Virtual prototype based method for hybrid reconfigurable assembly systems design in top class automotive industry

Changeability is mandatory for top class automotive industry to cope with new product development paradigms and demanding market. Hybrid Reconfigurable Assembly Systems (H-RMSs) address a customized flexibility on product families, given by coexistence or cooperation of human workers and robots. Key-issues for the effective design of harmonized hybrid assembly systems are: modularity; integrability of humans, machines and components; customization; convertibility; diagnosability of systems; and smart utilization of robots and skilled workers. Human and robotic tasks need a clear definition and allocation, for an effective enhancing of human dexterity and cognitive proactivity, together with robotic accuracy and strength. Virtual prototyping plays a strategic role within the H-RMS design optimization process, to explore different assembly setting and to interactively train operators but represents a challenging task and needs advanced tools. The present paper deals with the development of a Virtual Prototype based method for H-RMS design in top class automotive industry.