Machining using industrial robots is currently limited to applications with low geometrical accuracies and soft materials. This paper analyzes the sources of errors in robotic machining and characterizes them in amplitude and frequency. Experiments under different conditions represent a typical set of industrial applications and allow a qualified evaluation. Based on this analysis, a modular approach is proposed to overcome these obstacles, applied both during program generation (offline) and execution (online). Predictive offline compensation of machining errors is achieved by means of an innovative programming system, based on kinematic and dynamic robot models. Real-time adaptive machining error compensation is also provided by sensing the real robot positions with an innovative tracking system and corrective feedback to both the robot and an additional high-dynamic compensation mechanism on piezo-actuator basis

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Mobile robots offer a high potential for future manufaturing and assembly. To this day the co-operation and co-action is in these fields hardly applicable, because of safety regulations, insufficient technology and its missing integration. In order to fill the gap this paper presents the hard- and software design of the mobile assistant rob@work 2. This system is the second iteration of the rob@work system. As an exemplary work the conditions of a prototypic industrial application are analyzed and divided into modes of operation which are portable to generic assembly processes. For each mode of operation the safety requirements for human-robot interaction are surveyed taking into account recent regulations. In order to evaluate the performance of the robotic system, repeatability benchmarks and respective measurements are presented