FG Automatisierungstechnik
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Institute
Albeit augmented reality (AR) technologies first have been discovered in the third quarter of the 20th century, their widespread use began just two decades ago. Existing paper trails show that AR has a wide range of industrial application: it simplifies human-machine communication, improves human-machine interfaces (HMI) for quick information exchange in training (including feedback to study the workflow), correction of errors, machine maintenance, assembly assistance etc. However, broader industrial acceptance of AR, prior to all by small and medium-sized enterprises (SMEs), recently faced considerable problems and the expansion of AR solutions does not match the high potential it has demonstrated. That results in a limited practical use, mainly for demonstration and advertising purposes. This short review is to present the state of the art of the industry, challenges that SMEs face in adopting AR technologies, and several practical examples of a (commercial) adoption of AR. Some prospects for further development of AR and its ongoing integration into industry are briefly discussed in the summary.
The introduction of both mobile robots (MR) and AI-embedded mobile robots (AIMR) into the industry is very slow compared to other types of industrial robots (IR) and automation systems. Many scientific articles and studies are focused on the programming and design of MR. At the same time, integration issues, topical problems and related obstacles are almost entirely absent from the scientific literature. The authors of this paper acknowledge that the complete analysis of this area is a very challenging task. Therefore, for the purposes of this study, we focus on the local problem of analysing the introduction of MR and AIMR in small and medium-sized enterprises (SMEs). The authors offer the analysis of the current challenges and trends in the introduction of mobile robots into SMEs. They also propose solutions to these problems based on their own as well as external experience in the design, programming and implementation of mobile robots.
Evaluation of Marker-Based AR-Tracking with Vuforia in the Context of Rail Vehicle Maintenance
(2023)
Maintenance and repair jobs present a multitude of challenges. Digital assistance systems (DAS) can be used to support workers in tackling these challenges. One way of achieving this is by using a tablet with AR-technology to display necessary information seemingly in the real world. In order to place information at the correct positions, the DAS needs to know exactly where it is currently located. Multiple approaches are available to achieve this. One of those approaches is to use a marker which is placed somewhere in the real world as an anchor point for the system. In the context of rail vehicle maintenance, the workspace is inherently large with rail wagons having lengths of more than 10 m. This means that a marker that is placed somewhere on the wagon will not always be in the field of view of the DAS’s camera, resulting in a possible reduction of the precision with which virtual objects can be displayed. This paper examines the viability of the marker-based approach under realistic circumstances. It was found that with a distance of multiple meters between marker and a spot that is to be highlighted, the precision will decrease significantly.
Durch die Menschzentrierung in der Industrie 5.0 [1] sollten bestehende Ansätze hinterfragt und geprüft werden [2]. Gerade der, durch die Digitalisierung hervorgerufene, Technostress sollte neben dem Fachkräftemangel einen zunehmenden Betrachtungsfaktor im Produktionsumfeld erhalten. Da trotz bisheriger Maßnahmen eine stetige Zunahme von Stress zu verzeichnen ist [3]. Auffällig sind dabei die Arbeitsunfähigkeits-Fehltage, welche im letzten Jahr um weitere 6 % bzw. um 18,2 Fehltagegestiegen sind. Womit durchschnittlich jede Erwerbsperson 3,17 Tage unter der Diagnose „psychische Störung“ krankgeschrieben wurde [4]. Um diesen Trend entgegenzuwirken, betrachtet der Beitrag die Möglichkeiten der Software-Ergonomie, womit die Gestaltung von HMIs (Mensch-Maschinen-Interfaces) den Menschen gezielter berücksichtigt um etwaige Belastungen zu reduzieren [5]. Im Rahmen der komplementären Industrie 4.0 und der einhergehenden Informationsflut, bestimmen immer komplexer werdende Schnittstellen und Bedienoberflächen einen Großteil des Arbeitsalltags. Diese ermöglichen den Anwenderinnen und Anwendern neben einem schnellen Überblick über Maschinendaten, Prozessabläufe und Handlungsempfehlungen die Möglichkeit zur einfachen Bedienung der technischen Anlagen. Der hier vorgestellte Ansatz betrachtet am Beispiel einer Bestandsanlage, wo sich Potenziale in der Stressreduzierung im Bereich der visuellen Benutzerschnittstellen befinden und welche Auswirkungen eine Veränderung der Leitführung ermöglicht. Hierfür wurde eine mehrphasige Studie durchgeführt dessen Ergebnisse im Bereich des Eye-Trackings sowie anhand von Vitalwerten im vorliegenden Beitrag diskutiert werden.
Feature selection (FS) represents an essential step for many machine learning-based predictive maintenance (PdM) applications, including various industrial processes, components, and monitoring tasks. The selected features not only serve as inputs to the learning models but also can influence further decisions and analysis, e.g., sensor selection and understandability of the PdM system. Hence, before deploying the PdM system, it is crucial to examine the reproducibility and robustness of the selected features under variations in the input data. This is particularly critical for real-world datasets with a low sample-to-dimension ratio (SDR). However, to the best of our knowledge, stability of the FS methods under data variations has not been considered yet in the field of PdM. This paper addresses this issue with an application to tool condition monitoring in milling, where classifiers based on support vector machines and random forest were employed. We used a five-fold cross-validation to evaluate three popular filter-based FS methods, namely Fisher score, minimum redundancy maximum relevance (mRMR), and ReliefF, in terms of both stability and macro-F1. Further, for each method, we investigated the impact of the homogeneous FS ensemble on both performance indicators. To gain broad insights, we used four (2:2) milling datasets obtained from our experiments and NASA’s repository, which differ in the operating conditions, sensors, SDR, number of classes, etc. For each dataset, the study was conducted for two individual sensors and their fusion. Among the conclusions: (1) Different FS methods can yield comparable macro-F1 yet considerably different FS stability values. (2) Fisher score (single and/or ensemble) is superior in most of the cases. (3) mRMR’s stability is overall the lowest, the most variable over different settings (e.g., sensor(s), subset cardinality), and the one that benefits the most from the ensemble.
The Augmented reality (AR) technologies have been first discovered in the third quarter of the twentieth century. However, the wider development of them has taken place only in the last two decades. By now, the research has shown that AR can be used in various areas of human activity. In industry, AR simplifies humanmachine communication and improves human-machine interfaces (HMI) for fast and feedback-provided retrieval of training/guidance information for operation pattern study, error correction, machine maintenance, assembly assistance, etc. In spite of that, the broad practical implementation of AR in industry, including small and medium-sized enterprises (SMEs), has faced considerable problems. As a result, the following controversy emerged: the comprehensive study of AR is combined with a rather narrow practical use primarily for advertising and demonstration tasks. This chapter attempts not only to overview the current state of AR in the industry, but also demonstrate the current challenges the AR is facing, as well as to analyse their respective causes and suggest solution ideas. It is also intended to assess the prospects for further development of AR and its continued integration into the industry. For this purpose, several examples of AR projects, their development, practical use and upgrading (performed by the authors of this study as well) are presented.
The Smart Production Vision
(2022)
In this chapter, the Smart Production vision is discussed. The Smart Production approach is developed and described, and Smart Production is positioned in relation to Industry 4.0. Smart Production operationalize the journey towards Industry 4.0 and beyond. First, the need for a new approach to manufacturing is discussed, and from the perspectives of Industry 4.0, the Smart Production concept is derived. Then the framework is explored and finally, the approach is outlined. The Smart Production vision is an approach to make an integrated production system smarter by continuous digitizing, automating, and organizing towards supporting the company specific missions.
Qualification in Small and Medium-Sized Enterprises as the Key Driver for a Digitalized Economy
(2022)
Transformation processes towards a smart production reshape the way we work. Digitalization and the application of new technologies lead to additional interfaces between man and machine and thus, result in a tremendous change of employment, work environment and workforce qualification. This in turn means, to take full advantage of digitalization employees at all levels and sectors have to be evolved in the transformation process and need to be skilled for the upcoming challenges. To meet this need for qualification and to sensitize especially small and medium-sized enterprises (SMEs) to the matter of digitalization, the Competence Center Cottbus was founded.
Through a four-step approach, the Center addresses SMEs at all digitalization levels, from beginners to innovators. The central instrument for the Centers’ work is the self-developed LTA-FIT qualification concept. This concept is designed to impart the required knowledge and competences in accordance with the distinct qualification level of SMEs and their employees.
Intelligent Assistance Systems are a key technology for solving the problem of today’s quickly changing product configurations and the corresponding production requirements focusing on human needs. A recent study among industrial German companies identifies higher productivity, process control, quality, and cost-effectiveness as the main potentials of assistance technologies by reducing the worker’s cognitive load. Choosing the right combination of assistance technologies such as augmented reality, virtual reality, machine learning, and their functionalities like learning capabilities, situation awareness, and assembly activity recognition remain essential for their success. This chapter presents an assistance systems overview, focusing on assistance technologies, for application at production sites. Furthermore, an example of a gesture recognition-based assistance system is given, showing the benefits arising from today’s advanced assistance technologies.
This chapter will introduce the second part of the book. This part contains a collection of chapters aimed at supporting the SMEs in the transformation toward the Smart Production vision. In this part, different approaches are presented, which can assist SMEs in the formulation of a smart production vision and in the identification and prioritization of relevant initiatives, guiding the outline of a project roadmap. Furthermore, the part will introduce different regional innovation platforms in Denmark and Germany which support the SME transformations. Finally, it will be discussed how subscription-based methods could be used by SMEs to cut upfront investments and reduce requirements for digital competencies.
This book explains and exemplifies how SMEs can embrace the Smart Production approach and technologies in order to gain a beneficiary outcome. The book describes the Smart Production vision for SMEs, as well as the method to get there. The concept behind the book is based on the long-term experience of the authors in researching and tackling problems of SMEs in the manufacturing sector. The book provides applied methods and obtained solutions in different branches and different sizes of SMEs, encompassing a broad survey of our markets and societies. The perspective is systemic/holistic and integrated including human, organizational, technological, and digital perspectives.
Borck et al. evaluate the challenges and opportunities of Industrial Internet of Things (IIoT) and smart sensors in human-centered manufacturing. Particularly in small and medium-sized manufacturing with fewer machines and smart tools, it is significantly more difficult to automate processes and get the required information from the shop floor. Therefore, they give proven recommendations for the use of sensors based on a set of frequently occurring tasks in assembly, maintenance and logistics to achieve the support of smart data models in the context of Industry 4.0. “IIoT and smart sensors in human-centered manufacturing” concludes with concrete sample scenarios and describe the challenges and one solution using smart sensors and data models.
Schmitt et al. provide a brief overview of the key technology for Industry 4.0, the Industrial Internet of Things (IIoT). For this purpose, the paper first examines how this technology has developed, what its essential components are and what challenges still need to be overcome. The work particularly presents the specific requirements, challenges and opportunities for SMEs. “Industrial Internet of Things (IIoT)” concludes with an example about the integration of IIoT in a model factory.
Digitalization and automation represent both a major challenge and a long-term opportunity for SMEs to secure their business success. They often lack specialist knowledge and a sufficient financial scope and therefore need external support in meeting these challenges. This is of particular relevance and political interest as Brandenburgs economy is determined by SMEs. Knowledge and technology transfer between scientific institutions and companies is seen as a possible solution. However, different goals, approaches and expectations of researchers and companies inhibits or complicates a successful cooperation. Therefore, transfer intermediaries are needed as mediators.The book chapter uses the example of IMI Brandenburg to show how knowledge and technology transfer can be implemented by intermediaries and what key findings were obtained in the process. Furthermore, possible success factors for both the digitization of Brandenburg's SMEs and successful knowledge and technology transfer are discussed.The chapter addresses decision-makers in SMEs as well as research institutions and transfer intermediaries and is intended to raise awareness of the opportunities, challenges and solutions in the cooperation between science and industry.
Abstract. As product specifications change, manufacturing processes have to adapt. In manual production tasks, the human worker is forced to adapt at the same pace. Fast-changing work tasks lead to high stress and therefore increase failures. Digital assistance systems aim to support the human workforce by providing assembly instructions at the right time and in the right place to reduce the cognitive load. The latest digital assistance systems provide multimodal humanmachine interfaces, such as augmented reality, haptic feedback, and voice control to provide information or react to the user’s input.However, those digital assistance systems require the manufacturing information themselves, which are mostly provided through text-based or graphical programming. Both manufacturing experts and programmers are needed to create a digital assistance system workflow or adapt it to changes. This process is costly, time-consuming, and inflexible. This work presents a gesture recognition based approach for a self-learning digital assistance system. Therefore, assembly gestures are classified based on anatomical grip descriptions. Assembly sequences are recognized and learned by the digital assistance system using machine learning techniques. The learned procedures are used to automatically generate work instructions and guide the worker through the assembly task.
Learning factories constitute a promising approach for the acquisition of specific competencies, especially in terms of a digital transformation of the economy. Respectively, a variety of such factories differing in technology, learning concept, and potential audience have evolved. A precise and recent overview of those does not exist. However, such an overview is required for the implementation of concrete political measures, a future-oriented development of the individual learning factories, and an adequate selection by the audience. For this purpose, the authors investigate the current state of the art of European learning factories in the context of digitization. Thus, the terminology and definition of learning factories are provided. Moreover, using a structured literature review, the factories and their operation mode are outlined. Subsequently, the authors evaluate whether the different factories can build the required competencies among the audience and thus, support a successful digital transformation. Additionally, expert interviews with learning factory operators are performed to obtain profound information on the performance of learning factories. The findings help to assess the pertinency of European learning factories and provide a trace for their future development.
Intelligente Assistenzsysteme unterstützen die Mitarbeiter in der Produktion und erhöhen die Effizienz durch das Einblenden von situationsbasierten Aufgabeninformationen. Im Projekt Advanced Robot Assistance Solution (ARAS) im Rahmen des Kuka Innovation Awards 2021 wurde eine Assistenztechnologie entwickelt, um automatisiert Roboterprogramme für Montageabläufe zu generieren. Durch innovative Mensch-Maschine-Schnittstellen werden Montageschritte per maschinellem Lernen erkannt und in ausführbare Programme für Industrieroboter übersetzt. Dadurch können roboterbasierte Montageprozesse innerhalb von Minuten auf neue Produkte angepasst werden, ohne dass die Mitarbeiter über Kenntnisse des Programmierens oder der Robotik verfügen müssen. Ein Mitarbeiter muss den Montageprozess nur einmal vormachen. Das ARAS-System ermöglicht die kosten- und zeiteffiziente Integration und Adaption von Industrierobotern in der Montage für große und mittelständische Unternehmen.