A proposal of an assembly workstation for car panel fitting aided by an augmented reality device

In the automotive sector, panel fitting operations represent a delicate phase of the assembly process, during which car bodywork components are manually aligned attempting to comply with spacing tolerances. Digital technologies currently promoted by the Industry 4.0 approach, such as collaborative robots and augmented reality (AR), could assist workers for reducing execution times of this "trial and error"procedure. On the one hand, human-robot collaboration (HRC) can enhance assembly process efficiency, by combining human dexterity and cognitive capabilities with robot repetitiveness and support in heavy load handling; on the other, AR can provide interactive instructions to guide workers during the process. In this regard, the present paper is focused on the development of a novel assembly workstation using HRC and AR to support workers during car panel fitting operations. The system is based on the implementation of an algorithm able to convert the values on panel spacing, which are measured by laser gauge positioned on the collaborative robot, in the instructions for the worker to correctly carry out the panel fitting operation. The paper finally presents the application of the system to a real assembly example.