A lightweight robot system designed for the optimisation of an automotive end-off line process station

Purpose – 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. Design/methodology/approach – 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. Findings – 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. Research limitations/implications – 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. Practical implications – 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. Social implications – 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. Originality/value – 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.