This study examines the digital value chain in automotive manufacturing, focusing on the identification, software flashing, customization, and commissioning of electronic control units in vehicle networks. A novel precedence graph design is proposed to optimize this process chain using an automated scheduling algorithm, which combines structured data extraction from heterogeneous sources via natural language processing and classification techniques with mixed integer linear programming for efficient graph generation. The results show significant improvements in key metrics. The algorithm reduces the number of production stations equipped with expensive hardware and software to execute digital value chain processes, while also increasing capacity utilization through efficient scheduling and reduced idle time. Task parallelization is optimized, resulting in streamlined workflows and increased throughput. Compared to the traditional scheduling method, the automated approach has reduced preparation time by 50% and reduced scheduling activities, as it now takes two minutes to create the precedence graph. The flexibility of the algorithm’s constraints allows for vehicle-specific configurations while maintaining high responsiveness, eliminating backup stations and facilitating the integration of new topologies. Automated scheduling significantly outperforms manual methods in efficiency, functionality, and adaptability.

Robot interaction control is often limited to low dynamics or low flexibility, depending on whether an active or passive approach is chosen. In this work, we introduce a hybrid control scheme that combines the advantages of active and passive interaction control. To accomplish this, we propose the design of a novel Active Remote Center of Compliance (ARCC), which is based on a passive and active element which can be used to directly control the interaction forces. We introduce surrogate models for a dynamic comparison against purely robot-based interaction schemes. In a comparative validation, ARCC drastically improves the interaction dynamics, leading to an increase in the motion bandwidth of up to 31 times. We introduce further our control approach as well as the integration in the robot controller. Finally, we analyze ARCC on different industrial benchmarks like peg-in-hole, top-hat rail assembly and contour following problems and compare it against the state of the art, to highlight the dynamic and flexibility. The proposed system is especially suited if the application requires a low cycle time combined with a sensitive manipulation.

Insertion tasks are fundamental yet challenging for robots, particularly in autonomous operations, due to their continuous interaction with the environment. AI-based approaches appear to be up to the challenge, but in production they must not only achieve high success rates. They must also ensure insertion quality and reliability. To address this, we introduce QBIT, a quality-aware benchmarking framework that incorporates additional metrics such as force energy, force smoothness and completion time to provide a comprehensive assessment. To ensure statistical significance and minimize the sim-to-real gap, we randomize contact parameters in the MuJoCo simulator, account for perceptual uncertainty, and conduct large-scale experiments on a Kubernetes-based infrastructure. Our microservice-oriented architecture ensures extensibility, broad applicability, and improved reproducibility. To facilitate seamless transitions to physical robotic testing, we use ROS2 with containerization to reduce integration barriers. We evaluate QBIT using three insertion approaches: geometric-based, force-based, and learning-based, in both simulated and real-world environments. In simulation, we compare the accuracy of contact simulation using different mesh decomposition techniques. Our results demonstrate the effectiveness of QBIT in comparing different insertion approaches and accelerating the transition from laboratory to real-world applications. Code is available on GitHub3.

Automating complex tasks using robotic systems requires skills for planning, control and execution. This paper proposes a complete robotic system for maintenance automation, which can automate disassembly and assembly operations under environmental uncertainties (e.g. deviations between prior plan information). The cognition of the robotic system is based on a planning approach (using CAD and RGBD data) and includes a method to interpret a symbolic plan and transform it to a set of executable robot instructions. The complete system is experimentally evaluated using real-world applications. This work shows the first step to transfer these theoretical results into a practical robotic solution. Note to Practitioners—This paper is inspired by the actual deficit to automate maintenance tasks in manufacturing environments through robotic systems. The focus of this work is on providing a practical robotic solution which can automate maintenance tasks completely autonomously. For this, the different skills from manipulation planning to the control and execution are explained. One main aspect of this work is to show how to create elementary robot motion tasks from symbolic plans. The second important part is to explain the practical capabilities applied on real-world applications.

Robot learning is often simplified to planar manipulation due to its data consumption. Then, a common approach is to use a fully-convolutional neural network (FCNN) to estimate the reward of grasp primitives. In this work, we extend this approach by parametrizing the two remaining, lateral degrees of freedom (DoFs) of the primitives. We apply this principle to the task of 6 DoF bin picking: We introduce a model-based controller to calculate angles that avoid collisions, maximize the grasp quality while keeping the uncertainty small. As the controller is integrated into the training, our hybrid approach is able to learn about and exploit the model-based controller. After real-world training of 27 000 grasp attempts, the robot is able to grasp known objects with a success rate of over 92 % in dense clutter. Grasp inference takes less than 50 ms. In further real-world experiments, we evaluate grasp rates in a range of scenarios including its ability to generalize to unknown objects. We show that the system is able to avoid collisions, enabling grasps that would not be possible without primitive adaption.

The research and development of intelligent automation solutions is a ground-breaking point for the factory of the future. A promising and challenging mission is the use of autonomous robot systems to automate tasks in the field of maintenance. For this purpose, the robot system must be able to plan autonomously the different manipulation tasks and the corresponding paths. Basic requirements are the development of algorithms with a low computational complexity and the possibility to deal with environmental uncertainties. In this paper, an approach is presented, which is especially suited to solve the problem of maintenance automation. For this purpose, offline data from CAD is combined with online data from an RGBD vision system via a probabilistic filter, to compensate uncertainties from offline data. For planning the different tasks, a method is explained, which uses a symbolic description, founded on a novel sampling-based method to compute the disassembly space. For path planning, we use global state-of-the-art algorithms with a method that allows the adaption of the exploration stepsize in order to reduce the planning time. Every method is experimentally validated and discussed.