Abstract
In advanced industrial automation, industrial robots have been widely utilized on assembly lines in order to reduce labor dependence. However, many related layout design approaches proposed are prone to generating unsafe layouts: there generally lacks a consideration regarding robots’ heights and assembly range, which will lead to costly collisions in the operation stage. In order to address the problem, we propose a three-dimensional (3D) optimization approach to a safe layout design for an assembly line with robots. We define modeling rules for robots to judge assembly ranges. A quantitative safety indicator is employed as a trigger for 3D collision detection in order to determine the positional relationship and status of the safe assembly collaboration. The optimization goals are established for minimizing the logistical cost and layout area in the model. A combined algorithm of differential evolution and nondominated sequencing genetic II is applied, which effectively enhances the poor diversity and convergence of the mainstream optimization method when solving this model. The benchmark tests and validation proved that our approach yields excellent convergence and distribution performance. The case study verifies that the safe layout model is valid and our approach can generate a safe layout in order to optimize economics and safety.
Highlights
In the context of “Industry 4.0” [1], the market demand is constantly changing
Our experimental and statistical results of optimal layout plan for assembly lines increase by 14.5%, and our approach can generate a safety layout in order to optimize economics and safety
Our experimental and statistical results of optimal layout plan for assembly lines increase by 14.5%, and the safety performance of assembly line layout increased by 20.63%
Summary
In the context of “Industry 4.0” [1], the market demand is constantly changing. There is a trend that the customer needs personalized customization [2,3]. The above-mentioned researches have not taken into account the safety layout of the application scenarios of the assembly line with robots, a complete layout optimization of workstations, machines, robots, and 3D layout design that highlights safety is missing. This paper proposes a safety layout optimization approach, named SE-NSGA2, which considers safe 3D layout design for assembly lines with robots. This approach considers the height of equipment and determines the safety of different assembly process routes. The multi-objective combination method is based on the high-quality performance of NSGA-II and it integrates the DE algorithm in order to reduce repetitive planning and effectively increase the diversity of solutions. When compared with the original NSGA-II method, the safe layouts increase by 20.63%
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