Improving Ergonomics of Collaborative Robot Workcells Using Passive Reconfigurable Fixtures

In contemporary manufacturing settings, adaptability and human-robot cooperation are crucial to addressing the challenges of high-mix, low-volume production. This paper presents a novel methodology to improve workcell ergonomics by optimally placing reconfigurable fixtures and other workcell elements. Based on the personalized upper body models of human workers, we define a comfortable workspace for each arm. Through the development of comprehensive optimization problems, we compute workcell configurations to align with individual ergonomic needs without compromising production goals. We validate our approach through case studies in the automotive sector, including the assembly of light housings and car starters. Results from these studies, based on objective and subjective metrics, affirm the potential of reconfigurable workcell elements to improve ergonomic conditions for workers, thereby contributing to safer and more productive manufacturing environments. This research contributes to the field by prioritizing ergonomics in the design of collaborative manufacturing systems through the implementation of cost-effective reconfigurable solutions.