RROBOTICSOBOTICS ININ MMANUFACTURINGANUFACTURING TTECHNOLOGYECHNOLOGY RROADMAPOADMAP

November 2006

Prepared for

Prepared by: Acknowledgement

This Technology Roadmap was prepared as part of a project entitled “Robotically Enhanced Advanced Manufacturing Concepts to Optimize Energy, Productivity, and Environmental Performance.” Funding for this project was provided by the U.S. Department of Energy (Project #DE-FG36-05GO85046). Robotcs n Manufacturng Technology Roadmap

Table of Contents

Introduction ...... 1 Background...... 1 The Role of Robots in Manufacturing Today ...... 1

Trends Impacting the Future Use of Robotics ...... 5 Future Advances in Robotics ...... 5 Non-Technical Trends and Drivers...... 6

Barriers and Challenges to the Use of Robotics ...... 9 High Priority Technical Challenges and Barriers to Robotics in Manufacturing ...... 9 High Priority Non-Technical Challenges and Barriers to Robotics in Manufacturing ...... 11

Research and Development and Other Activities ...... 15 High Priority Research and Development ...... 15 High Priority Non-Technical Activities...... 20

References ...... 27

Appendix A: List of Participants ...... 29

Appendix B: Acronyms Used in Action Plans ...... 31

 Robotcs n Manufacturng Technology Roadmap

 Robotcs n Manufacturng Technology Roadmap

Introducton

Background allow for extremely precise manipulation of a tool “hand,” the addition of cameras, and the American manufacturers are facing increased integration of artificial intelligence into gov global competition, particularly from countries erning software have all enabled more rapid where labor costs are much lower than those and fine-tuned adaptation. in the United States. New technologies that The robotics industry has grown to provide a improve manufacturing cost competitiveness wide range of robots for use in global manu – including those that increase productivity or facturing industries. Precise assembly, repair, reduce energy use – will help meet this chal demolition, and other crucial manufacturing lenge. Industrial robots, which have been in steps can be accomplished efficiently, quickly, use since 1961, have the potential to make a and at lower cost than human labor. This greater contribution to productivity in manu increased productivity has contributed to an facturing. annual increase in both the number of user This Technology Roadmap for Robotics in Manufac industries and total robots shipped. turing is the result of a collaborative effort to Since 1990, some applications of robots have assess the future of robotics in manufacturing. enjoyed a cost advantage over human labor. To gain industry input to the roadmap, a work Falling prices and increasing machine capabili shop was held in June 2006 with emphasis on ties during this period dramatically decreased the application of small lot and flexible robot robot costs. In 2003, robots were being pro systems in manufacturing. In this workshop, duced at a fifth of the cost of a robot built in industry stakeholders outlined critical barriers 1990, with the same capabilities. In addition, to increasing the use of robots, and provided hourly wages have greatly increased since their thoughts on the research, development, 1990, particularly in the automotive industry, and other activities needed to overcome those making robots even more cost-competitive barriers. Contributors to the report are listed [UNECE 2004]. in Appendix A. The largest user of industrial robotics today The Role of Robots n Manufacturng Today is the automotive industry, which was respon sible for about 50 percent of all domestic Since the first industrial robot—essentially, a industrial robot purchases in 2004 [UNECE mechanical arm—received a patent in 1954, 2004]. Robots have been used since the late radical changes in global competition and 1970s in car production for welding, paint advancements in computer technology have ing, and assembly. Despite a recent down led the way for increased sophistication and turn in the American car industry, auto parts capability of this technology. The addition producers are growing and driving a surge in of three more axes (pitch, roll, and yaw) that robot orders, even when global automotive

 Robotcs n Manufacturng Technology Roadmap

end producers are lightening their demand. Furthermore, growth in industries such as The Robot Advantage: semiconductors, electronics, plastics, food, Accuracy, Speed, Increased Productivity, consumer goods, and pharmaceuticals assures and Flexibility the robotics industry an important place in Robots have several advantages over worldwide manufacturing [UNECE 2004, IFR humans which make them excellent for 2005]. Increased automation in these and other working in environments such as assem industries, such as off-road vehicles, applianc bly and manufacturing plants, hazardous es, aerospace, and metal fabrication, are also mines, and in situations where the work is contributing to the increased use of robots. mundane or monotonous. Most industrial robots worldwide are used Ro in welding and material handling or moving. Productivity and Cost Benefits bots can consistently produce more high- As shown in Figure 1, these two tasks com quality products than humans, never tire mand 88 percent of all robotic activity, while and can work nonstop without breaks, other tasks like painting, sanding, and assem and do not require benefits. This trans bly filling make up the remaining 12 percent lates into increased productivity, lower [Vincent 2006]. This range of tasks capitalizes manufacturing costs, and in some cases, on the advantages robots hold over human reduced use of energy and raw materials. labor in high-volume and harsh manufacturing environments. Advances in technology are also Doing Hazardous or Mundane Jobs beginning to allow complex, variable tasks to Robots can do the work that no one else be conducted robotically. wants, such as mundane, dangerous, bor ing or repetitive jobs. Robots can take In 2004, the majority of installed robots over in situations where work is extremely worldwide were multi-purpose articulated hazardous to human health, and can work robots, accounting for 62.5 percent of sales with humans to make their jobs easier. [IFR 2005]. Other more specialized varieties make up the difference (see Figure 2). Asia has Consumer Benefits Robots can pro the largest market for industrial robotics. Japan duce high quality goods quicker, which and Korea, long the market leaders in robot significantly reduces poorly-made goods ics production and purchasing, are experienc and lowers the cost of goods to the con ing healthy expansion, although the robotics sumer. industries in North America and Europe are catching up. North American robot sales are expected to show strong growth through 2008, as critical growth engines. In Europe, a num in part because of heavy Japanese automotive ber of synergistic projects are bringing togeth investment. Worldwide, the robotics industry er industry and academia to further develop is predicted to continue to grow through 2008 the robotics industry. The European Robotics [Vincent 2006]. Platform (EUROP) was recently approved at a level of $100 million per year. Similar initia Investment in robotics research and develop tives do not exist in the U.S., and currently ment is stronger and more coordinated in Asia there is no national strategy that focuses on and Europe than in the U.S. Both Japan and robotics. R&D outside of the U.S. has focused Korea are implementing a national agenda in primarily on legged mobility, perception, robotics, and both countries include robotics and autonomy to support manipulation and

 Robotcs n Manufacturng Technology Roadmap

Fgure . New Robot Sales Based on Expected Use [Vncent 006]

Assembly < 10 lbs

Other, Inspection & 3% Assembly > 10 lbs Material Removal 1% 3%

Spot Welding 24%

Material Handling >10 lbs 36% Arc Welding 20%

Dispensing/ Material Coating Handling <10 lbs 5% 8% Fgure . Worldwde Dstrbuton of Newly Installed Robots, 004 [IFR 005]

Scara 12% Cylindrical 10%

Linear/ Cartesian/ Articulated Gantry 63% 15%

 Robotcs n Manufacturng Technology Roadmap

other tasks. In the U.S., R&D has emphasized wheeled mobility, perception, and autonomy in navigation; the U.S. also leads in efforts to improve human-robot interaction [WTEC 2006].

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Trends Impactng the Future Use of Robotcs

Over the next 20 years, advances in robot  meet increased demand for 6-sigma qual technology are expected to continue. This and ity assurance; and other factors will directly affect the growth  handle the increasing number of micro- of the robotics industry and robotic applica systems requiring assembly. tions in manufacturing. Especially significant are those trends or factors that directly af Increased flexibility will make industrial robot fect the affordability, marketability, and ease ics more attractive to small-lot manufacturers, of deploying robots. Technical advances that one market that is still relatively untapped. increase task flexibility, technical capability, and Small businesses have long been deterred from improve ease of integration with the existing purchasing robots due to high capital costs, workforce could have a significant impact. the need for large production lines to make Non-technical trends such as economic glo robotic investment prudent, and prohibitively balization, the availability of low-cost foreign complex operation and repair interfaces. How labor, improved government incentives, and ever, small-scale manufacturing cells, user- the increased availability of a well-trained friendly programming interfaces, and labor workforce will also impact robot deployment. pressure arising from outsourcing are making robots more attractive to the small manufac Future Advances n Robotcs turer. Advanced Techncal Capabltes Flexblty New materials such as electroactive polymers, The development of more flexible robots that shape-memory alloys, and materials emerging are able to multi-task will increase the usability from developments in nanotechnology will and versatility of robotics, easing the adop facilitate the adoption of robotics in manufac tion of robotics for a greater variety of tasks. turing. The incorporation of these materials Robots that are self-learning and self-modify- into robotics systems will result in robots that ing with high-speed response capabilities will are lighter, sensor-based, and more functional be developed. Robot mobility, reconfigurabil as an extension of the human, giving them ity, and mass customization will increase, as greater applicability for manufacturing. will modularity and interoperability. This will enable robotics installations to be customized New technologies to improve robot sensing for size, payload, and capabilities, increasing and general machine vision (optical sensors, potential applicability for manufacturing pro tactile sensors), self-diagnosis capability, and cesses. Flexibility could enable manufacturers higher intelligence controllers will enhance to use robots to functionality. Wireless technology will also be integrated within systems, as will artificial  take advantage of opportunities created intelligence, allowing more human-like mo by an aging, retiring workforce;

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tions and greater awareness of environment. ture. As a result, U.S. companies are actively Greater capabilities, mobility, and intelligence, seeking new ways to reduce labor costs and all enabled by new technology, will continue to increase productivity to remain competi increase the attractiveness of robots for manu tive. Installing and fully utilizing robotics can facturing. Robots with a higher degree of pre provide a low-cost means of increasing worker cision and faster adaptability to design changes productivity and decreasing production costs. will stimulate use in industrial applications. As foreign companies invest in new manufac These improved sensory components and turing equipment, U.S. companies will have to flexible manufacturing cells combine highly improve efficiency or replace entire assembly specialized robots in an assembly-line produc lines to remain competitive. tion scheme to contribute to the growth of potential applications for industrial robots. Companies are also seeking ways to compete with the less strict manufacturing and labor Systems Integraton/Human Machne Interface standards in overseas markets. U.S. labor unions are an important factor in this dynamic. The development of robotics systems with While, there may be concerns about the effect advanced sensor technology and cogni of robotics on job security, robots may also be tive algorithms will improve robot ability to recognized for their ability to perform danger interface with humans and other robotics. ous tasks and keep human workers from being This could promote the use of robotics in injured. some manufacturing applications, particu larly those where humans and robots need to Secondary fabricators and manufacturers work side-by-side. Improved human-machine (those who buy pre-assembled goods for the interface will allow an increase in distributed production of larger goods) are now more ag networking and control, while enabling robots gressively searching out low prices, regardless to conduct complex tasks and understand the of what markets they have to enter to obtain relationships between task endpoints (i.e., task the lowest price. This phenomenon is evident ordering, connection, and priority). Improving in increased offshore outsourcing and the the human machine interface will also allow trend of American companies to take advan easier programming integration and improved tage of cheap foreign labor. In the near future, process control and functionality. as the economies of China and India grow steadily, there is likely to be greater investment Non-Techncal Trends and Drvers in new manufacturing equipment in these developing countries. Due to the size and re Internatonal Compettveness and Trade sources of these two countries, this increased investment could place greater pressure on As globalization increases, outsourcing of the U.S. to maintain a domestic manufacturing American jobs and movement of manufactur infrastructure. ing overseas is becoming a more volatile issue. Low-cost labor in Eastern Europe and Asia Sales of robotics are also impacted by down continues to put pressure on countries with turns in industries that face heavy international higher labor costs, particularly the U.S. For competition, particularly automakers. The eign producers have different safety, health, recent downturn in the automotive industry, and labor standards, and are often able to take for example, was accompanied by a signifi advantage of lower-cost labor and infrastruc cant reduction in robot sales to that industry –nearly 40 percent–in the first half of 2006.

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However, sales in other industries (e.g., food damental research is required, a lack of fed and consumer goods, life sciences, pharmaceu eral R&D investment could result in lagging ticals, biomedical, others) increased during this technology development. time period, and this trend is expected to grow. New orders for assembly robots as well as for Tranng, Educaton and Intellectual Captal material removal robots (both non-automotive Trends in training and education are expected applications) experienced a 33 percent increase to play a role in the adoption of robotics in in growth over the same period, serving as manufacturing. Education and curricula that further evidence that robotics are continuing supports the basic development of robotics to penetrate into new areas [RIA 2006]. expertise is available, as evident in the dramati Investment Drvers cally increasing levels of computer literacy among college and high school graduates. A number of financial elements could also For over two decades, universities have been increase adoption of robotics in manufactur producing scientists and engineers with an avid ing. Robotics will continue to become more interest in robotics, and these skilled experts cost-competitive, requiring less initial capital have contributed to many exciting new ad investment. As technology advances, robotics vances in the field. However, limited training will require less deployment time, decreasing programs for those who work with robot delays in adoption of new robotic systems. ics continue to hamper the use of robots in Both factors could increase the return on in manufacturing. vestment (ROI) of robot implementation. The cost of labor (including wages and health care) Safety and Regulaton is also expected to continue to increase, mak An increased focus on safety in human/ma- ing robotics more attractive. In addition, the chine interface is expected to lead to greater redeployment of existing robots is expected to incorporation of safety systems into robotics create a market for inexpensive, used robots. software. Safety regulations will become an Financial incentives (e.g., tax, R&D incen increasingly navigable reality for manufacturers tives) could also increase the use of robotics and other users of robotics. Greater incorpo in manufacturing by encouraging investments. ration of safety features will in turn lead to Continued federal funding of R&D could help easier robot deployment. The existence of to drive down the cost of robotics systems, jobs that are dangerous to humans and better particularly through technology advances that suited for robots, also emphasize safety as an are accelerated via federal initiatives (military important factor in the potential adoption of combat systems, space applications, nanotech robotics systems. nology). In some cases, particularly where significant pre-competitive or high-risk fun-

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 Robotcs n Manufacturng Technology Roadmap

Barrers and Challenges to the Use of Robotcs

While robotics has been demonstrated to be ing, since robots require a lot of energy and cost-effective in many applications, there are space on the plant floor in order to operate still a number of challenges to the more wide effectively. This requirement limits the specific spread implementation of robots in manufac tasks that robots can be used for, as size con turing. These challenges are both technological tributes to a lack of agility and dexterity, and barriers and external issues related to finance, energy requirements limit the size of a batch safety, and public perception. The most im that robots can cost-effectively power-up and portant of these have been identified and are power-down to process. Robot size also limits listed in Table 1 (technical) and Table 2 (non the potential for utilizing more than one robot technical). in close proximity to another, or for situating an operator and a robot in the same area. Hgh Prorty Techncal Challenges and Barrers The applications of robotics in manufacturing to Robotcs n Manufacturng are further hindered by the large amount of time that they require for changing tasks, their Flexblty and Scale limited reusability and their lack of flexibility for small-lot sizes and small batch manufac The scale of a robotic system is a barrier to turing. As manufacturers consider investing the expansion of robotics in manufactur Table . Hgh Prorty Techncal Challenges and Barrers to Robotcs n Manufacturng Flexibility  Generally low level of flexibility, agility, and reusability  Lack of flexibility for small lot sizes (200 parts or less)  Limited compactness and lack of flexibility and dexterity Systems Integration  Limitations of inter-operability (systems integration, interface with ERP/MRP/production controls systems, and software)  Short robot life-cycle Ease of Use and Human/Machine Interface  Difficulty in programming effectively (requires highly trained personnel, extensive setup)  Lack of adequate robot/human interaction  Inadequate operator interfaces Advanced Capabilities  Lack of sophisticated, reliable machine vision and artificial intelligence  Complexity of applications vs. robot capabilities (clumsy, stupid) Safety and Regulation  Cost and burden of safeguarding systems  Inadequate or difficult validation of safety features Standardization  Lack of recognized universal standards for performance specifications  Conflict between standards and rapid adoption of new technologies  Robotcs n Manufacturng Technology Roadmap

in robotics, these factors all limit robot ease ics in manufacturing. There are a variety of con- of use and potential return on investment. If trol languages involved in both human/machine manufacturers are able to purchase one ro integration and systems integration. Confusion bot that can perform multiple tasks, be used over what control language a system should use successively in different areas, and operate draws energy and resources away from improv- at a high level of efficiency regardless of the ing products, creating new and exciting applica batch size, then that manufacturer would be tions and adding value to robotic systems. Stan- more inclined to integrate robots throughout dardization of programming languages could their manufacturing processes. On the other stimulate growth in robotics in much the same hand, there is a capital investment required to way that standard protocols and programming integrate robotics into a manufacturing pro languages facilitated the entire growth of the cess. Limited robotic ability may result in a less internet, allowing companies to focus on value- attractive return on an investment; a lengthy added activities rather than fighting over whose transition period between tasks costs money in language and protocols should be used. time, labor, and energy. Lack of technology standardization compli Human Machne Interface cates the integration of arm, end effecter, and controller systems, and hinders plug and play Another key barrier for integrating robotic capabilities between unrelated systems. It also systems into manufacturing processes is the complicates the potential interface between level of skill and training required to operate a enterprise resource planning (ERP), manufac robot and successfully integrate it into exist turing resource planning (MRP), and production ing manufacturing facilities. Robots today are control systems software. difficult to program effectively, hindering an organization’s ability to maximize a robot’s The current lack of standardization in technolo functionality and the return on investment. gy, policies, and robot functions leaves an atmo Robots currently require highly trained person sphere of uncertainty for potential and existing nel and extensive setup time, which can make users of robotics. Potential users face uncer the implementation process costly. These fac tainty when comparing robot suppliers, imple tors not only limit an organization’s return on mentation plans, and safeguarding mechanisms investment, but also further the public percep due to the lack of performance specifications, tion that robots are hard to use and difficult to technology standards, and technical guidance. maintain. Prospective buyers also face a complicated land scape when assessing the potential to integrate Teaching a robot typically requires a more ex robots into their existing assembly lines or to tensive set of skills than those held by a robot incorporate the use of multiple robots. Existing operator. Because of this and other difficulties users can expect complications when hiring new in human/machine interface, robotic auto employees or training existing employees not mation may require a higher-paid employee familiar with their specific type of robot. presence to ensure that all robots in a system function well together. Advanced Capabltes Systems Integraton and Standardzaton While robots are currently able to perform a variety of specific tasks, there is a lack of suit The lack of standardization in technology is ability for more complicated tasks limiting robot another barrier to expanding the use of robot- applications in other areas of manufacturing.

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Table . Hgh Prorty Non-Techncal Challenges and Barrers to Robotcs n Manufacturng

Investment Issues  Lack of U.S. R&D funding/initiatives  Short-term financial focus of private sector (expect a simple payback in 2 years)  High deployment costs  Inability to predict return on investment (ROI) Training and Education  Limits to capabilities of current workforce  Lack of skilled employees for robot maintenance and service Public and Corporate Perception Perception that it is difficult to:  Acquire and deploy robots  Successfully integrate robots in manufacturing  Communicate robot specifications based on existing tasks  Use robots without taking jobs from people

Machine vision is currently unsophisticated Another barrier is that no national robotics and unreliable and artificial intelligence capa safety standard implementation guide currently bilities are limited. Robots also have limits to exists, leaving potential users on their own to their ability to adapt to new tasks like assembly meet safety regulations. Complications sur or welding, and they lack the precision and rounding safety and meeting national regula sensors necessary for micro-assembly tasks. In tions have been an area that robot users have addition, robots are not highly resistant to the had to navigate with minimal guidance. hostile environment often found in manufac turing. These areas of limited function result Hgh Prorty Non-Techncal Challenges and in robots not being able to perform tasks in Barrers to Robotcs n Manufacturng physical spaces with variable moving parts or spaces that are lacking close human control. Investment Issues

Safety and Regulaton Economic factors also limit the adoption of Although human/robot cooperation is closer robotics by the manufacturing industry. Be to becoming a reality, safety regulations con cause robots can be expensive, manufacturers tinue to limit the use of robotics in manufac want to have a tangible return on investment turing. Robots are not necessarily built with or other financial benefit from the purchase of safety as a top priority. They currently require a robot. Institutions of all sizes often require extensive protection for those who operate a payback of initial costs in about two years. them and for anyone else working in the area. Due to high initial costs and continuing oper Because safety procedures need to be tracked ating costs, an investment in robotics can take by the Occupational Safety and Health Admin longer to pay its cost back in full. The cost of istration (OSHA) and validated by regulatory the system surrounding the robot, including bodies, robots are generally required to be in the interface and safety measures, also drive enclosed areas to limit access and ensure that up the price of a new installation. Operating all safety regulations are met. As a result of costs are also high due to the costs associated these space demands, the presence of robots with programming, powering, and maintaining tends to severely impact the space available for robotic systems. other robotic systems and humans.

 Robotcs n Manufacturng Technology Roadmap

Users do not currently have the ability to accu The barrier of an untrained workforce is also rately predict their return on investment while due to a cultural fear of technology, inad accounting for the cost of training, system equate education programs, and impediments integration, upgrading a robotic system at a from unions and regulators. The current labor later date or replacing parts. New users also do pool is neither comfortable with robots nor not have the benefit of having knowledge of able to utilize their technology effectively. The the best robotic system for their specific au result is a lack of understanding of opportuni tomated manufacturing needs. A complicated ties for robots to provide an advantage and in decision process can slow procurement and crease efficiency. Until this type of knowledge may require valuable personnel and financial is plentiful, inadequate training and education resources. will continue to be a barrier to expanding the use of robotics in manufacturing. A lack of connection sometimes exists be tween manufacturing needs and corporate Publc and Corporate Percepton R&D investment. Manufacturing efficiency and productivity may benefit greatly from Perception and communication issues also sur more R&D. However, the inability to properly round the adoption of robotics by the manu communicate the real benefits to management facturing industry. Manufacturing is perceived can result in corporate investments directed as simple labor that provides jobs to millions more toward developing new products or of Americans, while robots are often seen as applications rather than lowering the costs of threats to those jobs or potential replacements manufacturing existing products. for humans in the manufacturing process. Another financial barrier is the general lack of Internal communication barriers limit the use funding for robotics research in the U.S. when of robotics in manufacturing. Developing compared with other countries. This lack of robot specifications in relation to specific tasks government support and limited investigation and user requirements is a very difficult task into new technologies and applications slows and requires a high level of expertise. It is also the development of safer, more adaptable difficult to assess new applications for robots robots. beyond their initial intended use. Tranng and Educaton On the organizational or corporate level, many managers believe that robotics would be im The lack of personnel with robotics expertise possible to implement in their facilities, or they within most manufacturing facilities is another question the financial benefits tied to robotics. barrier to the growth of robotics in this sector. Another commonly held belief is that robots Programming or teaching robots typically re are not available quickly and require thorough quires different skills from those of a machine study and planning before purchase and imple operator. Employees with this training or mentation. Also, managers may not envision education are in short supply despite a strong any advantages in quality control from robots demand. Robots are useless without a skilled as compared to less expensive labor overseas. human able to train, operate, and service them. These barriers of perception limit the extent These issues of education and experience to which robots are pursued. When robots ap overlap with investment barriers, as employees pear too complicated or a threat to jobs, they with advanced skills require higher pay. may not be considered an option.

 Robotcs n Manufacturng Technology Roadmap

Research and Development and Other Actvtes

Outlined below are activities that are needed process remains a formidable barrier to the to expand the use of robotics in the manufac increased use of robotics in manufacturing. turing sector, organized into technical research The development of a simple user interface and development and non-technical activi and enhanced connectivity between robotic ties. The six activities most likely to make the systems and other equipment would sim largest impact on the application of robots in plify the human/robot interface. This can manufacturing are outlined in more detail in be accomplished through R&D on interface Activity Action Plans shown later in this sec templates, electrical, mechanical, and com tion. A list of acronyms used in these plans is munications technology. Supporting R&D in provided in Appendix B. software engineering and programming should also be pursued, as should programming-by- Hgh Prorty Research and Development demonstration and integrating radio frequency identification devices (RFID) into robot design Technical activities are oriented towards specif to make them more flexible and responsive. ic technology goals achievable through R&D. The development of robotics systems with Table 3 summarizes the high priority technical advanced sensor technology and cognitive activities identified as necessary to increase the algorithms will also improve robot ability to deployment of robots in manufacturing. interface with humans and other robotics. User Interface and Ease of Use Improved human/machine interface will result in greater ease of use and fewer skill require The complexity of training a robot and ments for robot operators. Making robots integrating it into an existing manufacturing easier to control will increase the potential for Table . Hgh Prorty Techncal Research and Development

Ease of Use  Develop simple user interface  Enhance robot connectivity to other equipment  Develop user-friendly software Sensor Integration & Machine Vision  Conduct research on machine learning methods  Integrate advanced sensor technology into robots  Improve intelligent grips Standardization  Assemble a private/public sector steering committee to assess standards for reproducibility  Outline standards for interface, software, and hardware  Build framework for technical standards and software standards Safety Platforms and Guidelines  Clear safety guidelines  Flexible risk analysis and supporting R&D in human/robot safety

 Robotcs n Manufacturng Technology Roadmap

distributed controls and completion of com in their manufacturing tasks. Research and plex tasks. Improving sensor function has the development in these areas will enhance robot potential to improve human/machine inter adaptability and reduce the need for constant face by allowing robot controls to be oriented human supervision. more towards programming by demonstration, where a robotics system gathers information Standardzed Robot Controls, Programmng Languages while an operator completes a task and then and Operatng Systems duplicates the same task. Improving human machine interface will also allow easier pro Developing greater standardization will ease gramming integration and improved process the integration of arm, end effecter, and control. This will result in reduced training controller systems, and improve interoper requirements, allowing operators to train ro ability between unrelated systems. Greater bots themselves rather than requiring a more standardization in the robotics industry could expensive, highly qualified robot specialist. be achieved by empowering or creating a steering committee group to develop a means Sensor Integraton and Machne Vson (R&D) to measure standards for reproducibility and repeatability. Early efforts will be needed To further improve the flexibility of current to standardize a programming language for robotics technology, the industry must pur simulation and robot operation. A common, sue research and development in the areas of non-proprietary operating system and operat sensor integration and machine vision. This ing interface should be established to enhance research and its resulting technology develop plug and play opportunities between unrelated ments will enable robotics to play a larger role robotic systems, and even create interface in the automation of advanced assembly pro opportunities for ERP, MRP, and produc cesses through enhancing the ability of robots tion control systems and software. This effort to navigate products and assembly lines. The should facilitate the growth of the robotics robotics industry would benefit greatly from industry as a whole, allowing companies to investments in new research paradigms in pur focus on adding value to products and ap suit of the capabilities and flexibility necessary plications, rather than competing over whose for robots to play an increased role in assem language and protocols should be used. bly processes. Standardization will also enable robots to Other areas requiring further research include better integrate with other robots and exist improving motion control programming; ing manufacturing processes through simple, embedding sensors in tooling and grippers to easily replicated steps. Standardization will measure force, temperature, visuals, and touch; also enable robot operators to gain maximum and enhancing robots and end of arm tooling value out of their existing robot experience, (EOAT) with wireless controls and connec regardless of the model or manufacturer that tors. All of these research areas will enhance they have worked with in the past. Addition flexibility and allow robots to follow more ally, standardization will provide more cer precise instructions and expand their range tainty to potential robot users when compar of abilities to a broader variety of manu ing robot suppliers, implementation plans or facturing tasks. These technologies will also safeguarding procedures. enable robots to respond to changes in their surroundings and in the materials involved

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Better integration between robots will also their employees. Safety guidelines will also lead enable robotic systems to perform more to a more streamlined process of robot de thorough self-diagnosis of fault conditions ployment. These guidelines will be established and operate more efficiently with their sur through a joint effort by safety organizations rounding systems. System managers will be and the robotics industry and will result in the able to take advantage of greater drop-in, development of a technical safety platform. plug-and-play functionality, which helps to maximize a robot’s functionality and return on This same partnership will also promote the investment,while reducing personnel costs. development of inherently safe robots and work cells through conducting flexible risk Safety Platforms and Gudelnes analysis and supporting R&D in the area of human/robot safety. From these efforts, safer Developing clear safety guidelines will reduce robots will be developed with more self- the burden on robot users to develop and contained safety systems and inherently safe maintain extensive protection measures for design features.

PROJECT TITLE: EASE OF USE & INTELLIGENCE

Key Objectives Key Milestones/Schedule Milestone Schedule  Identify suitable  Suitably demonstrate program under application conventional application  Build structure/system  Program simulator conventionally and suitable for developing demonstrate success with corresponding this technology code on system ()3 & 4  Build corresponding  High school student can program system virtual system with less than XX (to be determined) minutes (5)  Establish registration  Demonstrate successful application from and feedback between task level description (6) virtual and actual system  Develop task level interface for recognition  Develop task level interface for action  Build automatic code generator for above 2 items  Apply against conventional application and validate

Enablers Expected Benefits Project Leader & Partners Next Steps  Funding  Ease of use  DOD  Request for

 Champion  Rapid deployment  DOE Proposals (RFP)  Reduced integration  NIST

cost  NSF

 Reduced labor cost  RIA

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PROJECT TITLE: S YSTEMS INTEGRATION & STANDARDS

Key Objectives Key Milestones/Schedule Milestone  Distributed control  Develop safety standards which support distributed control architecture which architectures (RIA)

supports plug and play  Standard interfaces documents (IEEE, ISO, etc.)  Make integration a  Convince robot manufacturers to participate and have more intuitive process ownership  Standards for end effector integration  Standards for sensor integration

Enablers Expected Benefits Project Leader & Partners Next Steps  Single advisory  Lower installation and  RIA  OSHA  Form coalition

and coordination programming cost  NIST  NIOSH advisory group group consisting similar to  Faster deployment  DOE  FDA st of within new industries USCAR or 21 representatives  DOD  NIH century truck and applications from industry,  Solicit government government and research and industry match regulatory funding agencies, and universities

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PROJECT TITLE: S AFETY CONSTRAINTS

Key Objectives Key Milestones/Schedule Milestone  Define a method of risk  Find or develop tool to do risk analysis

analysis that defines  Find or develop tool/tools to mitigate risk at the lowest cost the safety risk  Define risk analysis that impacts costs (weight, speed, soft surfaces, sensing, floor space)  Develop the appropriate set of cost factors that achieve safe/low cost operations

Enablers Expected Benefits Project Leader & Partners Next Steps  Risk analysis tool  Safe work environment  RIA  Identify interested  Cost optimization  Low cost manufacturing  OSHA tool parties  Evaluate/  Technology development develop tools - Lightweight robotics - Appropriate speed robotics - Soft-surface technology - Sensing technologies - Floor space minimizing technologies

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Table 4. Hgh Prorty Non-Techncal Actvtes

Training, Education & Research Collaboration  Create collaboration “Centers of Excellence” for universities, private industry, and government research  Identify champion or organizing body  Expand the expertise of existing and future domestic labor pool Communications/Corporate Perception  Focus on key points “Robots boost efficiency” and “Robots keep jobs at home”  Launch campaign at government level and at industry level  Develop and publish “case studies” on corporate experience with robot deployment Market Stimulation  Foster U.S. competitiveness in global robotics industry  Explore potential federally-supported tax and other financial incentives  Examine promising foreign technologies for adoption in U.S.

Hgh Prorty Non-Techncal Actvtes botics technologies being developed in Europe and Asia. The non-technical activities identified as pri The most effective way to start such collabo orities are more focused on process. As shown ration and reach out to new stakeholders is in Table 4, these activities address major bar through the efforts of a single champion or riers in training and education, perception of organizing body. This entity would develop re robots, and market stimulation. lationships with other organizations and allow Tranng, Educaton and Research Collaboraton the robotics industry to pool resources, make strategic investments, and provide leverage to Increasing educational collaboration and effectively communicate messages from the training in robotics-oriented technologies will industry as a whole. An example of a strategic create a larger supply of skilled, experienced goal that could be pursued is the expansion of workers able to research, develop, and operate the programming community. Such an expan complicated robotics systems. This could be sion could foster the skills necessary to use achieved by establishing collaborative “Cen Programmable Logic Controllers (PLCs) or ters of Excellence” to foster the development to change the perception of robots as “too of robotics applications in the private sector complex” for manufacturing. Increased col and bolster the supply of qualified employees. laboration for education and other initiatives These “Centers of Excellence” would offer will result in a workforce that is familiar with free assistance to small companies and foster robots and a manufacturing industry that is collaboration between industry, universities, more likely to deploy robots. and government to develop robotics solutions to manufacturing problems. To prepare stu Communcatons / Corporate Percepton dents for advanced study, high schools should The barriers created by the current public also incorporate education and simulations on and corporate perceptions of robots could be robotics, programming, and other topics. On addressed by national education campaigns, a larger scale, “Center of Excellence” col the development of case studies (including laborations could be extended globally to reap examples of successful robot implementation, domestic benefits from knowledge about ro

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maintenance ROI and programming in the Market Stmulaton manufacturing sector), and the organization of resource centers for robot users involved Stimulating the market for robotics in manu in manufacturing. Themes to be emphasized facturing will be achieved through both include: financial and policy measures. Tax incentives are one method of reducing the initial capi  robots are solutions to many manufactur tal investment required from a manufacturer ing inefficiencies when deploying new robots. These incentives  robots can help keep jobs in the U.S. should be focused on rewarding users whose  robots can increase U.S. manufacturing implementation of robotics leads to societal efficiency and help avoid the relocation of benefits, such as increasing worker safety or factories overseas conserving energy. Other means of directing financial support towards the use of robots Addressing these issues will help to alleviate in manufacturing include loans from the corporate concerns with investing in robot Small Business Administration (SBA) which ics systems. Far-reaching campaigns could target automation, robotics or intelligent as focus on broad issues, while case studies could sist devices (IAD). One method of pursuing be used to tackle barriers surrounding robot these incentives could be to contact legislative implementation, costs, maintenance, and pro groups, such as the U.S. Congressional Com gramming. Case studies should be published in petitiveness Caucus, to stress the capabilities manufacturing journals, mainstream business of robots to increase domestic manufacturing press, and other publications, describing user efficiency. expectations, disappointments, and successful integrations. Forums could also be established Investment in robotics could be further for users to exchange knowledge with one sparked by fostering a national resolve for the another, allowing for organic communication U.S. to become more competitive in the global between existing and potential robot users. robotics industry. This effort would require campaigns to educate the government and All of these communications initiatives could private industry on the need for additional indirectly stimulate the increased deployment dedicated funding for robotics R&D develop of robots in manufacturing by better inform ment, and how robotics might contribute to ing corporate investors and providing a road- U.S. competitiveness and keeping manufactur map for robot deployment. Both robotics case ing jobs from moving overseas. studies and a national campaign should focus on the use of robots in new industries, with an A survey of foreign robot technologies, their emphasis on opportunities in manufacturing. capabilities and applications, and their suit ability for transfer to the U.S. could help to identify and stimulate penetration into new markets. Competitions could then be held among ”Centers of Excellence” to explore ro bot technologies suitable for a specific market, task or application.

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PROJECT TITLE: C OLLABORATION & KNOWLEDGE TRANSFER PARTNERSHIPS

Key Objectives Key Milestones/Schedule Milestone Schedule  Form collaborative 1) Identify key industries/users that need partnerships to explain competitive assistance; identify target market 6-10 mos. and enhance use of 2) Assess state of the art: successful robotics in U.S. for applicationsvs. deficiencies 2-3 mos. competitive advantage 3) Identify short-falls During #2  Technical R&D 4) Call for participants to establish projects of  Education-workforce work/specific needs 6 mos. skills/acceptance 5) Group participants to tasks for each objective6 mos.  Address regulatory agencies (OSHA) 6) Identify funding servicesparticipants/ associations/government 1 mo.  Technology/knowledge transfer 7) Formal project proposals 6-18 mos. 8) Run projects 2-3 years Total 5-7 yr cycle

Enablers Expected Benefits Project Leader & Partners Next Steps  Initial starting Commercialization of Industry (users and  Gather enablers team enabling technologies suppliers) to start Step 1  Industry  <5 years—2-3 projects Academia associations  <10 years—10%  Government  Members industry participation Industry associations- would be optimal   Academia RIA  Suppliers

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PROJECT TITLE: INVESTMENT IN ROBOTICS R&D FUNDING

Key Objectives Key Milestones/Schedule Milestone  Identify areasneeding  Identify champion(s) for key technical tasks R&D work Formulate/articulate plan for matching resources and funding - High return—best ROI  (i.e., robotic surgery,  Identify key players in emerging markets/applications assembly)  Identify potential R&D resources - Academic programs - National laboratories - Small business - Research institutes  Identify sourcesof funding - Government - Industry - Foundations

Enablers Expected Benefits Project Leader & Partners Next Steps  Associations  New applications  NIST  Solicit R&D resources  Consortia  New markets  University robot programs Identify targets  Federal budget  Improved process  Contests Improved safety  Identify current   sources of  Education  International funding User need/input competitiveness   User needs  New collaboration conference

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PROJECT TITLE: R EDUCING INVESTMENT RISK, PART I

Key Objectives Key Milestones/Schedule Milestone Schedule  Develop standardized  Establish working group of manufacturers decision-making tool for and users process analysis to  Develop system approach/tools, key assist with specifying attributes, etc., that define a group of applications robotic systems with

built-in flexibility in  Programming and validation various plant Total time: 2 years applications (flow chart- qualitative)

Enablers Expected Benefits Project Leader & Partners Next Steps  Funding source  Avoidance of stranded  RIA (leader)  Post on public

 Industry interest assets  Manufacturers RIA website

 General feasibility of  System integrators use  Academia  Better, more flexible system specification

PROJECT TITLE: R EDUCING INVESTMENT RISK, PART II

Key Objectives Key Milestones/Schedule Milestone Schedule  Develop accurate cost  Establish working group to develop a model/template (include model/template using a manufacturers and users)

spreadsheet and  Data acquisition quantitative analysis

for:  Model development - Initial costs  Model verification

- Operating costs Total time: 1 year

Enablers Expected Benefits Project Leader & Partners Next Steps  RIA/federal  More reliable ROI  RIA (leader)  Post template on

funding results  Manufacturers public portion of RIA website  Data input from  Increased management  Academia manufacturers confidence in and previous investment applications  Actual results from various companies

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PROJECT TITLE: R EDUCING INVESTMENT RISK, PART III

Key Objectives Key Milestones/Schedule Milestone  Develop/improve  Establish working group

simulation and  Decision on software platform demonstration tools to

improve confidence in a  Development of user-friendly model for

robotic installation; purchaser use current simulation  Model verification

available only after  Model release purchase of system  Customer ability to do modeling prior to purchase

Enablers Expected Benefits Project Leader & Partners Next Steps  RIA  Improved confidence  RIA  TBD prior to purchase  Suppliers  Supplier decisions  Funding source  Simulation software  Improved sales ability supply for suppliers due to increased

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References

IFR 2005—The World Market of Industrial Vincent 2006—Vincent, D. “State of the Robots. IFR International Federation of Robot Robotics Market and Outlook for the Future.” ics 2005. http://www.ifr.org/statistics/key- Presented at the Robotics in Manufacturing Data2005.htm Roadmapping Workshop, Baltimore, MD. June 2006. RIA 2006—Robotics Industries Association. News 2006. www.roboticsonline.com/public/ WTEC 2006—Assessment of International articles R&D in Robotics. World Technology Evalua tion Center. 2006. www.wtec.org/robotics/re- UNECE 2004—“Buoyant robot sales port in North America.” Press release ECE/ STAT/04/P07. United Nations Economic Commission for Europe. October 2004.

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Appendx A: Lst of Partcpants

Robert Ballard, Robotic Workspace George Mochnal, Forging Industry Technologies, Inc. Association Lawrence Boyd, Energy Industries of Ohio Wyatt Newman, Case Western Reserve University George Brown, MeadWestvaco Corp. Joseph Pack, The Timken Company Nicholas Dagalakis, National Institute of Standards and Technology John Roemisch, FANUC Robotics America, Inc. Steve Dickerson, CAMotion, Inc. Nipendra Singh, S&A Consulting Group LLP Jeff Fryman, Robotic Industries Association Herschel Smartt, Idaho National Laboratory Leo Gruber, General Die Casters, Inc Joseph Stetter, SRI International Ralph Hollis, Carnegie Mellon University Charles Tolle, Idaho National Laboratory Sarne Hutcherson, The Timken Company Brian Valentine, U.S. Department of Energy Larry Keller, The Timken Company Gideon Varga, U.S. Department of Energy Thomas Kurfess, Clemson University Donald Vincent, Robotic Industries

Lonnie Love, Oak Ridge National Laboratory Association

Howard Mayer, Queen City Forging Derek Wadsworth, Idaho National Laboratory Ian Mitchell, Consolidated Industries, Inc.

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Appendx B: Acronyms Used n Acton Plans

DoD U.S. Department of Defense NIST National Institute of Standards and Technology DOE U.S. Department of Energy NSF National Science Foundation FDA U.S. Food and Drug Administration OSHA Occupational Safety and Health IEEE Institute of Electrical and Administration Electronics Engineers RIA Robotics Industry Association ISO International Standards Organization ROI Return on Investment NIH National Institutes of Health USCAR U.S. Council for Automotive Research NIOSH National Institute for Occupational Safety and Health

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