{"id":7931,"date":"2018-05-30T15:08:10","date_gmt":"2018-05-30T13:08:10","guid":{"rendered":"https:\/\/bergerwp.co-de.de\/33-networked-robots-polish-cookware-to-a-high-shine\/"},"modified":"2026-05-13T14:33:33","modified_gmt":"2026-05-13T12:33:33","slug":"33-networked-robots-polish-cookware-to-a-high-shine","status":"publish","type":"post","link":"https:\/\/www.bergergruppe.de\/en\/33-networked-robots-polish-cookware-to-a-high-shine\/","title":{"rendered":"33 NETWORKED ROBOTS POLISH COOKWARE TO A HIGH SHINE"},"content":{"rendered":"<p><strong>Industry Gazette (05\/30\/2018), Uwe B\u00f6ttger<\/strong><\/p>\n<p><strong>Many people talk about Industry 4.0 and do little. Heinz Berger Maschinenfabrik from Wuppertal is taking the topic seriously and has won the Robotics Award with a system in which 33 networked robots make their own decisions. <\/strong><\/p>\n<p>It wasn&#8217;t that difficult to get Andreas Gro\u00df on the phone, the Managing Director of Heinz Berger Maschinenfabrik in Wuppertal. The usual initial contact turned into an hour-long technology talk about robots, grippers, polishing paste, pots and pans and I learned more and more about the huge system with 33 robots with which Heinz Berger won this year&#8217;s Robotics Award. After the conversation, I wondered why this man was even available to me. As it turned out during the phone call, Andreas Gro\u00df is not only the managing director, he also developed the system as head of design and is the chief photographer in his company, who takes photos and videos of the finished and still sparkling clean systems. And he obviously also takes care of the trade press.    <\/p>\n<p>But above all, Andreas Gro\u00df is a robotics specialist through and through. &#8220;Heinz Berger Maschinenfabrik is just sixty years old,&#8221; he says. &#8220;And in the last 20 years, we have completed around 700 robot integrations.&#8221; Every year, the Wuppertal-based company installs between 40 and 70 of the steel workers. And if that includes a project with 33 machines, then that&#8217;s a really big number for the specialists from the Bergisches Land region.    <\/p>\n<p>Since the system was delivered to the household goods manufacturer WMF in Geislingen, Swabia, Andreas Gro\u00df has not only been familiar with robots, but also with pots and pans. He has all the standard diameters and jacket heights in his head, from saucepans to meat pots, he knows the typical volume of a pressure cooker and knows that pans have a diameter of 280 mm. &#8220;My wife is happy about that,&#8221; he jokes. &#8220;But I had no idea about any of this before I built the system.&#8221;   <\/p>\n<p>The new knowledge of cookware was inevitable, as the system processes the complete range of WMF pots and pans. On one side, the unprocessed raw pots from the deep-drawing press go in and on the other side, a model that is basically ready for sale comes out every ten seconds, perfectly sanded inside and out and polished to a high gloss. All that is missing are the handles, the lid and the price tag. The whole process is fully automated. Inside the plant, which is supervised by two employees, 33 networked robots work under conditions that are hard to imagine. &#8220;Polishing is dirt,&#8221; summarizes Gro\u00df. &#8220;Dirty polishing paste is distributed in the cells around the clock.&#8221; And yet the technology has to work reliably.       <\/p>\n<p>The difficult environment was one of the reasons why it took around three years to develop the system. &#8220;Many employees were involved in the design, work preparation and later in the construction,&#8221; explains Gro\u00df. &#8220;A process engineer was on site for almost two years and supervised the production and training of the staff.&#8221; Andreas Gro\u00df himself was in Geislingen at least twenty times. &#8220;Of course, not everything went smoothly right from the start, that&#8217;s clear,&#8221; admits the Managing Director.    <\/p>\n<p>That would also have been a miracle. At 35 x 20 m, the machine park is roughly the size of a handball court, making it the largest project that the Wuppertal-based company has ever completed. The system consists of three lines, each with eleven robots that work together sequentially. All robots are networked with each other and process pots and pans fully automatically. &#8220;Everyone is talking about Industry 4.0 today and has corresponding solutions in their product range, but not all of them include Industry 4.0,&#8221; says Andreas Gro\u00df. &#8220;But in our case, we have 33 networked intelligences that organize themselves and each unit can make decisions.&#8221;     <\/p>\n<p>This is exactly what is meant by Industry 4.0: decentralized intelligence that processes input signals and derives consequences from them. This could be a tool change, for example, if the workpiece, i.e. the pot or pan, changes. In this case, the system retools itself fully automatically within 2.5 minutes, without a worker in the hall turning a screw or pressing a button anywhere. An intelligent switch recognizes the workpiece provided, a plausibility check is carried out and then all 33 robots change over one after the other independently. The system adjusts to the new workpiece, so to speak. The short formula could be: New pot, new program. At the same time, however, all workpieces in the system continue to be processed. Processing and retooling run in parallel. The system grinds, polishes and rebuilds itself without interruption (see also interview).        <\/p>\n<p>A formed piece of sheet metal like this, fresh from the press and still completely unfinished, only remotely resembles a branded pot. Even the layman immediately recognizes that there is still a lot to do here. But it is remarkable that eleven robots are immediately pouncing on the part. In practice, a pot or pan passes through a complete robot line. The first six machines process the outside of the workpieces, while the remaining five robots are intended for internal processing. Before it can even start, the robot has to pack the pot correctly for processing. The Wuppertal-based company has developed a special combi-gripper especially for external processing, which firstly sucks itself onto the base of the pot via a vacuum inside the pot and simultaneously extends a spreading tool. &#8220;Imagine you reach into the pot with your right hand and then spread your fingers,&#8221; says Andreas Gro\u00df, illustrating the process. &#8220;That&#8217;s roughly how our gripper works.&#8221; Gro\u00df is right to call it &#8220;our gripper&#8221;, because the part was developed in the design department at Heinz Berger Maschinenfabrik. It took almost a year and a half to develop.          <\/p>\n<p>Once the pot is fixed with the combi gripper, round one of external machining begins. The unmistakable traces of deep-drawing are ground away from the base of the pot and the lateral surfaces. These are typical wavy lines on the surface, which are caused by irregularities in the blank that cannot be influenced during forming. All of this must be ground smooth before the next work step. The so-called pouring rim of the pot is also ground smooth so that the user cannot injure themselves and the product looks good at the end. The robots carry out all operations in different processes and with different tools.     <\/p>\n<p>Sanding is followed by polishing and burnishing the outer sides. While all the necessary components such as abrasive and bond are already present on the backing material during grinding, polishing only works with an additional polishing paste. The polishing wheel itself is guided by the robot. The paste contains grease and abrasive grains that ensure the desired removal.   <\/p>\n<p>Andreas Gro\u00df and his employees therefore had to find a way to get the polishing paste between the polishing wheel and the workpiece &#8211; always in the right amount and in the right place. Finding the right place proved to be a particular challenge during the development of the system, as a polishing wheel changes over time. At the beginning, it has a diameter of 500 mm and when it is used up after around a thousand pots, the diameter has shrunk to 300 mm. This is not insignificant for the automatic application of the polishing paste.   <\/p>\n<p>So the Wuppertal-based company installed a so-called high-pressure polishing gun above the wheel, which shoots between 2 and 6 mm\u00b3 of paste between the pot and the polishing wheel at a pressure of 15 bar. This takes place at regular intervals, which can be programmed. However, the gun must shoot at the right place and hit its target precisely. As the polishing wheel shrinks during use, it is also a moving target. In the example, the radius of the wheel shrinks by 100 mm. As the polishing paste always has to hit exactly between the workpiece and the tool, this travel distance is compensated for by a variable launch angle. The robots also take care of this. They change the angle at which the gun fires the paste.      <\/p>\n<h2>A pot or pan is on the ghost train for around 30 seconds<\/h2>\n<p>For Andreas Gro\u00df, this is &#8220;a completely new and totally crazy technology&#8221; that, as far as he knows, has never been seen before. The robot-controlled adjustment of the polishing paste gun is not only unique, but also inexpensive. &#8220;Our solution costs less than 10,000 euros and with 33 robots, it makes a huge difference whether this detail ends up costing 10,000 euros or twice as much,&#8221; Gro\u00df rightly emphasizes. Well equipped with the right polishing wheel and enough polishing paste in the right place, the robots get to work and give the cookware its final, shiny surface.   <\/p>\n<p>The remaining five robots are intended for the internal processing of the pots and pans. The processing steps are repeated here, from grinding and polishing to burnishing. There is also a special gripper developed in-house for this work step, which holds the pot on the base with a vacuum. The cookware travels on this ghost train for around 30 seconds. And as there are three of these lines, the system spits out a finished product every 10 seconds. Like everything else in the system, the tool change is fully automatic. It is obvious that a different polishing wheel is needed for a small saucepan with a jacket height of 70 mm than for a 300 mm high pressure cooker. The polishing discs differ not only in diameter, but also in weight. While the narrow model weighs around 25 kg, the wide wheel weighs 80 kg. The grinding tools with which the robot processes different regions of the workpieces also have to be changed.         <\/p>\n<p>Polishing wheels are never completely round, i.e. they will wobble during processing. This is why the tool must be pressed against the workpiece with considerable pressure. &#8220;If you hold the wheel in front of it like a girl, you can polish until doomsday and get nowhere,&#8221; says Gro\u00df. This is why the system is equipped with &#8220;heavy-duty robots&#8221; that apply a contact pressure of between 50 and 80 kg. In this specific case, these are the KR 180 models from the manufacturer Kuka, which are designed for a maximum payload of 180 kg.    <\/p>\n<p>The robots are not only strong, change over automatically and take care of adjusting the polishing gun. They also involve their flesh-and-blood colleagues. This means that the robots always know how many people are in the hall. Usually, two workers look after the system. Their work includes providing the polishing wheels, which are then gripped by the robots. Each robot knows how long its tool stock will last, but also knows the stocks of the other models. And because all the robots are networked and communicate with each other, they can coordinate their stock levels and avoid conflicts.      <\/p>\n<p>An example: Because robot number 13 can foresee that its supply of polishing wheels will run out at the same time as robot 17&#8217;s supply, it sends a worker to the warehouse two hours earlier as a precaution to fetch supplies. This optimizes the capacity of the system and at the same time avoids the most feared scenario: an expensive standstill. There are various ways in which the robot can contact the worker. One is via cell phone. There are also screens in the hall where the orders can be read off.    <\/p>\n<p>Despite all the adverse conditions under which the robots work, the Wuppertal-based company has managed to guarantee the required availability of 95% for the entire system. This means that each robot must work with a reliability of 99%. &#8220;And last but not least, the spindles for the polishing wheels also have to work in all that dirt, and they have to do so for years,&#8221; emphasizes Gro\u00df. But the specialists from the Bergisches Land region also got this problem under control in the end.   <\/p>\n<h3>&#8220;The system is constantly changing&#8221;<\/h3>\n<p>MR. JOHANN, THERE WERE MANY HURDLES TO OVERCOME DURING THE DEVELOPMENT OF THE SYSTEM. WAS THERE NEVERTHELESS SOMETHING LIKE THE BIGGEST CHALLENGE? WHAT DID YOU FIND MOST CHALLENGING DURING THE REALIZATION?<br \/>\nThe whole project was actually a big challenge, especially for us as a medium-sized company that doesn&#8217;t usually build such large systems. The task of ensuring that each robot knows which pot is currently present at the right moment was certainly particularly exciting. The entire system then adjusts to this pot and changes over automatically. The pot determines the program.   <\/p>\n<p>BUT AT THE SAME TIME THE POTS THAT ARE STILL IN THE SYSTEM ARE BEING FINISHED?<br \/>\nCorrect. The system is constantly rebuilding and processing the workpieces at the same time. While one robot is polishing a pot, the other is changing the tool or gripper for the next pot. The retooling runs like a wave through the system, which is also what makes it so fascinating. You stand next to it and see how everything changes over, as if controlled by a ghost. Of course, there is no ghost behind it, but a sophisticated control technology.     <\/p>\n<p>WAS THIS CONCEPT REQUESTED BY THE CUSTOMER?<br \/>\nWe had to proceed in this way, otherwise we would not have been able to meet the required product changeover time. We can&#8217;t empty the system before we introduce a new product. <\/p>\n<p>THE DEVELOPMENT OF THE SYSTEM TOOK THREE YEARS. DURING THIS LONG PERIOD, DID YOU HAVE ANY DOUBTS ABOUT ACHIEVING THE GOALS YOU HAD SET?<br \/>\nOur managing director never had any doubts. We all pulled together, looked ahead, divided the tasks into packages and distributed them throughout the company. By working together in a coordinated manner, we were able to complete this major project.  <\/p>\n<p>HAND ON HEART: DID SPECIFICATIONS FALL BY THE WAYSIDE?<br \/>\nGood question. There was an extensive specification from the customer. In the time available to us, we ended up implementing everything. Including things that we didn&#8217;t know the solution for at the beginning. We also developed completely new ideas in the three years.    <\/p>\n<p>WHAT, FOR EXAMPLE?<br \/>\nThe feed system for the polishing paste. We have been putting this story off for a long time. The robot basically takes the paste nozzle in its hand and pushes it into the right position. And we don&#8217;t need any additional drives. For a long time, we couldn&#8217;t imagine how we were going to solve this and feared that it would be a big problem. But then came the brilliant idea.     <\/p>\n<p>HOW LONG WILL THE SYSTEM BE IN OPERATION?<br \/>\nAt least ten, possibly twenty years. Maybe even longer. I&#8217;ve been working at Heinz Berger since 2005 and all the systems I&#8217;ve built are still running.  <\/p>\n<p>INDUSTRY 4.0 IN REINKULTURE<br \/>\nThe jury once again demonstrated a sure instinct when selecting the winner of the Robotics Award 2018. After all, it was almost impossible to show what the complex system from Heinz Berger Maschinenfabrik can actually do with the limited possibilities of an application. Even the video provided could only give a first impression. During my research for this story, I realized: Wow! The solution is Industry 4.0 in its purest form and rightly deserved the gold medal.    <\/p>\n","protected":false},"excerpt":{"rendered":"<p>Industry Gazette (05\/30\/2018), Uwe B\u00f6ttger Many people talk about Industry 4.0 and do little. Heinz Berger Maschinenfabrik from Wuppertal is taking the topic seriously and has won the Robotics Award with a system in which 33 networked robots make their own decisions. It wasn&#8217;t that difficult to get Andreas Gro\u00df on the phone, the Managing [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":7932,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_et_pb_use_builder":"","_et_pb_old_content":"","_et_gb_content_width":"","footnotes":""},"categories":[391],"tags":[400],"post_folder":[],"class_list":["post-7931","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-press","tag-robotics-award-2018"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.7 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>33 NETWORKED ROBOTS POLISH COOKWARE TO A HIGH SHINE - Berger Gruppe<\/title>\n<meta name=\"robots\" content=\"noindex, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"33 NETWORKED ROBOTS POLISH COOKWARE TO A HIGH SHINE - Berger Gruppe\" \/>\n<meta property=\"og:description\" content=\"Industry Gazette (05\/30\/2018), Uwe B\u00f6ttger Many people talk about Industry 4.0 and do little. 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Heinz Berger Maschinenfabrik from Wuppertal is taking the topic seriously and has won the Robotics Award with a system in which 33 networked robots make their own decisions. 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