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Automation and flexible manufacturing:

why do we need more vision

and more robotics?

Ignazio E M Piacentini

ignazio.piacentini@imaginglab.itwww.imaginglab.it

Giovedi 8 Ottobre 2009, Museo del Patrimonio Industriale, Bologna

Martedi 13 Ottobre, Technotown Villa Torlonia, Roma

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Agenda Who are we / who is ImagingLab / what do we

do?

The machine vision and robotics market: few

numbers

What is Flexible Manufacturing? Vision and robotics in flexible manufacturing: an

example

Questions and answers

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Who i

sImagingLab? The mission is in our logo

Our best product is our

know-how From consulting to

systems

Our robotics applicationsare 'vision centric':Machine Vision addsflexibility and extend theapplication range ofrobotics

We have purchased /integrated more than 50robots over the past threeyears (2007 2009)

Alliance Member of

National Instruments

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Where are we?

In Lodi, 30 km south of Milan, in anhistorical building dating back from1450

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Who am I? Who are we? Key figures Ignazio Piacentini, 55 years old, M. Sc. from the Polytechnic of

Central London A past in research working for the European Commission (Euratom: thermonuclear

fusion, 1976-1991)

Co-founder and president of Graftek Italia (Machine Vision)

In 1996: Graftek France software machine vision library is acquired by NationalInstruments (Austin, Texas)

From 1999 to 2003 joins NI Corporate as Machine Vision Business DeveloperManager for Europe

In 2004 soft shut-down and restart in ImagingLab Srl

Francesco Roman, 31 years old, Degree in MechanicalEngineering, Polytechnic of Milan Co-founder of ImagingLab

The full team: today 8 people (6 engineering, 2 admin) 2004-2008: from 2 to 7 people, from 250 k to 1.2 M

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Not only industrial but also: Domestic services

Logistics

Space

Surveillance & security

Edutainment

Military

Machine Vision and Robotics is a growing mkt

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We might be biased (90% of oursmall company business islinked to the tight integration ofvision and robotics), but there isa fast growing presence of MVin the field of robotics

There are plenty of newareas for robots, especially

low payload, high accuracyones

Today only 5-10 % ofrobotics apps make use ofMV, but these number is

destined to grow: 35% by2012 ??

The number of robots in Europeis also increasing (+11 % in2006)

Machine Vision and Robotics is a growing mkt/2

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Markets and statistics

Gathering statistical data is a difficult and lengthy process There are three kind of lies: lies, damned lies, and

statistics ... Accurate trends are more important than accurate

absolute values (i.e. If you make mistakes keep makingthe same!)

You may come across several discrepancies: data aregathered via different associations, often with overlappingareas of interest, different methodologies, ...

What is included within the 'MV market'? Fromcomponents to the added value of system design and

integration

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World Robotics 2007World Robotics 2007World Robotics 2007World Robotics 2007 WorldWorldWorldWorldyearly supply: > 100,000 robots/yearyearly supply: > 100,000 robots/yearyearly supply: > 100,000 robots/yearyearly supply: > 100,000 robots/yearEstimated yearly supply of industrial robots

by regions 2004 - 2006

0 10 20 30 40 50 60 70 80

Americas

Europe

Asia/Australia

'000 of units

2006

20052004

Source:World Robotics 2007

-19%

+11%

-18%

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World Robotics 2007World Robotics 2007World Robotics 2007World Robotics 2007 EuropeEuropeEuropeEurope

Germany and Italy : largestGermany and Italy : largestGermany and Italy : largestGermany and Italy : largest mrktsmrktsmrktsmrkts and growingand growingand growingand growingEstimated yearly supply of industrial robots

in Europe by countries 2005 - 2006

0 2.000 4.000 6.000 8.000 10.000 12.000

all other countries

Turkey

Denmark

Switzerland

Austria

Sweden

United Kingdom

Central/Eastern Europe

BENELUX

Spain

France

Italy

Germany

units

2006

2005

Source:World Robotics 2007

Some numbers from SIRI (Italian Robotics Association):2006: Anthropomorphic 3421, SCARA 72, tot 34932007: Anthropomorphic 3948, SCARA 240, tot 4188

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Japan: by far highest robot densityJapan: by far highest robot densityJapan: by far highest robot densityJapan: by far highest robot densityEstimated number of operating industrial robots per 10,000

persons employed in the manufacturing industry

349

187 186

138

12399 92

7970

372

168176

130 122

91 8776 71

0

50

100

150

200

250

300

350

400

Japan Korea Germany Italy Sweden UnitedStates France Spain Austria

units

20062005

Source: World Robotics 2007

Average Europe 2006: 97

Un commento: In Giappone: un uso meno tecnologicamente esasperato dei robot

Velocit mediamente inferiori

Compiti x robot pi semplici / maggior numero di robot

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The graph shows delivery of allEuropean companies tospecific regions/countries

Italy: 2205 4.4%, 2006 4,4%,

change 2006/2005 11.8% Germany to the WORLD:

approx 1 bl

Italy exports > 70% of'machines' (which alsoinclude MV)

Roughly 1/7 of Germanyturnover: approx 150 M ??

Let's try to find our waybetween data analysis andeducated guess ...

Share of Italy in the MV market

Source: EMVA 2007 survey

Machine vision mkt in Italia: probabilmente attorno ai 200 - 250 M

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Italy: 'meccanica e macchine' :

the weight of Italy in Europe

The weight of Italy in Europe: GDP (GEP?), manufacturing industry,machines production

Italy ranks at the 4th place, but machine manufacturing is 2nd after Germany

Noi italiani siamo bravi a fare macchine

Source: Federmacchine / Eurostat

Weight of Italy in Europe

Germany UK France Italy SpainOther EUmembers

% of Gross European Product 20.0% 16.4% 15.4% 12.8% 8.5% 26.9%

Manufacturing industry 26.0% 11.3% 15.1% 14.2% 7.5% 25.9%

Machine manufacturing 33.4% 9.4% 11.1% 19.5% 5.0% 21.6%

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The overall goods trade balance (2006)

is positive only for the 'machines' and

fashion/furniture segments The 'machines' segment has registered

+ 12.500 M in 2006 vs. a 21.400 M

of all commercial goods

Italy: 'meccanica e macchine' : the weight of

machine production in the Italian economy

Source: Federmacchine / ICE

Goods commercial balance 2006 (bl

Euro)

Instrumental goods (machines) balance 1990-2006 (bn Euro)

Continuos growth over an

extended period

All goods

Agro-food

Fashion &

furnitureRubber-chemistry

Mineral ext

industry

Machines

Other mnfg goods

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Machine vision and robotics:tight integration

Robot application without vision usually require simpleprogramming

Very simple applications can be programmed directly from

the teaching pendant When vision is present, programming gets more complex

(dynamic missions / dynamic programming) In machine vision + robotics application vision should not be

considered an add-on, but designed / programmed as a

whole unit and possibly in a single programming environment Measurement in the loop can also add to the application

complexity (correlate RT measurements with actual position)

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Robot types and payload / size range

SCARA: 4-axis Anthropomorphic: 6 or more axis Inverted spiders or Delta: fast / less accurate, sometimes

considered only a manipulator Range: payload from 1 to 1.000 kg

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Why and what is 'flexiblemanufacturing'? 1: market changes

Market and economics changes have adeep effect on engineering

Production methods and requirementshave changed a lot in recent years: Smaller production lots Faster time to market Lowering production costs to respond to agressive

new competitors (China, India mkts) Flexibility vs production speed

Cycle time: what does it really means? Design for speed

Design for flexibility

Design for ease of use Design for low cost of ownership

Pictures courtesy of Automatismi Brazzale and Cabur

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Why and what is 'flexiblemanufacturing'? 2: robotics Assembly machines need to be able

to produce different objects / products: At least in the same class of products No re-tooling required Fast production lot change with limited or no

operator intervention Used by non skilled personnel Reconfigurable / reusable for new products In-process quality control (as opposed to end-of-

line quality control) Flexible automated assembly:

Loading / feeding components Putting the components together

Flexible and reconfigurable

mechanics for handling andassembly Highly modular The answer is: more robotics

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Why and what is 'flexiblemanufacturing'? 3: machine vision

The robots need to performmore complex and dynamic(i.e.) work cycles

Robots need to see! Vision is used to:

Locate the parts and send info to

the robot Perform quality inspection of single

components Verify assembly correctness

In-process vs end of linequality control: Discards only defective component Prevents machine malfunctioning /

jamming

The answer is: more vision

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Why and what is 'flexible manufacturing'? 4:better integrated software

Machines need to be reconfigurable by the end user Vision and robotics sw needs to have simple user interface The integration of robotics and vision must take care of

calibration procedures, machine commissioning and start-uptools, etc

The answer is: high level software libraries and toolsspecific to vision and robotics integration

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Flexible manufacturing / flexible feeding:

the feeding station

Conventional vibrating bowl-feederare adjusted for a specificcomponent: lack of flexibility!!

Flex feeders: computer-controlledvibration amplitude, direction andfrequency

Machine vision identifies the

components Robots pick and place the part

LabVIEW offers one single softwareplatform

Advanced tools for auto-calibration Advanced tools for system

configuration

Quality control of the selected parts

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Flexible assembly on the factory floor

Co-design and collaboration isa key to success (ImagingLab,Automatismi Brazzale, Cabur)

From the early prototype to thedeployed machine

A short video-clip

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Questions &

answers