Assembly: Camera station. Assembly: Fitting of steering gear. Body Shop: Aluminium Competence Center, weight reduced aluminium front end, joining of cowl. Body Shop: BMW 5 Series, joining outer side frame, flexible line for Sedan and Touring. Body Shop: BMW 6 Series/7 Series, joining of side frame, flexible line for BMW 6 Series and BMW 7 Series. Body Shop: BMW 5 Series, Inline measurement of body shells and roof. Assembly: Engraving of VIN. Assembly: Pre-assembly of front end.

Arc wire spraying of the aluminium insert. Production Magnesium Diecasting Cell. Gluing direction indicator mount front side panel BMW 6 Series.

Body Shop: BMW X5, adhesive attached to door frames. Body Shop: BMW X5, robot welding of outer side.

Body Shop: ROBCAD simulation, meeting.

In the beginning we did not have as many robots. We had humans doing the work that robots are doing now. It was a repetitive work. It was heavy work, it was hard work. Now the robot can pick a part up, place it in a fixture, go back and pick up a weld-gun, and go on and weld that part. So you don’t have the repetitiveness to the operator, to the human, that you had before. Before when we want to measure the dimension quality of a car, we have to pull it out the line, take it somewhere else to measure it. Now we can take a laser-measurement-camera, mount it to a robot, take that camera by at a robot to the car, we can measure the repeatability of the process. So that we can compare car to car to car how our process is working. This helps us to build a better-quality-car. Previously when we wanted to move a car from one place to another in the line we would do it by means of a lifter. Just simply pulling it into a lifter, raising it up. Now we are utilizing what’s known as “co-operating” robots. We take two robots, they are hooked to one controller, they do the job of one, they do the same thing. They can pick up a car, they can present it to an operator for inspection, they can move it to a higher level for shipping on to the next station, it is known as cooperating robots.

Assembly Line. Paint Shop. Electric Assembly. Assembly Small Robots. Carbon Fiber arm. Calibration. Run Off.

Simulation. Programming. Training. Training co-operating robots. Training robot welding.

The ROBOCOASTER uses the advantages of an almost complete freedom of motion and high dynamics of an industrial robot within the line of leisure and amusement business.

On Orbit Servicing: Demonstration of the semi-autonomous rendezvous and docking maneuver of a free-flying satellite. The dynamic behaviour is simulated by KUKA industrial robots. The KUKA-DLR light-weight robot shows the capabilities of sensitive impedance control in a vision-assisted assembly task. Control of a four-finger robot hand using support-vector machine-driven high-dimensional lower arm EMG signals, with application in prosthetics and rehabilitation. The lightweight robot and hand catches with high dynamics and autonomously a thrown ball. The humanoid robot “Justin” is capable of safely performing two-handed manipulation tasks in human environments. Demonstration of a bi-manual manipulation task with the humanoid robot “Justin”. Preparation of a glass instant tea. In this experiment DLR develops and evaluates new technologies for telepresence, with which satellites can be repaired in earth-orbit in the future. Telepresence means that the space robot behaves like an extended arm of the operator, who feels presence in the space. In the virtual assembly the user perceives visual and haptic feedback from the virtual world. It is used for evaluation of maintainability of technical systems (satellites, automobiles, aircrafts, etc.) and for the training of the technical staff.