torque means more weight for the ERM.

After collecting all the data from the companies, the result was to use the

recommended tools from Schunk (see Appendix 2). For that reason, a Human-

Industrial Robot Collaboration application will be introduced in the assembly

station as a solution. The robot that will be used for this application is IRB

4600 from ABB [47].

Because IRB 4600 is an industrial robot, safety sensors must be installed to

ensure the safety of the operator.

Sub-Question a: In which assembly station is better to present this

application?

Answer: The introduction of automation will take place in the first assembly

station (D1), that was selected depending on the funnel method, the concept

classification tree and the list of criteria that was created. The study case was

selected from one of the sub-assembly procedures.

Sub-Question b: Will this be functional for the company and the workers?

Answer: This application is a start of introducing automation in the assembly

area. For the workers it will be functional since the unergonomic procedures

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are going to be done by the robot, and the workers will also have the

opportunity to spend more time in other sections.

This application will not be that functional for the company since it is costly,

and a better solution can be found in the future. Nevertheless, it´s scalable and

because there are different kinds of air blocks all around the assembly section,

this application can be effective since there will be the possibility to assemble

all these air blocks in the same robot station, that will have as a result to

minimize the sub-assembly stations. As stated before, in the answer of the

research question 1, some companies could provide valuable information and

solutions for this assembly procedure. This kind of solutions would be the most

valuable and functional ones.

Sub-Question c: What are the possible derivatives that could be applied in this

application for future demands?

Answer: In the future this robot station can be used for all the different kinds

of air blocks that the assembly area has. They can upgrade the station in a way

that the robot can assemble all these air blocks. A change in the program of

the robot and at the tray, so all the fittings will have appropriate position, is

enough to start the mass production of all the air blocks.

Another possible derivative that could be applied, is to upgrade the table so it

can fit more than four blocks if the company needs to have more production

of air blocks.

Research Question 2: What benefits will this application have for the

company?

Answer: This thesis has been a benchmark for further researches to learn and

understand better the robot´s capabilities and limitations. This application is

an introduction of automation and a start to understand what can and what

cannot be applied in the assembly area. This application will have ergonomic

benefits for the workers and quality benefits for the products.

Future Master thesis or researches for automated solution in the assembly, will

have as a start this thesis. Every valuable information can be exported from

here and be used in a better way in the future.

Research Question 3: Will this application be applicable for possible changes

in the design of the product?

Answer: This application can be customized if any change in the design of the

product needs to be done in the future. The programming of the robot can be

changed to adapt to the new design of the product; additional changes could

be done for the tray, where the bolts and nipples are placed. Furthermore,

changes in the orientation of the whole robot station can be done if needed.

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7 Future Work and Recommendations

Further research is needed to conclude to a better solution and that can be

achieved by future work and recommendations. Here, some recommendations

for Volvo CE, as well as for future researches are stated.

7.1 Recommendations for future research To better understand the results found in this project, future studies can address

to the release of Master thesis opportunities from Volvo CE, so the research

will continue to a new level and the students from Linnaeus University will

have the opportunity to have new experiences with Volvo CE.

Additionally, experiments can take place in Epic Technology Center either

with the already existing robots or with new robots that might be purchased in

the future.

Furthermore, Volvo CE can release short term student projects for the course

Product Development in Linnaeus University. The students will have an early

view and understanding of what they are dealing with so they can be prepared

before they start their thesis with Volvo CE.

7.2 Recommendations for Volvo

7.2.1 Simulation Software

In RobotStudio, to simulate human activity is limited for now to do in a good

way. RobotStudio has SDKs that allow system integrators to continue

development of the software.

For that reason, a software that is better to be used in order to have a better

simulation experience is recommended. This software is Siemens Process

Simulate (represented by Ditwin AB in Sweden). The possibilities with

Siemens Process Simulate software [48] are quite big in this part. It combines

the human skills with the machine´s capabilities to team them up. In this

software, ergonomic analysis for the human and vision tests are possible to be

done as well [49].

Due to the possibilities that it provides, it is a powerful tool for a company that

wants to make a very realistic human simulation. Additionally, in Siemens

Process Simulate software the programmer can import different robots from

different companies like ABB, KUKA and YASKAWA. This is a big

advantage because there is no need to learn and use multiple software for each

robot brand [49].

7.2.2 Tools

Due to the situation of Covid-19 and the limited time that there was to

complete this thesis, it was not easy to have good contact with all the

companies that would help to find the best automated solution.

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After a lot of research and discussions with companies, the conclusion is that

the best tools to apply the amount of torque needed on the bolts and nipples is

from Atlas Copco company. They have a variety of tools and they can

customize them depending on the product.

Atlas Copco´s tools can be mounted on a robot as well; this can make the

assembly procedure easier, faster and less costly. There is no need of using a

big robot of a 45kg load because these tools can be mounted on a smaller robot

as well.

7.2.3 Change in the design

This project gave the opportunity to learn and understand a lot of things about

robotics and automation solutions. One of the things that achieved from this

thesis is that to successfully introduce automation to a totally manual assembly

area is difficult.

Every company must consider the fact that they must change a lot of things in

the assembly process in order to have good automated applications. A change

in the design of some products could be one of them since the robot is not a

human and has different limitations and movements.

Another factor that they must take into consideration is the change in the

assembly line. To install automation in the main assembly line will be difficult

to do without a new arrangement of it.

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Appendix 1

Multi-tool from Schunk

The content of appendix 1 is the multi-tool (ISO angle adapter plate).

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Appendix 2

Solution from Schunk (changing tools)

# Part Name Part ID Part code Qty Price

sek / pc

1 Adapter 0321555 A-SWK-071-

ISO-100 1Pc 3174

2 Tool changer master 0302370 SWK-071-000-

000 1Pc 19959

3 Module for sensor on

Tool changer master 9942041 SWO-R19W-K 1Pc 4654

4 Module for servo on

Tool changer master 9965723 SWO-REP10-K 1Pc 6111

5 Tool chager tool side 0302371 SWA-071-000-

000 2Pc 5483

6 Module for sensor on

Tool changer tool side 9935816 SWO-R19-A 2Pc 2994

7 Module for servo on

Tool changer tool side 9965724 SWO-REP10-A 2Pc 4340

8 Rotating unit with servo

motor 0310552

ERM 160-8-CB-

090-MSK050B 2Pc 54522

9 Gripper 0318592 PGN+P 160-1 2Pc 11325

10 Sensors for gripper 0301034 MMSK 22-S-

PNP 4Pc 515

11 Adapter between SWA and ERM (needs to be designed)

12 Adapter between ERM and PGN+P (needs to be designed)

13 Fingers for smaller part (needs to be designed)

14 Fingers for bigger part (needs to be designed)

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Appendix 3

Interview with the engineers

Questions Answers

What kind of tool can be created

that we can add to the robot to lift

the elbow nipples?

Is better to change the elbow

nipples to be straight.

How can we achieve that? There is already existing one that

we are using it in another air block.

Is it going to be accurate?

Yes, it will be exactly the same as

before. These nipples do the same

work with the elbow ones.

What about the elbow part?

There is a plastic elbow nipple,

swivel that can be clicked on easily

like the T-nipple swivel.

Do you have any other ideas that we

can discuss with our supervisor

here?

Unfortunately, no, this was the best

idea that we can come up with.

Why you do not use it for this air

block at that current moment?

We have a lot of old parts in stock

so first we need to finish them and

then order the new ones.