BMW Group Harnesses Potential of Innovative Automation

BMW Group Harnesses Potential of Innovative Automation

02.03.2017: ...and Flexible Assistance Systems in Production The BMW Group continues the persistent modernization of the work

...and Flexible Assistance Systems in Production





The BMW Group continues the persistent modernization of the work environment in the company’s production areas. Innovative automation and state-of-the-art assistance systems offer great potential for workstations.




As a result, it will be possible to further reduce ergonomically unfavourable and strenuous tasks, giving workers an opportunity to apply their unique cognitive skills to the best effect.



While in the past, man and machine worked in separated areas cordoned off by protective fences, the last few years have changed this setup: modern lightweight robots, smart devices and exoskeletons support workers as a direct part of people’s work environment in production, making the production system leaner and more adaptable.



Christian Dunckern, Head of BMW Group Production System, Planning, Toolmaking and Plant Engineering: “The digitalization allows the BMW Group to tap a growing range of options on how to advance the production system in many respects.




 People are more than ever becoming the designers of their own workplaces and can provide answers to the questions of an increasingly complex automotive production.”






Purposeful application of assistance systems and lightweight robots



The allocation of roles between workers and available tools is clear: their high level of expertise, creative and cognitive skills make humans ideally suited for tasks that focus on actual value creation, specific precision work and quality management.



Assistance systems, on the other hand, support people in carrying out strenuous and repetitive tasks that constitute a stereotypical strain. In production, lightweight robots do not require any additional fixed points and are relatively mobile in where they can be applied.




Moreover, they can work directly with people. As a rule, the application of assistance systems is about finding reasonable solutions for the respective purpose, always with the focus on the specific benefit to be achieved.





Man and machine bringing together their respective strengths



As early as 2013, the BMW Group commissioned a first lightweight robot that took its place among the workers at the assembly line of BMW Group Plant Spartanburg in the USA. Miss Charlotte, as the line crew calls their robot, is still in use mounting sound insulation to doors, but many things have changed since.





Today, over 40 lightweight robots are in use at the BMW Group plants; a total of 60 will be in operation by mid-year. They assume tasks that would be physically strenuous for workers and often pose particular challenges due to the high level of precision required and the repetitiveness involved.



At BMW Group Plant Dingolfing, for instance, a ceiling-mounted lightweight robot in the axle transmission assembly lifts the bevel gears, which may weigh up to 5.5 kilos, and fits them accurately without any risk of damage to the gear wheels. In this production area, workers and robots work together “hand in hand” in a confined space without any safety fences.



 This collaboration gives people extra time to carry out tasks better suited to their capabilities while the lightweight robot applies exactly the force needed over a long period of time. Safety sensors monitor the functions at all times and stop the process immediately if an obstacle is detected.



Equally demanding is the application of the adhesive to the front windows. What makes this task particularly challenging is that the viscous adhesive must be spread over the large glass surface in one go and without any fluctuation in film thickness.



At BMW Group Plant Leipzig, this task is carried out by a lightweight robot that works directly at the line with the human workforce.





But lightweight robots are also becoming more common in areas in which large robot facilities work behind safety fences. Their flexibility, modest space requirements and high level of safety grant people access to areas that used to be off-limits.




Thanks to the broad range of possible applications, lightweight robots open up new potential in the field of traditional automation and give workers more leeway to implement improvements.



Today, direct man-machine cooperation is also possible with the traditional, large-scale industrial robots. In the transmission installation unit at BMW Group Plant Regensburg, a worker leads a large industrial robot to the screw bonding station.



While a laser-based system supports the process of placing the industrial robot, the exact position is determined by the trained worker. The idea for this application was developed by the on-site team itself.



Like in other use cases, safety is always the top priority: should a person get too close to the robot while the latter gets into position, state-of-the-art safety technology slows down the movement of the robot arm, if needed to a total standstill, before any danger can arise.



Due to the high forces required in the screw bonding process, this particular task cannot be assigned to a lightweight robot.






Digital production assistants to strengthen workers



Up until the beginning of the new millennium, phones were primarily used for making actual phone calls. Today, they fulfil a great variety of functions. And just like our everyday living environment changes, so does the working environment in production.



Work gloves are fitted with barcode scanners on the back of the hand to omit the cumbersome steps of picking up the scanner, scanning an object and putting the device back. The scan process is now triggered by the worker pushing a button on the index finger with the thumb.



This way, individual production processes can be improved and accelerated, leading to improvements in process quality and occupational ergonomics. 230 of these innovative work gloves will be in use at the BMW Group before the end of the year.



Another example is the use of augmented reality applications on smart devices such as tablet computers, on which the image of a component can be overlaid with virtual specifications. The tablet computer then compares and evaluates the actual and target states, allowing the worker to determine whether the part matches the target requirements and identify and resolve potential issues early on.



Augmented reality applications are applied at the BMW Group in early-phase concept validations, initial sampling inspections and tool acceptances at suppliers as well as in the maintenance of running systems.






Innovative exoskeletons worn directly on the body can act like a second skeleton, i.e. as an external support structure for the body. The BMW Group uses both upper-body and lower-body exoskeletons. The exoskeleton vest for the upper body strengthens the movement of the upper arms of people who have to carry out tedious tasks.



The vest’s joints have an integrated mechanical spring support that gives arms greater strength. 24 of these exoskeleton vests are currently in use in the series production of BMW Group Plant Spartanburg; 44 more will be added over the course of the year.



Lower-body exoskeletons can be found in the production areas of several BMW Group plants in Germany. Acting as a chair-type support, this kind of exoskeleton improves workers’ posture and offers relief in carrying out assembly tasks that require crouching or remaining in other positions that might affect people’s health.



On top of that, the leg support structure can transform prolonged standing into sitting and thus improve the comfort and flexibility of working conditions. The exoskeleton consists of movable splints that can be affixed to the legs or torso and locked in different positions. At present, the BMW Group’s German plants use a total of 11 lower-body exoskeletons.







Efficiency and effectiveness at the workplace – more room for creativity




The BMW Group aims to ensure an efficient, stable and flexible production. At the same time, the company pursues the goals of assigning staff according to people’s individual strengths and capabilities and of developing the work environment further. Being spared particularly strenuous activities, workers have the time and energy to tackle more demanding and creative tasks.



Christian Dunckern: “In the time of smart devices and digitalization, we must still keep an eye on the added value the applied technology offers to the company.



Nobody is better qualified to judge this than the people who actively shape our production system on a daily basis. This way, technology at the BMW Group actually serves the people and expands their creativity and efficiency.”






Sandra Schillmoeller- photos BMW

Permanent-URL: http://www.automobilsport.com/bmw-group-innovative-automation-production---161376.html

02.03.2017 / MaP

More News

Toyota nimmt an Wasserstoff-Forschungsprojekt in den Emiraten teil
02.03.2017
Fahrtests mit dem Toyota Mirai beginnen im Mai 2017    Aufbau einer auf Wasserstoffnutzung basierenden Gesellschaft    Ausgiebige Tests und Demonstrationen unter extremen klimatischen Be more >>
Where the future goes into production: the Volkswagen Group's think tanks
28.02.2017
    37 competence centers and IT labs are already currently developing solutions for the mobility of the future – and that number is on the rise    Experts are working on forward-looking fields such as artificial more >>
Efficient Race Car Tracking System by Greaves 3D Engineering
21.02.2017
The Greaves 3D wheel mounted tracking bars are becoming increasing popular down the pit-lane with teams using the tracking system to ensure that their car has been correctly set-up.The Greaves 3D wheel mounted tracking bars are a fast and easy way to track a more >>
Kolloquium in Mlada Boleslav bereitet ,Zukunftspakt für tschechische Autoindustrie‘ den Weg
16.02.2017
› Tschechische Regierung, Branchenverband AutoSAP, ŠKODA AUTO und weitere Vertreter der tschechischen Wirtschaft wollen Pakt zur Stärkung der heimischen Automobilindustrie erarbeiten› Ministerpräsident Bohuslav Sobotk more >>
BMW Motorrad and LEGO® Technic present the Hover Ride Design Concept
16.02.2017
- BMW Junior Company creates futuristic LEGO Technic model as a life-size reproduction.The LEGO Technic BMW R 1200 GS Adventure is not just a fun model kit consisting of 603 parts, it is also the result of the successful and creat more >>
JEC Group celebrates composite innovation at JEC World 2017
18.01.2017
... and hands out JEC Innovation awards t 13 "Composite Champions"While this year’s show will take place from Tuesday March 14 to Thursday March 16, 2016 at the Paris Nord Villepinte Exhibition C more >>
Volkswagen Group realigns management development
15.12.2016
    Blessing: "We are strengthening entrepreneurial action, as well as fostering innovation capabilities, agility and Group-wide cooperation"    Diversity — more women and international pers more >>
Daimler supports Cyber Valley research initiative
15.12.2016
.....through endowed professorship    Automated learning as a key topic for the future    Endowed professorship for Entrepreneurship in the Digital Transformation more >>
SEAT promotes the talent of future engineers through the Formula Student
26.08.2016
SEAT continues to support the inventiveness of talented young engineers, and for the seventh consecutive year is sponsoring the Formula Student Spain, which begins today and will run until next Sunday at the Barcelona-Catalunya circuit in Montmeló. more >>
Rutronik unterstützt Formula Student Team aus Pforzheim mit Bauelementen
09.08.2016
Foto: Das Team der Rennschmiede Pforzheim testet seinen Rennwagen.Im Rahmen ihres Sponsorings hat die Rutronik Elektronische Bauelemente GmbH die Rennschmiede Pforzheim, das Formula Student Team der Hochschule Pforzheim, nun mi more >>
Audi at Formula Student 2016: countdown at the Hockenheimring
04.08.2016
Automobile manufacturer supports five student teams      Information on entry possibilities for young talented persons      “Audi Vorsprung Award” for most innovative lightweight concept more >>
Der KIT10 in den Startlöchern
12.05.2010
Rollout des KIT10 – 11. Mai 201050 Studierende verschiedener Studiengänge, sieben Monate intensive Planung, Konstruktion und Fertigung, unzählbar viele Stunden in der Werkstatt, unendlich viel Energie und Motivation – alles für ein Ziel: more >>
KA-RaceIng Rollout des KIT10 am 11.5.2010
11.05.2010
Enthüllung - der KIT10 drängt ins Licht der ÖffentlichkeitAm 11. Mai um 19.30 Uhr wird es spannend. Nach harter Arbeit ist es endlich so weit. Der neue Rennwagen KIT10 wird enthüllt. Sieben Monate lang haben die Studenten des KA-RaceIng- more >>
3. Formula Student CAE Workshop bei Altair
04.09.2009
Altairs CAE Hochschulrennsporttag lockte 100 Teilnehmer nach Böblingen22 Formula Student Rennteams nutzten die Veranstaltung des Softwarehauses zum Informationsaustausch zwischen Studenten, Industrie und AltairAltair Engineering, eines der führenden Unternehmen im Bereich CAE-Technologie und Services gibt heute bekannt, dass am 27. August more >>
DEKRA ist auch 2008 Technischer Partner der Formula Student Germany
08.08.2008
Jungkonstrukteure starten in Hockenheim DEKRA geht auch in diesem Jahr wieder bei der Formula Student Germany an den Start. Als einer der Hauptsponsoren und als Technischer Partner des Konstruktionswettbewerbs unterstützt die Sachverständigenorganisation die Racingteams von Hochschulen aus aller Welt. Die Nachwuchsingenieure treten mit selbst entwickelten R more >>
Ingenieurnachwuchs fördern und fordern
22.07.2008
- 3. Internationaler Konstruktionswettbewerb am Hockenheimring - Neuer Teilnehmerrekord: 78 Hochschulteams angemeldet - Automobilbranche setzt auf Formula Student Germany Vom 6. bis 10. August steht der legendäre Hockenheimring ganz im Zeichen der Formula Student Germany. Zum internationalen Konstruktionswettbewerb treffen sich 78 st more >>
FH Köln Motorsport beim Formula Student Event 2007
16.08.2007
Formula Student Event 2007 am Hockenheimring Mit einem 32. Gesamtrang beim Formula Student Event Germany 2007 in Hockenheim am vergangenen Wochenende kehrt FH Köln Motorsport zurück in die Domstadt. Unerwartet starke Leistung des Teams wurde nicht belohnt - Planungen für 2008 haben bereits beg more >>
Results 2007
14.08.2007
Formula Student Germany - Award Team   Formula Student Germany Champion University of Stuttgart Formula Student Germany – 2nd place Graz University of Technology Formula Student Germany – 3rd place University of Applied Sciences Joanneum Graz Engineering Design Award – 1st place Technical University Munich Engineerin more >>
Results - Presentation event
14.08.2007
Formula Student Germany 6 Rennteam Uni Stuttgart Uni Stuttgart 75,00 1 1 TUG Racing Team TU Graz 74,00 2 69 Hawks Racing Team Hamburg HAW Hamburg 73,00 3 2 Stadia Motorsport Helsinki Polytechnic 72,00 4 4 Oxford Brookes University Brookes 72,00 4 85 Racetech Racing Team TU Bergakademie Freiberg e.V. TU Freiberg 70,00 6 more >>
Results - Overall Results
14.08.2007
Formula Student Germany   6 Rennteam Uni Stuttgart Uni Stuttgart 95,16 75,00 120,00 44,49 69,17 133,84 350,00 12,05 899,72 1 1 TUG Racing Team TU Graz 86,08 74,00 145,00 34,09 66,36 69,63 339,72 24,66 839,55 2 111 joanneum racing graz FH Joanneum 87,88 64,72 140,00 40,84 68,60 106,40 281,89 16,87 807,19 3 2 Stadia Motorsport Hel more >>
Results - Acceleration
14.08.2007
Formula Student Germany 53 raceyard Kiel FH Kiel 4,22 4,22 4,11 4,11 4,40 4,40 4,17 4,17 4,11 75,00 1 6 Rennteam Uni Stuttgart Uni Stuttgart 4,32 4,32 4,21 4,21 4,55 4,55 5,22 5,22 4,21 69,17 2 7 Lions Racing Team TU Braunschweig 4,22 4,22 4,23 4,23 4,44 4,44 4,38 4,38 4,22 68,60 3 111 joanneum racing graz FH Joanneum 4,42 4,42 4,22 4,22 4,6 more >>
Results - Autocross
14.08.2007
Formula Student Germany 27 TU Darmstadt Racing Team e.V. TU Darmstadt 57,155 1 59,155 64,999 4 72,999 57,540 2 61,540 54,604 54,604 54,604 150,00 1 103 University of Wisconsin-Madison Formula SAE UW-Madison 57,922 2 61,922 55,147 2 59,147 56,502 1 58,502 54,731 54,731 54,731 148,35 2 4 Oxford Brookes University Brookes 62,518 3 68,518 59,184 59,184 more >>
Results - Cost event
14.08.2007
Formula Student Germany 90 LUMotorsport Loughborough University 8,75 8,63 38 40 95,38 1 6 Rennteam Uni Stuttgart Uni Stuttgart 10,00 7,16 40 38 95,16 2 31 TUfast TU München 9,75 6,74 38 40 94,49 3 103 University of Wisconsin-Madison Formula SAE UW-Madison 9,50 9,95 38 37 94,45 4 27 TU Darmstadt Racing Team e.V. TU Darmstadt 7,00 9,36 more >>
Results - Design event
14.08.2007
Formula Student Germany 31 TUfast TU München 150 1 1 TUG Racing Team TU Graz 145 2 111 joanneum racing graz FH Joanneum 140 3 3 DUT Formula Student Racing Team TU Delft 135 4 103 University of Wisconsin-Madison Formula SAE UW-Madison 130 5 2 Stadia Motorsport Helsinki Polytechnic 125 6 4 Oxford Brookes University Broo more >>
Results- Endurance
14.08.2007
Formula Student Germany 6 Rennteam Uni Stuttgart Uni Stuttgart 1454,654 1454,654 350,00 1 1 TUG Racing Team TU Graz 1465,216 1 1467,216 339,72 2 9 student-racing team FH Stralsund 1468,990 5 1478,990 330,24 3 12 Rochester Institute of Technology R.I.T. 1476,244 6 1488,244 322,90 4 2 Stadia Motorsport Helsinki Polytechnic 1467,063 16 more >>
Results - Fuel
14.08.2007
Formula Student Germany 57 Swansea University Race Engineering Swansea University 2,40 1687,71 2,40 50,00 1 23 Running Snail Racing Team FH Amberg-Weiden 2,66 1658,70 2,66 41,58 2 58 ISAT ISAT 3,19 1793,37 3,19 28,67 3 1 TUG Racing Team TU Graz 3,40 1467,22 3,40 24,66 4 69 Hawks Racing Team Hamburg HAW Hamburg 3,66 1606,71 3,66 20,34 more >>
Results - Skid pad
14.08.2007
Formula Student Germany 12 Rochester Institute of Technology R.I.T. 5,842 5,328 5,585 5,334 5,247 5,291 5,168 5,086 5,127 5,211 5,092 1 5,277 5,127 50,00 1 4 Oxford Brookes University Brookes 5,415 5,396 5,406 5,321 5,118 5,220 5,942 5,422 5,682 5,422 5,262 5,342 5,220 44,66 2 6 Rennteam Uni Stuttgart Uni Stuttgart 5,520 5,300 5,410 5,352 5,326 1 5, more >>
Stuttgart gewinnt Formula Student Germany
14.08.2007
• Rennteam der Universität Stuttgart Sieger in Hockenheim • 1.200 begeisterte Studierende beim Konstruktionswettbewerb • Bester Newcomer: Universität Karlsruhe Die Universität Stuttgart ist Sieger der diesjährigen Formula Student Germany am Hockenheimring. In einem spannenden Finale setzten sich die Schwaben gegen 53 internationale S more >>
FH Köln Motorsport beim Formula Student Event 2007
08.08.2007
Formula Student Event 2007 am Hockenheimring Jetzt geht´s in die heiße Phase - vom 9. bis 12. August messen sich am Hockenheimring 58 Hochschulen beim internationalen Konstruktionswettbewerb der Formula Student Germany. Erstmals am Start: Das Team von FH Köln Motorsport! Studenten bauen more >>
AVL Testtag in Bitburg
25.07.2007
Am 24. Juli trafen in Bitburg zwei höchst unterschiedliche Monoposti aufeinander: ein Dallara OPC-Challenge und ein Formula Student. Arrangiert hatte das ungewöhnliche Treffen die Formel-3-Vereinigung im Rahmen eines Testtages, den die AVL Deutschland GmbH angeregt hatte. Über 20 angehende Ingenieure der Universitäten Darmstadt und Karlsruhe nahmen an dem Testtag im Moto more >>
Ingenieurnachwuchs früh rekrutieren
23.07.2007
• Automobilbranche setzt auf Formula Student Germany • Internationaler Konstruktionswettbewerb am Hockenheimring • Rekord: 59 Hochschulteams angemeldet Vom 9. bis 12. August messen sich am Hockenheimring 59 Hochschulen beim internationalen Konstrukti more >>
Geschichte
23.07.2007
Geschichte 1981 rief die „Society of Automotive Engineers" (SAE) in den USA die „Formula SAE®" ins Leben, an der jedes Jahr rund 140 Studententeams aus der ganzen Welt teil-nehmen. Seit 1998 veranstalten die SAE und die IMechE (Institution of Mechanical Engineers) in more >>
Konzept - Anforderungen- Wettbewerb
23.07.2007
Formula Student Germany    Konzept Studenten bauen in Teamarbeit einen einsitzigen Formelrennwagen, um damit im Wettbewerb gegen Teams aus der ganzen Welt anzutreten. Bei der Formula Student Germany gewinnt aber nicht einfach das schnellste Auto, sonder more >>

23.07.2007
more >>

2001-2020 automobilsport.com full copyright