Manufacturing Track 

Task 2: 

Gear unit assembling 

This rule is subject to change. 

This task consists of the 

following three subtasks: 

Subtask 1. Fasten roller bolts on the base plate 

Subtask 2. Insert metal collars and gears 

Subtask 3. Tighten gears with a nut 

Items (for subtasks 1-3): 

I. Parts 

1. Base Plate: 6-Surface Milled Mounting Plates 

2. Two different sized Spur Gears (30 and 40 Tooth) - Bearing Built-in Type 

3. Two Cantilever Shafts 

4. Two Metal Collars 

5. Two Metal Washers 

6. Two Nuts 

II. Peripherals 

1. Open end wrench (17mm) 

2. Nut driver (M12) 

3. Parts tray 

4. Thread-lock sealant (dummy) 

Assembled gear unit is shown in Figure 1. All parts are available from MISUMI. 

Parts list including order numbers for MISUMI is shown in Table 1. We have 

confirmed that parts are available from Japan, U.S.A., France, Germany, U.K., 

China, Korea, Thailand, and India. 

Drawing of the gear unit and STL data of the parts are available at 

https://www.nist.gov/el/intelligent-systems-division-73500/roboticgrasping-and-manipulation-competition-manufacturing
Table 1. Parts list 

Part 

No. Item Number 

of items MISUMI Order 

1 Base Plate 1 HFMQA-SCM-A150-B90-T15-X35-Y45-M12-L70-MA12 

2 Spur Gear 

(30 tooth) 1 GEABDM2.0-30-20 

3 Spur Gear 

(40 tooth) 1 GEABDM2.0-40-20 

4 Cantilever 

Shaft 2 FXNAC15-15-F22-N12-MA12 

5 Metal Collar 2 NCLM15-25-11 

6 Metal 

Washer 2 FWSSM-D24-V12-T6 

100 M12 Hex 

Nut 2 LBNR12 

Table 2. Tools list (example) 

Part 

No. Item Number 

of items URLs of Amazon.com 

1 Open end 

wrench 1 https://www.amazon.com/gp/product/B01F511QLK 

2 Nut driver 1 https://www.amazon.com/gp/product/B00O7ELVEO 

https://www.amazon.com/gp/product/B00F9Y1LAU 

3 Part tray 1 https://www.amazon.com/gp/product/B01L2F9Q8I 

Figure 1. Assembled gear unit
Open end wrench (17mm) and nut driver (M12) must be prepared by each 

team. If hand tools without any modifications are used, bonus points are added. 

If the hand tools do not have the ratchet or the robot does not use the ratchet, 

bonus points are added. 

Part tray must be prepared by each team. Its dimensions should be within 

330x250x100[mm] (length x width x height) and more than 200x120x20[mm]. 

There is no limitation on its color and material, but if magnetic type is used, no 

bonus points will be added even without fixtures. 

Before this competition, teams must send the information of tools consisted of 

Open end wrench and nut driver including part tray, for example, the URLs of 

Amazon like table 2. The organizing committee will check them and if they 

decide tools are not good for this task, the team must change the tools. The 

deadline will be announced separately. 

Thread-lock sealant is artificial so that the shaft can be easily disassemble. It is 

a blue colored viscous liquid that replaces the contents of a bottle of Loctite 

1329467 243 Blue Medium Strength Threadlockers available at Amazon (Figure 

2): https://www.amazon.com/gp/product/ B009I2UC3Q . The cap of the bottle is 

already removed and the robot system need not open the bottle. 

Figure 2. Thread-lock sealant 

(The cap will be removed in the competition.)
Gear unit assembly task has been designed as a trial task for Industrial 

Robotics Category, World Robot Challenge, World Robot Summit. We are 

considering more difficult tasks for Pre-competition in 2018 and final competition 

in 2020. 

Gear unit assembly task will be divided by three subtasks. Each subtask starts 

from a given initial condition so that teams who failed to complete the previous 

task can move onto the next subtask. Between subtasks, teams cannot 

manually change their software and hardware. During the subtasks, the timer 

will not be suspended. Teams may also skip some operations (e.g. applying 

thread-lock sealant) depending on the performance of their robot system. The 

initial state can also be adjusted. Parts can be placed at predefined locations so 

that the robot system can pick them up blindly or the competition staff can place 

them at arbitrary location. The arbitrary location method requires that the robot 

system have functionality to automatically determine part locations. Note that 

the timer will not be suspended even during the staff places the parts at 

arbitrary location, because the required time for that operation would be very 

short. 

Scoring is still tentative but basically points will be accumulated when each 

operation is successfully completed. Bonus points will be given if teams select 

difficult conditions, such as arbitrary initial locations, no fixtures, and using hand 

tools. 

Gear unit parts will be provided to each team of the Manufacturing Track of the 

2nd Robotic Manipulation and Grasping Competition, thanks to the Industrial 

Robotics Category, World Robot Challenge, World Robot Summit. The parts are 

also available worldwide from MISUMI with reasonable cost (approximately 

US$150). Using the STL data, teams can make replica parts quite easily using 

3-D printers. Note that replica parts would be suitable for grasping test but 

would not for parts fitting test. For parts fitting practice, it is recommended to 

use the real parts provided from us or purchased from MISUMI. 

Teams get two set of gear unit parts; one is provided before the competition, 

and the other is provided at the venue just before the competition starts. 
Teams should bring their own gear unit parts to the competition site because 

the organizing committee cannot provide any gear unit parts to each team 

during the setup days. In the competition, teams are not allowed to use their 

own gear unit parts instead of new gear unit parts provided by the organizer. In 

the competition, teams cannot change the condition of the provided gear unit 

parts, for example using the lubricant like as CRC 5-56. If robots break the parts 

during the competition, the team will get the penalty (minus points). 

The working area is the area where the end-effector of the robot is allowed to 

move. The maximum size of the working area is 2.0x2.5[m]. 

Assembly area is the area where the robot system can assemble the gear unit. 

The size of the assembly area is 0.3x0.3[m]. Teams can specify this area 

anywhere inside the working area. Any peripherals for assembly, such as jigs, 

should be inside this area. When the team wants to challenge arbitrary location 

of the base plate, the team should clearly indicate this area, for example by 

colored tape, so that the competition staff can place the base plate arbitrary 

inside this area. 

Parts area is the area where the part tray should be located. The size of the 

parts area is 0.35x0.35[m]. Parts area can be specified anywhere by the team 

as long as it is inside the working area and no overlap with the assembly area. If 

a team elects the additional challenge of arbitrary location located parts, the 

team should clearly indicate this area, for example by colored tape, so that the 

competition staff can place the part tray arbitrary inside this area and place the 

parts arbitrary inside this part tray. 

The tool area is the area where the hand tools (and thread-lock sealant) should 

be located. The size of the tool area is 0.2x0.3[m]. Tool area can be specified 

anywhere by the team as long as it is inside the working area and overlap with 

neither the assembly area nor parts area. If a team elects the additional 

challenge of arbitrary located hand tools (and thread-lock sealant), the team 

should clearly indicate this area, for example by colored tape, so that the 

competition staff can place the hand-tools (and thread-lock sealant) arbitrary 

inside this area. Customized tools and hands prepared by the team can be 

placed anywhere except inside assembly area and parts area. Hand-tools (and 
thread-lock sealant) must be placed inside the tool area after their use (not 

necessarily at the same location). 

Figure 3. Area definition 

(The above layout is just an example. Each area can be assigned anywhere 

inside the working area as long as they are not overlapped.) 

Using wireless communication like as Wi-Fi is not limited. But the organizing 

committee does not guarantee the communication quality at the venue. 

Working area

Tool area

Assembly Parts area

area 
Subtask 1: Fasten roller bolts on the base plate 

Difficulty: Level 4 

Standard Time: 15 minutes 

Achievable Points: 85 (includes maximum possible bonus points) + Time bonus 

Competition setup: 

 Base plate is placed on the table within the assembly area. Its location can 

be predefined by the team or arbitrary (chosen by the competition staff). 

Bonus points are given for arbitrary location. But the robot system should 

complete at least one part assembling to get the bonus. 

 The team can introduce fixtures for base plate. Bonus points are given if no 

fixtures are used. But the robot system should complete at least one shaft 

tightening task to get the bonus. 

 Two cantilever shafts are placed in the parts tray. The tray location can be 

predefined by the team or arbitrarily chosen by the competition staff. Shaft 

locations can be predefined by the team or arbitrarily chosen by the 

competition staff. Parts are not overlapped. Teams can use any items (e.g. 

fixtures) to secure the parts location in the parts tray. Bonus points are 

given for the arbitrary location method without any fixtures. The robot 

system must pick up the parts to get the bonus. 

 An open-end wrench is placed on a table within the tool area. Its location 

can be predefined by the team or arbitrarily chosen by the competition staff. 

Bonus points are given for the arbitrary location method. The robot system 

must pick up the tools to get the bonus. 

 Thread-lock sealant is placed on a table within the tool area. Its location can 

be predefined by the team or arbitrarily chosen by the competition staff. 

Bonus points are given for the arbitrary location method. The robot system 

must pick up the bottle of thread-lock sealant to get the bonus. 

Competition: 

1. The robot system picks up a cantilever shaft 

2. The robot system applies thread-lock sealant to the bolt part (can be 

skipped) 

3. The robot system threads and drives a shaft until fully seated on the 

base plate 

4. Repeat 1 to 3 for each shaft 
5. The robot system uses the open-end wrench (or a customized wrench) to 

tighten shaft to a specified torque 

6. Repeat 5 for two shafts. 

Initial state of Subtask 1 Goal state of Subtask 1 

Figure 4. Subtask 1 

(Thread-lock sealant in this figure is not the one specified in this competition. 

Assembly area, parts area, and tool area must be clearly shown in the 

competition.)
Figure 5. Flow of Subtask 1 

Subtask 2: Insert metal collars and gears 

Difficulty: Level 5 

Standard Time: 30 minutes (including setup time) 

Achievable Points: 130 (includes maximum possible bonus points) + Time 

bonus 

Competition setup: 

 The base plate assembled with two cantilever shafts are placed on the table 

within the assembly area. Its location can be predefined by the team or 

arbitrarily chosen by the competition staff. Bonus points are given for the 

arbitrary location method. 

 A team can introduce fixtures for localizing the base plate. No bonus points 

are given in this subtask if fixturing is used. 

 Two metal collars and two different size gears are placed in the parts tray. 

The tray location can be predefined by the team or arbitrarily chosen by the 

competition staff. Part locations on the tray can be predefined by the team 
or arbitrarily chosen by the competition staff. Parts placed by the 

competition staff will not overlap with each other. When using the 

predefined method, teams can use any items (e.g. fixtures) to secure the 

parts location in the parts tray. Bonus points are given for the arbitrary 

location method without any fixtures. The robot system must pick up the 

parts to get the bonus. 

Competition: 

1. The robot system picks up a collar and insert it onto a shaft. 

2. Repeat 1 for the assembly of each collar. 

3. The robot system picks up a gear and inserts it onto the shaft. 

4. Repeat 3 for assembling each gear onto a shaft. When inserting the 

second gear, mesh it with the first one 

 

Initial state of Subtask 2 Goal state of Subtask 2

Figure 6. Subtask 2 

(Assembly area and parts area must be clearly shown in the competition.)
Figure 7. Flow of Subtask 2 

 
Subtask 3: Tighten gears with a nut 

Difficulty: Level 4 

Standard Time: 15 minutes (including setup time) 

Achievable Points: 85 (includes maximum possible bonus points) + Time bonus 

Competition setup: 

 The base plate assembled with two gears are placed on the table within the 

assembly area. Its location can be predefined by the team or arbitrarily 

chosen by the competition staff. Bonus points are given for the arbitrary 

location method. 

 A team can introduce fixtures for localizing the base plate. Bonus points are 

given if no fixtures are used. But the robot should complete at least one nut 

tightening task to get the bonus. 

 Two nuts and two washers are placed in the parts tray. The tray location 

can be predefined by the team or arbitrarily chosen by the competition staff. 

Parts locations can be predefined by the team or arbitrarily chosen by the 

competition staff. Parts placed by the competition staff will not overlap with 

each other. When using the predefined method, teams can use any items 

(e.g. fixtures) to secure the parts location in the parts tray. Bonus points are 

given for using arbitrary location method without any fixtures. The robot 

must pick up the parts to get the bonus. 

 Nut driver is placed on a table within the tool area. Its location could be 

predefined by the team or arbitrary (chosen by the competition staff). Bonus 

points are given for arbitrary location. But the robot must pick up the tool to 

get the bonus. 

Competition: 

1. The robot system picks up a washer and inserts it into a shaft. 

2. Repeat #1 for assembling a washer onto to each shaft 

3. The robot system picks up a nut and starts its thread on a shaft. 

4. Repeat #3 for assembling a nut to each shaft 

5. The robot system uses the nut driver or a customized tool to tighten the 

nut to a specified torque 

6. Repeat #5 for each nut. 
Initial state of Subtask 3 

 Figure 8. Subtask 3 

(Assembly area, parts area, and tool area must be clearly shown in the 

competition.)

 

Figure 9. Flow of Subtask 3 

Goal state of Subtask 3 

(assembly completed) 
Towards “agile one-off manufacturing” 

The Industrial Robotics Category in WRC aims at realizing future manufacturing 

systems that can respond to variously changing orders (ultimately, even an 

order for one-off product) by reconfiguring the system in agile and lean 

manners. Such robot systems should recognize, grasp, and assemble various 

parts including flexible parts, and assemble a new product by quickly 

reconfiguring the system without teaching and jigs (fixtures). 

Toward this goal, we expect teams to assemble the gear unit as a single task as 

shown in Figure 10 in the near future. In WRC/WRS in 2018 and 2020, we are 

planning to design more difficult tasks than the gear unit. We welcome the 

teams who participate in Manufacturing Track of 2nd IROS Robotic Manipulation 

and Grasping Competition to participate in the WRC/WRS 2018 and 2020. 

 Initial state of overall assembly task Goal state of overall assembly task 

Figure 10. Overall assembly task 

 
Scoring (tentative and subject to change) 

Subtask1 

points 

5 bonus arbitrary location of base plate 

5 bonus no fixture for base plate 

10 bonus arbitrary location of shaft 

5 bonus arbitrary location of wrench (-2 points when not returned properly) 

5 bonus arbitrary location of sealant (-2 points when not returned properly) 

5 apply sealant to the bolt 1 

5 apply sealant to the bolt 2 

10 drive shaft 1 (100% points for fully seated) 

10 drive shaft 2 (100% points for fully seated) 

10 tighten shaft 1 (100% points with predefined torque) 

10 tighten shaft 2 (100% points with predefined torque) 

5 bonus use hand tool 

 

85 total 

Subtask2 

points 

20 bonus arbitrary location of base plate 

0 bonus no fixture for base plate (no bonus point for this subtask) 

10 bonus arbitrary location of gear 

10 bonus arbitrary location of collar 

5 insert collar 1 

5 insert collar 2 

30 insert gear 1st (100% points for fully inserted) 

50 insert gear 2nd (100% points for fully inserted) 

 

130 total 

Subtask 3 

points 

10 bonus arbitrary location of base plate 

5 bonus no fixture for base plate 
10 bonus arbitrary location of washer 

10 bonus arbitrary location of nut 

5 bonus arbitrary location of driver (-2 points when not returned properly) 

5 insert washer 1 

5 insert washer 2 

5 fit nut 1 

5 fit nut 2 

10 tighten nut 1 (100% points with predefined torque) 

10 tighten nut 2 (100% points with predefined torque) 

5 bonus use hand tool 

 

85 bonus 

Time bonus 

The following time bonus will be added in each subtask when subtask is 

completed faster than standard time. To get time bonus, all parts (except tools) 

should be placed in arbitrary locations. 

Time bonus = INT((standard time[sec] – spent time[sec]) /10) x 1 point 

[Definitions of task completion] 

Subtask 1: Two shafts are tightened and points are given. 

Subtask 2: Second gear is fully inserted 

Subtask 3: Two nuts are tightened and points are given. 

Reset 

Resetting (and start over) is possible only twice for each subtask. Five minutes 

are given for starting over. Time counting is suspended during the reset but 

certain time (1 min for 1st reset and 4 min for 2nd one) is removed from their 

allotted total time as well as standard time for the corresponding subtask. 

Time Shift 

60 (=15+30+15) minutes are allotted to each team including setup time for 

Subtasks 2 & 3. A team can stop the current subtask and move on to the next 

subtask anytime. A team can spend time for each subtask as long as they want. 

After 60 minutes, the gear unit assembly task must be stopped. 
Note: Time for placing parts and tray at arbitrary location by competition 

staffs will be included in the 60 minutes allotted time, because required 

time should be very short. 

Specified torque 

 Shaft Nut 

100% (Full) score >= 24 [Nm] >= 12[Nm] 

50% score >= 9[Nm] >= 5[Nm] 

20% score >= 3[Nm] >= 1[Nm] 

Torque will be measured by releasing the shaft and nut by digital torque wrench 

which can show the peak torque. 

 
Scoring sheet for the referee 

SubTask Number: # 1 , Date: / Sep / 2017 , Team Name: 

Time Recording (hh:mm:ss) 

Start Task : : End Task / Reset #1 : : Process 

Restart #1 : : End Task / Reset #2 : : Time 

Restart #2 : : End Task : : : : 

Before SubTask 

No. Process 

Condition 

Points Check✓ Comment 

Fixture Set by whom

a-1 

Location of 

the base 

plate 

Use --- 

Not use 

Team --- 

Staff --- 

a-2 Type of the 

part tray 

Magnetic --- 

Not magnetic --- 

a-3 Type of the 

hand tool 

Use the ratchet --- 

Not use the ratchet --- 

a-4 Location of 

the shaft 

 Team --- 

If the part tray 

is magnetic 

type, its 

condition is 

same as using 

fixture. 

Not use Staff --- 

a-5 Location of 

the wrench 

 Team --- 

Not use Staff --- 

a-6 Location of 

the sealant 

 Team --- 

Not use Staff --- 

During SubTask 

No. Process Condition Points Check✓ Comment 

b-1 Bonus 

for a-4 

The robot picks up 

one of the shafts. 

0 a-4: team 

+3 a-4: staff 

b-2 Bonus 

for a-5 

The robot picks up 

one of the wrenchs. 

0 a-5: team 

+3 a-5: staff 

b-3 Bonus 

for a-6 

The robot picks up 

the bottle of sealant. 

0 a-6: team 

+3 a-6: staff 

b-4 Sealing #1 Apply sealant to the bolt 

part of the shaft #1. 5 can be skipped

b-5 Sealing #2 Apply sealant to the bolt 

part of the shaft #2. 5 can be skipped
b-6 Drive #1 Drive shaft #1 

on the base plate 10 Seated length 

?? 

b-7 Drive #2 Drive shaft #2 

on the base plate 10 Seated length 

?? 

 ”pick up” means that the target is removed from the part tray.

After SubTask 

No. Process Condition Points Check✓ Comment 

c-1 Bonus 

for a-1 

Assembled one or more 

parts 

0 a-1: fixture

+5 a-1: team 

+10 a-1: staff 

c-2 Bonus 

for a-5 

The wrench is returned 

properly. 

0 a-5: team 

+2 a-5: staff 

c-3 Bonus 

for a-6 

The sealant is returned 

properly. 

0 a-6: team 

+2 a-6: staff 

c-4 Bonus 

for hand tool 

hand tool is not 

modified. 

0 c-1: 

unchecked 

+3 a-3: use 

ratchet

+5 a-3: not use

c-5 

Tighten shaft 

#1 

Torque 

Tighten shaft #1 

Can be 

skipped 

2 >= 3[Nm] 

5 >= 9[Nm] 

10 >= 24[Nm] 

c-6 

Tighten shaft 

#2 

Torque 

Tighten shaft #2

Can be 

skipped 

2 >= 3[Nm] 

5 >= 9[Nm] 

10 >= 24[Nm] 

c-7 Broken parts Some parts are broken -30 

Referee Name (signature) : 

 
Scoring Sheet for the referee 

SubTask Number: # 2 , Date: / Sep / 2017 , Team Name: 

Time Recording (hh:mm:ss) 

Start Task : : End Task / Reset #1 : : Process 

Restart #1 : : End Task / Reset #2 : : Time 

Restart #2 : : End Task : : : : 

Before SubTask 

No. Process 

Condition 

Points Check✓ Comment 

Fixture Set by whom 

a-1 

Location of 

the base 

plate 

Use --- 

Not use 

Team --- 

Staff --- 

a-2 Type of the 

part tray 

Magnetic --- 

Not magnetic --- 

a-3 Location of 

the gears 

 Team --- If the part tray 

is magnetic 

type, its 

condition is 

same as using 

fixture. 

Not use Staff --- 

a-4 Location of 

the collars 

 Team --- 

Not use Staff --- 

During SubTask 

No. Process Condition Points Check✓ Comment 

b-1 Bonus 

for a-3 

The robot picks up 

one of the gears. 

0 a-2: team 

+10 a-2: staff 

b-2 Bonus 

for a-4 

The robot picks up 

one of the collars. 

0 a-3: team 

+10 a-3: staff 

b-3 Insert collar #1 Insert collar #1 5 

b-4 Insert collar #2 Insert collar #2 5 

b-5 Insert gear #1 Insert gear 1st 30 Insertion length

?? 

b-6 Insert gear #2 Insert gear 2nd 50 Insertion length

?? 

After SubTask 

c-1 Broken parts Some parts are broken -30 

Referee Name (signature) : 
Scoring Table for the referee 

SubTask Number: # 3 , Date: / Sep / 2017 , Team Name: 

Time Recording (hh:mm:ss) 

Start Task : : End Task / Reset #1 : : Process 

Restart #1 : : End Task / Reset #2 : : Time 

Restart #2 : : End Task : : : : 

Before SubTask 

No. Process 

Condition 

Points Check✓ Comment 

Fixture Set by whom 

a-1 

Location of 

the base 

plate 

Use --- 

Not use 

Team --- 

Staff --- 

a-2 Type of the 

part tray

Magnetic --- 

Not magnetic --- 

a-3 Type of the 

driver

Use the ratchet --- 

Not use the ratchet --- 

a-4 Location of 

the washers

 Team --- 

If the part tray 

is magnetic 

type, its 

condition is 

same as using 

fixture. 

Not use Staff --- 

a-5 Location of 

the nuts 

 Team --- 

Not use Staff --- 

a-6 Location of 

the driver 

 Team --- 

Not use Staff --- 

During SubTask 

No. Process Condition Points Check✓ Comment 

b-1 Bonus 

for a-4 

The robot picks up 

one of the washers. 

0 a-4: team 

+10 a-4: staff 

b-2 Bonus 

for a-5 

The robot picks up 

one of the nuts. 

0 a-5: team 

+10 a-5: staff 

b-3 Bonus 

for a-6 

The robot picks up 

the driver. 

0 a-6: team 

+3 a-6: staff 

b-4 Insert 

washer #1 Insert washer #1 5 

b-5 Insert 

washer #2 Insert washer #2 5 
b-6 Fit nut #1 Fit nut #1 5 

b-7 Fit nut #2 Fit nut #2 5 

After SubTask 

c-1 Bonus 

for a-1 Tighten one or more nuts

0 a-1: fixture 

+5 a-1: team 

+10 a-1: staff 

c-2 Bonus 

for a-6 

The driver is returned 

properly. 

0 a-6: team 

+2 a-6: staff 

c-4 

Bonus 

for hand 

tool 

hand tool is not modified.

0 c-1: unchecked 

+3 a-3: use ratchet 

+5 a-3: not use 

c-4 Tighten nut 

#1 Tighten nut #1 

 Can be skipped 

2 >= 1[Nm] 

5 >= 5[Nm] 

10 >= 12[Nm] 

c-5 Tighten #2 

Torque Tighten shaft #2

 Can be skipped 

2 >= 1[Nm] 

5 >= 5[Nm] 

10 >= 12[Nm] 

c-6 Broken 

parts Some parts are broken -30 

Referee Name (signature) : 
Change log 

 2017/09/07 add the scoring sheets. 

 describe the game time between subtasks. 

 add the tool information as the Table 2. 

 make a deadline for teams to send the tools information. 

 2017/09/14 describe about the guarantee for wireless-network. 

describe the penalty for breaking parts including using the 

lubricants. 

Deadline is announced separately 

Time for arbitrary placement by competition staff will be 

included in the allotted time (timer will not be suspended) 

No manual change of hardware and software is allowed 

during the subtasks