In the complex world of High Mix Low Volume (HMLV) manufacturing—specifically in custom battery assembly—efficiency often depends on the management of specialized equipment. Assembling these components can require over 20 different tools, and the constant need to locate and transfer them creates frequent interruptions, delays, and physical strain for workers.
To address these challenges, the Key Intelligent & Interactive Robotic Operator (KIRO) was developed as part of the ARISE Challenge 7, which focuses on using Human-Robot Interaction (HRI) to improve worker efficiency in high-precision, flexible tasks. KIRO is a collaborative solution designed to empower workers rather than replace them.
Natural Interaction and Intelligent Mobility
KIRO is a mobile robotic manipulator built on an open-source framework (ROS 2) that navigates dynamic factory environments autonomously. The foundation of this solution is a mobile robot originally designed and developed from scratch by IKH, which iLink has further enhanced with advanced AI-driven interaction.
Unlike traditional industrial robots that require complex programming, KIRO uses Large Language Models (LLMs) to process natural voice commands. This allows a worker to simply state their need, such as “Bring me the electric screwdriver,” and the robot will identify, pick, and deliver the tool precisely to the requested location.
According to the Proof of Concept (PoC) results, the system utilizes a robust hardware platform:
- Physical Specifications: A 150kg mobile base capable of carrying over 100kg.
- Manipulation: A high-precision UR10e robotic arm equipped with a custom vacuum gripper and a vision camera for secure tool handling.
- Social Navigation: With technical support from the ATHENA Research Center, the robot’s navigation stack was refined to move safely and efficiently in environments rich with human activity. Using sensors like LiDAR and Ultra-Wide Band (UWB) positioning, it tracks both its own location and the positions of workers in real-time.
Safety and Resilience in Busy Environments
Safety is integrated into the core of KIRO’s operation through dynamic safety zones. These zones allow the robot to adjust its proximity and speed based on worker movements, ensuring a comfortable and secure collaborative space.
The PoC also demonstrated the system’s resilience through a “Resilient Scenario.” In a busy environment where a path might be completely blocked, KIRO is programmed to handle the obstruction safely.
If it cannot complete its mission independently, it can stop and request human assistance before resuming its task, ensuring a high level of fault tolerance and trustworthy interaction.
A Shared Contribution to the ARISE Ecosystem
A key objective of the KIRO project is to foster open innovation. The project has developed several reusable ROS 2 modules that are being contributed to the ARISE catalog for the broader industrial community. These include:
- Social Navigation: Algorithms for path planning and obstacle avoidance in environments rich with human activity.
- Tool Recognition: A computer vision system, refined in collaboration with ATHENA, for identifying industrial tools and estimating their pose for high-precision grasping.
- Close-Proximity Interaction: Systems that use real-time feedback to adjust safety zones during human-robot collaboration.
The integration of these modules is managed via a centralized data hub (FIWARE Orion LD), allowing the robot to communicate seamlessly with warehouse management systems and mobile applications used by the staff.
Global Impact and Social Value
The potential for this technology extends beyond battery assembly into sectors such as electronics, logistics, and healthcare. By automating repetitive, low-value tasks like tool fetching, KIRO allows workers to focus on creative, high-value tasks that require human expertise.
The social and industrial benefits are significant:
- Efficiency: A projected 15-20% increase in productivity by reducing task overhead.
- Enhanced Safety: A 50% increase in operator safety through collision-avoidance algorithms and real-time tracking.
- Inclusivity: The voice-controlled interface makes the technology accessible to workers with diverse technical backgrounds or physical limitations, reducing the cognitive and physical workload.
By prioritizing human-centricity and open-source collaboration, KIRO sets a new benchmark for Industry 5.0, demonstrating how robotics can serve as a powerful tool for a more sustainable and equitable industrial future.
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