Innovations in the Smart Assembly research project

Electronics manufacturing service (EMS) companies are faced with major challenges due to labor shortages and require flexible and cost-efficient automation solutions for manual assembly of electronic products, especially using through-hole technology (THT). OEM with inhouse electronics manufacturing also recognize the growing need for action in this area.

To address this need, a team of automation experts from SFA GmbH & Co. KG and researchers from the IPS worked together to develop an intelligent assembly system for THT within the Smart Assembly R&D project.

In the early project phase an ABB YuMi robot served as a basis for the intelligent assembly system controlled via Robot Operating System (ROS) and utilizing simple cameras with load cells. The system has delivered promising results in THT assembly. Based on its sensory data, the YuMi robot could deal with gripping deviations while inserting various electronic components. This achievement was honored with the Best Paper Award at the 2023 International Conference on Control, Mechatronics and Automation in Norway (A Cost-Efficient Robotic Through-Hole Assembly System for Dual-Pin Component Insertion | IEEE Conference Publication | IEEE Xplore).

To achieve particulary precise movements, the project team made the next step and developed a Hexaglide manipulator, which belongs to the class of closed kinematic chains. It provides exceptional absolute accuracy and can be combined with various robots. The core sensor and control concept is the same as in the initial YuMi system, but the Hexaglide moves the printed circuit board (PCB) instead of the electronic component. Our article about the development and validation of the manipulator has made it to the cover of a renowned German manufacturing journal wt Werkstattstechnik Online! Inhalte der Online-Ausgabe 9-2024

Multiple companies across Germany have supported us on our way. They have provided valuable practical insights and real products for experimentation. Our special thanks is to them and we are excited about upcoming projects in robotic system integration.

Funding Reference:

This project is supported by the Federal Ministry for Economic Affairs and Climate Action (BMWK) on the basis of a decision by the German Bundestag.

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