With a combination of sensor systems and six degrees of freedom independent kinematics, the Smart Flex Effector compensation module of the Bosch Rexroth intelligent end-effector gives industrial robots a human-like sense of touch, providing an option for automating processes that were previously difficult to handle or had to rely on manual execution. This innovation was awarded the Hermes Prize 2023 – one of the most prestigious international industry awards – during the Hannover Messe. The Smart Flex Effector, an intelligent end-effector, sensitively compensates tolerances in real time, thus expanding the range of applications for robots, enabling users to automate joining processes, complex assembly operations or difficult handling tasks. For existing robot applications, the compensation module can also be retrofitted accordingly.
Bosch Rexroth was awarded the Hermes Prize 2023 at the opening ceremony of the Hannover Messe. (Image source: Bosch Rexroth AG)
Thomas Donato, Member of the Executive Board for Factory Automation at Bosch Rexroth, said: "Bosch Rexroth is shaping the future of automation through the intelligent connection of hardware and software. Through the interaction of sensors and software, industrial robots can reduce the workload of repetitive or high-intensity tasks for operators. "At present, robots are generally only able to perform gripping and assembly tasks with high quality and high standards if the workpiece is always in the programmed position. Since fixed programming often does not flexibly sense and react to changes, even small position deviations can lead to errors.
The intelligent end-effector is designed for articulated robots or Cartesian linear systems and is based on a kinematic system with six degrees of freedom. With haptic technology, the sensor detects the exact position of the workpiece to be clamped and reports the actual position in real time to the controller, which adjusts the motion sequence of the fixture to a specific position. In this way, the intelligent end-effector automatically compensates for tolerances while removing and positioning the workpiece, thus reducing the need for programming, especially when handling different parts. In addition, if the employee does not have programming knowledge, the robot can be manually taught by manually moving the fixture to the correct position. This innovative product was developed by the Bosch Research Institute in cooperation with Bosch Rexroth.
The compensation module is extremely sensitive and can even handle workpieces made of fine materials such as glass safely. Intelligent end-effectors improve the quality of process monitoring by recording and documenting every movement as a data set. Based on this data, deviations can be detected immediately by the control system or higher-level systems, corrected or reported to the operator to prevent errors and avoid additional costs due to product non-conformance or subsequent remediation work.
The Smart Flex Effector can communicate with the relevant controller via a common interface and can therefore be easily integrated into existing robots. As a result, it enables more applications that were previously not equipped with automation solutions to be upgraded.
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