For the first time, BMW is set to implement humanoid robots in car production across Europe.
Two robots developed by Hexagon Robotics are set to begin working in manufacturing during the summer. They are currently undergoing testing at the Leipzig factory.
"This will represent the future of vehicle manufacturing," states Michael Nikolaides, head of process management and digitalization at BMW.
Automobile manufacturers have utilized robotic arms and other forms of automation for many years.
What is the reason behind the shift towards human-like robots?
"If you possess a humanoid shape, you can essentially assign it to any workplace where a human is currently employed, as it has the same dimensions and abilities," says Nikolaides.
The price of robots has decreased, yet it is still costly to reconfigure the production line. Consequently, it is now more economical to employ robots that can integrate with current human workflows.
"If a robot costs 17 million, you would restructure your factory around the robot, but that's no longer the case," says Bill Ray, a senior VP analyst at Gartner.
So now you're trying to incorporate it into your current workflow.
Called Aeon, the Hexagon robot has a human-like shape and is 1.65 meters (5 feet 5 inches) in height, with a weight of 60 kilograms (9 stone 6 pounds).
They can reach a maximum speed of 2.4 meters per second and are capable of carrying 15 kilograms for brief durations, or 8 kilograms on a continuous basis.
Aeon features 21 sensors, such as cameras, radar, a microphone, and force and torque sensors used for handling tasks.
At BMW, robots were taught through a mix of teleoperation (with sensors worn by humans) and simulation within a digital replica of the factory, utilizing software from Nvidia.
The machine within the simulation was assigned a task and underwent multiple iterations to discover the most effective solutions, a method known as reinforcement learning.
Teleoperation was employed for activities like retrieving a component, allowing the physical robot to understand the various methods a human uses to perform the task.
The development of robot training is advancing quickly - the faster you can train a robot, the better.
One of the most thrilling elements of applying AI to the real world (physical AI), as noted by Arnaud Robert, Hexagon's robotics president, is imitation learning.
This is where the robot acquires the ability to perform a task by observing how it is carried out, either through videos captured from various perspectives or using motion sensors attached to a person. Robert mentions that imitation learning can significantly reduce the training time for a robot, from months down to just a few days.
The most effective translation [from human to robot] occurs when the teacher and student share the same physical structure.
Could the robot observe a person loading boxes for a while and then participate?
That's the most extreme situation," remarks Robert. "You're likely talking about something that's a year or two away.
Ray from Gartner predicts that in three to five years, a robot will be capable of following basic voice commands to complete a task efficiently.
Aeon offers a battery life of just three hours, yet a shift lasts eight hours, which is why the robot was created to replace its own battery in approximately three minutes, including the time needed to travel to and from the charging station.
The robots at BMW will be responsible for supplying components to manufacturing equipment and performing pick-and-place operations during battery assembly. Despite being versatile, these robots, similar to human workers, will not be required to switch tasks often.
Nikolaides notes that robots can assist with tasks that are repetitive or physically demanding for humans, and they can also help alleviate a shortage of workers.
"We are aware that there will be a shortage of staff within a few years, and human-like robots can assist," says Nikolaides.
When we automated car production in the 1970s, everyone claimed this would result in numerous job losses, but the opposite happened," he states. "New jobs were generated by this technology, and that's how we view [humanoid robots].
Other automobile manufacturers are also showing significant interest in advanced robotics.
For instance, Toyota intends to implement Digit humanoid robots from Agility Robotics after a successful trial. China's Xiaomi has experimented with two of its own humanoid robots in electric vehicle manufacturing.
Hyundai is employing Spot robots for factory inspection andhas announced plansTo utilize Atlas humanoid robots, which are developed by Boston Dynamics, a company in which Hyundai holds a majority stake.
BMW has previously used humanoid robots in Spartanburg, United States, where the Figure O2 robot assisted in assembling 30,000 X3 model vehicles. It operated at the same speed as a human worker.
One finding from the United States indicated that robots utilizing artificial intelligence handle variations more effectively than earlier equipment. "If you slightly move the sheet metal, shift it, or tilt it, a conventional industrial robot would experience a problem," explains Nikolaides. "These human-like robots can assess the situation and continue operating without interruption."
A major distinction between the Figure and Aeon robots is that Figure moves on foot, whereas Aeon uses wheels instead of legs.
"It is more logical on a shop floor [to have wheels] since Aeon can move from one location to another," says Nikolaides.
BMW has also employed a Boston Dynamics Spot robot, which resembles a canine, as a security monitor for maintenance purposes.
He needed to be capable of climbing stairs," says Nikolaides. "He was able to descend to the basement, where a significant amount of equipment was located.
The robots have been received positively by the staff, according to Nikolaides. He envisions individuals will name them, similar to how they have named previous non-humanoid robots.
If it lacks a name, it's just a machine," notes Gartner's Ray. "If it makes an error, it's considered faulty. But if it has a name, people are more understanding and willing to forgive its mistakes. One of our recommendations to businesses is to assign names to your robots.
Aeon features a display on the front of its head instead of a human face, showing symbols like a line while it works and a circle when it's listening.
"We're still developing that [visual language], but we are very convinced that Aeon should communicate in a manner that is intuitive for humans," says Robert.
Humanoid robots are beginning to appear in work environments alongside people, but Ray thinks these robots have been exaggerated in their capabilities, particularly due to high-profile showcases.
The main application for a humanoid robot today is to walk on stage and artificially boost your stock price," he states. "Robots dancing or anything similar: That's not really that challenging to accomplish.
There is a possibility that individuals may exaggerate a robot's abilities, he mentions.
When you observe a humanoid robot moving, you expect it to be capable of running, climbing, and jumping. In reality, it cannot perform any of these actions, yet your mind fills in those missing details. We are setting unrealistic expectations when these robots are put into use.
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