Lightweight Cobot Takes on Dishwasher Testing at BSH Hausgeräte GmbH

Summary

Since mid-2024, a lightweight robot from Kassow Robots has been efficiently managing a range of testing tasks for domestic dishwashers in the development department of BSH Hausgeräte GmbH in Dillingen, Germany. The aim of the cobot is to simulate a human operator. The testing process records the pressure and traction forces at the gripper at defined measurement intervals. The solution, which uses the KR1018, was implemented by Heldele Automation GmbH, a Kassow Robots integrator and sales partner and Certified Excellence Partner of Bosch Rexroth. The project took seven months to complete.

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The 7th axis was one of the main reasons why BSH opted for a solution with a cobot from Kassow Robots. The added flexibility compared to models with just six axes was a deciding factor. The additional ease of programming and operation meant that all requirements were satisfied. The robust construction, such as the aluminum housing and premium-quality drive systems, was a further positive point.

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The challenge

In the past, the dishwashers were inspected using other test benches. However, being relatively inflexible, these require multiple different pieces of equipment.

What was needed was a flexible solution that enables the forces arising during the operation of the dishwasher to be recorded.

The brief was to design a new test bench that can easily test each variant of a BSH dishwasher with the help of this cobot solution. This meant that a single solution was required that could handle different design types, unit heights, and handle variants.

Although BSH was already using a range of robot models from other manufacturers, the company was looking for a highly stable model with a lightweight construction. The unit also needed to withstand high stresses while also being easy to program and operate.

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The solution

Heldele Automation developed a flexible test bench that consists of a mobile dishwasher platform and a mobile robot platform equipped with a Kassow Robots cobot. Also included is a Rexroth ctrlX control unit with an HMI panel. This controls the test bench, which is connected to the BSH in-house network. Both platforms can be docked either to one another or to an existing stationary dishwasher platform.

The KR1018 robot model not only met the customer’s specification for stability and ease of operation, but, as a 7-axis unit, is also highly mobile with a small footprint. The movements of the lightweight robot from Kassow Robots resemble those of a human arm because only the 7th axis allows the robotic arm to reach around corners. This aspect is relevant because the test bench was designed to be space-saving and compact but also needed to allow for a sideways reach. The 7th axis not only expands the range of test procedures but also enables repeated photos to be taken of a specific area for later documentation of the test.

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The dishwasher is operated by a hook, constructed and manufactured by Heldele and fitted to the end of a cobot arm.
The cycles to be performed for all individual tests/movements can be input at the HMI.

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The robot platform also includes a 3-axis force sensor and a camera installed on the robot, which enables repeated photographs of specific areas to be taken for later documentation of the test.
An automated email notification function was also implemented that guarantees continual monitoring and rapid reaction to any issues arising during the fatigue test.
The measuring data of the force sensor and the photographs from the camera are sent to the BSH in-house network via ctrlX.

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Advantages

The test bench with the 7-axis cobot from Kassow Robots enables a wide range of BSH domestic dishwashers to be tested. Because the activation operations performed by the KR1018 have to match to how customers handle the appliances, they need to be adjustable with high flexibility and sensitivity.
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The key benefits at a glance:

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• The solution is extremely compact and yet highly flexible, thanks to the high maneuverability of the 7-axis cobot.
• Some key movements are only possible thanks to the 7th axis, including the robot’s task of taking repeated photos of specific areas on both sides.
• With its robust construction, the KR1018 is robust enough for 24/7 operation.
• At the same time, the lightweight robot is easy to operate and program to enable variable configuration of the program sequence. A range of different tools can also be easily integrated.
• Protective fence and housing are not required in this case.
• There is one mobile platform for the robot and another for installing the dishwasher. Both platforms can be easily fixed in position and connected mechanically.
• The robot platform can also be used for other existing dishwasher test stations.

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