Public Funding for Hal Robotics Ltd

_Variability_ _is traditionally the enemy of automation__, but with today's focus on customisation and choice this needs to change. To be widely used and adopted across UK manufacturing. automation must be able to handle large dimensional changes and be capable of changing quickly and effectively between different operations. This project addresses this issue with the development and application of an adaptive path planning system that will alter the pre-set robot program whilst in use so that changes in part shape and size can be accommodated._ _A technology demonstrator of an automated linishing and polishing_ _automation cell will be built_ _to highly polish plastic parts. The system will have the capability to measure and react to the size, shape and requirements of the part to be processed thereby making it self-programming and adapting._ _Blanson_ _are a manufacturer of highly engineered acrylic parts and will be supported by two SME, robotic technology partners, A3L and HAL Robotics. A3L are robotic integrators focused on delivering automated finishing operations to SME's but they hope to become a high-end global supplier of automated finishing solutions. HAL Robotics are specialists in adaptive robot path planning, their software Framework allows the use of sensor or/and measurement data to alter robot programs 'on the fly' thereby allowing for the process to be flexible and controlled by the attributes of the part._ A3L will work together with HAL to deliver an innovative finishing solution that can be utilised within Blanson's manufacturing facility. We are aiming for a 'one size fits all' approach to finishing automation, i.e., the system will be able to process multiple parts without reprogramming. It will utilise sensor data to determine where the process needs to be applied and when it is complete i.e., surface roughness or part geometry readings will be fed back into a software solution which will determine fitness and automatically generate any necessary corrective robot toolpaths. AI will also be used to process data to optimise use of abrasive consumables. Current best practice is to use the abrasives for a set time period and then dispose of them (whether they are spent or not), we believe the volume of consumables used monthly can be greatly reduced delivering huge cost savings and driving a greener approach.

Connectivity between devices in a manufacturing chain is key to enabling Industry 4.0 and Smart Manufacturing by closing feedback loops and increasing flexibility and adaptability of automation cells. In a contemporary factory, the connections between sensors, robots, end-effectors, PLCs, CNC machines and other devices are made via cables operating Fieldbus protocols. Achieving the same with a wireless technology opens innumerable possibilities by connecting more devices, faster, and in a more flexible manner, effectively giving manufacturers greater control over their connectivity. 5G promises a number of useful properties for industrial communications in manufacturing. The first is often referred to as Ultra-Reliable Low Latency Communications (URLLC). Ultra-reliable means that the probability of a message not reaching its target is between one in a million and one in a billion (10-6 -- 10-9). Low latency refers to millisecond latencies, ensuring that the time between a message being sent and actually entering the network is five times lower than 4G and WiFi. 5G also allows massive connectivity, supporting one million connected devices per km2. Together these properties put 5G on a par with contemporary industrial communication protocols. To actually achieve these properties in a network requires advanced mechanisms and algorithms to make complex, real-time decisions about the orchestration and management of the network resources and nodes. The focus of the UK cluster of the European ANIARA project is to develop 5G edge and distributed solutions for intelligent control, monitoring and performance enhancement of industrial manufacturing assets, process flows and in-factory product optimisation. This entails creating a dedicated network slice, or a private network, for a manufacturing facility where network and radio resources can be optimised to provide the required reliability, low latencies and predictable connectivity for industrial operation. ukANIARA will develop edge and semi-distributed AI techniques, most notably data-driven deep neural networks, combined with traditional model-based approaches to handle real-time resource management and orchestration. The network itself will be supported by a flexible, cloud-native, micro-service architecture with defined application programming interfaces (APIs) to facilitate orchestration and ensure scalability and modularity for the addition of new industrial applications. An edge-cloud architecture will support dynamic management of underlying resources to provide the single-digit millisecond latencies and ultra-high reliability required of 5G for factory scenarios. The project will demonstrate the possibilities of 5G in manufacturing on controlled-industrial site networks and results will be disseminated in high-calibre industrial and academic events.

no public description

International competitiveness requires the UK to modernise its industrial capabilities, which are steering industries towards widespread development and adoption of automation, and autonomous based solutions. These technologies have the potential to create novel and disruptive manufacturing capabilities leading to significant improvements in quality, accuracy, precision, and cost to manufacture. High integrity welding is a key enabling technology for UK manufacturing and the purpose of WeldZero is to develop and showcase the benefits of adopting intelligent welding robotic system solutions within a cyber-physical production system (CPPS). The WeldZero project will develop and showcase the benefits of digital technologies applied to welding operations in an industrial manufacturing context to support a zero defect strategy. By bringing together state-of-the-art data integration approaches and data handling with real-world manufacturing to work to the achievement of zero defects in a multi-stage production line. This will prove the effectiveness of digital welding and accelerate the wider adoption of the new Industry 4.0 strategies in the existing manufacturing systems -- improving the competitiveness of the UK. The system created will be based around a data rich manufacturing environment whereby both direct machine control and feedback can be collated and processed in real-time. Coupled to this system will be a number of additional technology applications such as weld toolpath planning and simulation, advanced sensor integration and control algorithms, machining learning and data analysis. This will then feedback into specific welding cell control systems to substantially improve manufacturing performance. The project will demonstrate the impact of WeldZero using four different welded product applications from the construction, automotive and off-shore manufacturing sectors; each using different welding process solutions; with the aim of increasing productivity by at least 40%. WeldZero contributes to all key innovation areas under the Manufacturing Made Smarter competition: Smart connected factory: application and use of use of real-time data to optimise operational efficiency capture, analysis and visualisation of manufacturing processes. Connected and versatile supply chain: Full process information integration, communication and traceability are a key aspects of WeldZero. Design, make, test, including: Primarily contributing to virtual product testing, verification and validation, quality monitoring and inspection -- in the context of weld processing and manufacturing sequencing design. Adaptable, flexible manufacturing operations: Enable adoption of advanced welding technologies in a human-centric automation and autonomy, enabling flexible manufacturing systems.

Distributed Manufacturing for Off-site Construction (DMOC) proposes a system to extract manufacturing information from an enhanced Building Information Model (BIM) and automatically dispatch production tasks to multiple facilities based on, among other factors, process capabilities, capacity and geographic location. DMOC enhances existing Design for Manufacturing and Assembly (DfMA) approaches, including those for Platforms, by embedding manufacturing process data in digitally designed components and assemblies. This data can be converted directly to machine toolpaths, effectively automatically programming robots. This removal of manual programming is critical to enabling automation for small batch production typical of the construction supply chain. The DMOC solution will include a hybrid-cloud orchestrator which will communicate with connected production cells to efficiently distribute all authorised workloads which have been submitted to it. The orchestrator will also handle reassigning tasks should any faults occur at a production facility adding supply-chain robustness, guaranteeing business continuity, increasing manufacturing efficiency and improving planning for just-in-time (JIT) delivery. DMOC production cells will each include an embedded edge-compute device which will handle communication between the orchestrator and robotic hardware controllers, simulate tasks to ensure safe execution and prepare machine code for that specific cell's mechanical configuration. Successful execution of the project will lower the barrier to entry of automation by simplifying programming, increasing utilisation of machinery and reduce the requirement for capital investment by leveraging existing facilities. It will also grow automated MMC capacity, improve building performance through tighter tolerances and increase productivity in construction processes by up to 40% supporting the goals of the _Construction Sector Deal_. The project consortium will bring together experts in a number of fields to deliver a solution that would not be feasible without their combined skillsets. aLL Design has expertise in DfMA and have developed modular housing designs using a Platforms approach. Hoare Lea has significant experience with modular construction, BIM and off-site manufacturing. Together they provide the construction experience required to successfully deliver the project. Robotic software SME, HAL Robotics will provide the integration of manufacturing processes with BIM, machine simulation and procedure validation, and communication with industrial machines. Konica Minolta will build upon previous work on their Distributed Cloud Intelligence (DCI) platform to integrate hardware and production process requirements into its orchestration capabilities creating the automated link between BIM and manufacturing cells.

"Traditional construction is a low-tech but flexible manufacturing process. It is carried out 'on-site' using pre-manufactured components (windows, doors, bricks, blocks etc) and the manufacture of basic elements such as concrete, plaster etc. Whilst its flexibility has much to commend it (given the bespoke nature of buildings and their geographic distribution) it is inefficient in time and costs, and prone to skills, quality, waste and H&S issues that are more complex than in conventional factory manufacture. It also does not lend itself to efficient automation; sales of robots to construction companies is much lower than in other sectors. **COSCR** project partners (a consortium of construction companies and robotic solution providers) are working to develop cost effective, reconfigurable robots that can be deployed throughout construction supply chains for the factory based manufacture and assembly of component parts that can then be transported to the construction site prior to installation. However, on-site construction presents additional challenges in that robots must be rugged and mobile, and readily reconfigured to new tasks, to enable them to move easily between locations and activities. They must be capable of accurate but autonomous positioning such that activities match the building design (included in a digital Building Information Model). Safety in use is essential; construction sites are dynamic environments, with human workers needing to carry out tasks, potentially in close proximity to a robot. If these challenges can be addressed there are potentially huge benefits in terms of construction productivity and quality (e.g. potentially dangerous tasks such as drilling at height completed 4 times faster than is possible by human workers) as well as health and safety benefits. On-site robotics will also help to address ongoing skills shortages in construction whilst presenting greater opportunities for upskilling. The COSCR project will therefore develop and assess an innovative, mobile construction platform equipped with robotic arm, that is capable of delivering a range of repetitive on-site activities in a safe, cost effective manner. The project will be led by UK SMEs **HAL Robotics** and **I****nnoTecUK** together with multinational robotics and construction equipment manufacturers **ABB** and **Skyjack**. **Skanska**, a leading international construction contractor will pilot and assess the COSCR solution in the context of real on-site construction projects to enable project partners to identify and plan the next steps needed for the development of a full commercial system. We believe that there is a huge opportunity for use in construction sectors globally."

The project will innovate in adaptable, reconfigurable robotic and supporting digital manufacturing technology to deliver a step change in productivity in processes that manufacture & assemble a range of products in small production lots. It will focus on construction product manufacture but outcomes will also be applicable to other manufacturing sectors. Robots have not, to date, been used in these contexts as it has not been possible to easily reconfigure them between different product runs leading to low utilisation, preventing the productivity gains needed to justify investment in automation. However, recent advances in robotics mean that the time is ripe for innovation. Robots must be adaptable and linked to digital design & management capabilities to enable reconfiguration, with manufacturing processes/supply chains reengineered to optimise overall productivity. The project will therefore develop a reconfigurable robotic solution for construction product manufacture and assembly that links to digital Building Information Modelling (BIM). As a use case it will take supply chains for steel fabrication, and mechanical and electrical (M&E) equipment in which parts are factory-manufactured, then assembled near to a construction site in a temporary ‘flying factory’. Successful implementation will lead to a 30% improvement in supply chain productivity. It will create a new market for UK companies (including an SME) providing robotic and related digital solutions for construction. The project solution will be applicable to wider manufacturing sectors where the ability to manufacture multiple product types in low lot sizes is key.

Large companies that manufacture products in high volumes have long been able to justify the significant investment required to set up robotic manufacturing processes. Inovo Robotics are developing an innovative modular robotics ecosystem that is a versatile tool to suit the needs of an SME with frequently changing applications. Using a set of ‘plug and play’ components we will enable SMEs to easily configure a robot for their application using basic interfaces, but also to reconfigure it for different applications. Current robot arms available on the market are typically expensive and difficult to program, and SME 's find it difficult to justify them for their ever changing needs. However, UK SME's need to benefit from RAS to remain competitive with large corporations and foreign businesses. We aim to develop a verstaile RAS product for SME's, Services, Agriculture, Healthcare, Mobile production, and logistics. The outcome of this project will enable all manufacturing SME's to improve efficiency, increase growth, maintain competitive advantage and take a step into RAS by owning a modular platform which can be upgraded in the future.

Construction accounts for 9% of UK GDP, employing 3M people. Whilst the size of the construction industry suggests that there should be many opportunities for the use of robotics, uptake has been slow. Projects are often bespoke, with complex supply chains. Demand also fluctuates, leading to a risk-averse approach to investment. Previous work has shown that individual construction tasks can be efficiently and effectively automated. However, to achieve the overall efficiency improvements needed to justify investment it is essential that robotics and autonomous system (RAS) solutions can move between different activities (either on-site or in a temporary construction component assembly factory) and to be easily reconfigured by non-expert staff. Mobility and positioning is a key component of this but existing mobile solutions are not suitable for use in harsh, dynamic environments that typify construction. The project will therefore build on recent innovation in the development of construction RAS. It will develop, demonstrate and assess a proof of concept version of a robust mobile 'platform' and supporting visioning and positioning capabilities that can support, place and control a robotic arm in a 'flying factory' or small product manufacturing factory.

Concrete is widely used in construction due to its ability to provide structural capacity andfunction cost effectively and at scale. However, its role in construction does not lend itself tocreativity in design. High-end clients typically demand state-of-the-art designs, presenting achallenge in a sector where every building is essentially different to the last. The CAMBER project will seek to develop an innovative 3D concrete printing (3DCP) platformthat meets these demands. 3DCP has the potential to deliver more creative designs whilst stillmaintaining building function cost effectively. However, there are challenges that need to beovercome in terms of materials supply to the printing nozzle, providing support material for theconcrete prior to setting to produce complex geometries and overhangs, finishing afterplacement to provide a suitable surface and materials formulation. Work is also needed to linkthe 3DCP to building information modeling capabilities. Additionally a 3DCP capability needsto be mobile such that it can be readily set up and used on a construction site (or in temporary,near-site factory) in order to optimize productivity in line with recent construction processinnovation.Building on recent R&D work and IP developed within the consortium CAMBER will addressthese barriers and opportunities. Led by Skanska to ensure that user needs remain a focus andto provide a route to market, it brings together a strong, supply chain-orientated consortiumfrom construction (Skanska, Tarmac, Fosters + Partners, BRE), manufacturing automation(ABB, MTC, Loughborough University) and an SME digital solutions provider (HAL). It builds onprevious R&D work (and IP) by project partners (including innovation in the application of BIMto product design, as well as materials, process and finishing). It will develop a mobile additivemanufacturing platform (and associated supply and processing capabilities) for the costeffective,mainstream 3D printing of a wide range of large concrete components (includingcomplex geometries), such as façade units, wall panels, partitions, street furniture etc. inprecast concrete factories or via the mobile platform in a near/onsite flying factory. The initialfocus will be on meeting the requirements for 'high-end' markets. However, successfulimplementation and subsequent economies of scale will mean that the approach will be costeffective in more mainstream construction markets. The platform will integrate recent digitalconstruction sector innovations -- especially Building Information Modelling (BIM).