The progression of digitalization in production is driving the Fourth Industrial Revolution (Industry 4.0) significantly. Thus, the gap between virtual and real world continues to decline and equipment involved in the production plants, machines, components, sensors or tools become identifiable and linked devices in an Industrial Internet of Things (IIoT).
The presented Roadshow Trail “Smart Sensor and Production Systems for Industrial IoT” aims to present innovative solutions for consistent and comprehensive digitization in production across the entire value chain. Here, the main focus of the various aspects of the IoT is on sensor-based delivery of device data, their analysis and evaluation, and finally the feedback of production-relevant information. With the visualization of devices in Virtual / Augmented Reality, this trail presents scenarios of end-to-end digitalization.
- Sensor and actuator users
- Manufacturing companies
- System integrators
- Industry 4.0 users
Partners from research & industry:
|Fraunhofer IWU||Production Systems, data & Information management , energy efficiency, Industry 4.0, Robotics, Industrial IoT||Dr. Tino Langer,|
Dr. Jan Reimann,
|Fraunhofer ENAS||Sensor, actuator and system development, Industrial IoT||Dr. Martina Vogel|
|N+P Informationssysteme GmbH||Industry 4.0, augmented reality, Industrial IoT||Björn Schuster|
|Agilion GmbH||Industrial Supply Chain Tracking, Radio localization, Industry 4.0||Andreas Werner|
|AMAC ASIC- und Mikrosensoranwendung Chemnitz GmbH||System & ASIC design, microtechnology, microelectromechanical Systems (MEMS)||Dr. Claus Dittrich|
|Chemmedia AG||Knowledge Transfer, KnowledgeCloud, E-Learning, training||Lars Fassmann|
|Chemnitzer Wirtschaftsförderungs- u. Entwicklungsgesellschaft mbH||Business promotion, location development||Sören Uhle|
|EDC Electronic Design Chemnitz GmbH||Development, production & test of discrete, integrated circuits, control, Sensor and evaluation electronics||Dr. Steffen Heinz|
|Fraunhofer IIS/EAS||Integrated sensor interfaces for MEMS, complex signal processing, smart evaluation algorithms||Andreas Brüning|
|Institut für Werkzeugmaschinen und Produktionsprozesse (IWP), Technische Universität Chemnitz||Machine tools, production processes, Virtual / Augmented Reality, Industry 4.0, Industrial IoT||Dr. Philipp Klimant|
|Technologie Centrum Chemnitz||Promotion of young enterprises, start-up support, business development||Jens Weber|
|Zentrum für Mikrotechnologien ZfM||Micro and nano systems (sensors, Actuators, arrays), design of components and systems||Prof. Dr. Karla Hiller|
Smart production systems do not only aim for a high level of communication or a self-sufficient energy supply by connecting electronic components, micro and nano sensors and actuators with interfaces. But those systems are increasingly equipped with the ability to communicate and cooperate. Their connectedness thus forms an industrial IoT and the machines, components and sensors etc. involved in the production processes and production systems are regarded as networked devices. These form the basis for IoT in the Industry 4.0 application area. In addition, parts of it can also be integrated into other IoT applications (mobility, society, energy or healthcare).
In this trail, we focus on digitization in production and present demonstrators covering the entire value chain:
- Identification of the customer requirement,
- Proposal of possible concepts,
- Feasibility to capture customer-specific parameters via sensors,
- Development of customized sensors,
- Integration into production processes,
- Collection and analysis of data,
- Intelligent information acquisition from the data (Smart Data),
- Preparation and visualization of data,
- IoT -based control and monitoring of the customer’s production process
This trail is divided into two phases. Phase 1 implements a pure teaser trail. For this, demonstrators of the Fraunhofer Institute IWU and ENAS, as well as the N+P Informationssysteme GmbH (N+P) are presented, which will take no more than half a day. The other partners (see section 3) are involved in the construction and development of the demonstrators, are technology suppliers or contribute to the integration of the demonstrators into real production processes. The main foci of this phase are on the presentation of individual aspects of the value chain and the networking of the industrial devices. In addition to the demonstrator inspection, guests also have the opportunity to take action. The focus is on discussion and the bilateral exchange of knowledge in workshops, Design Thinking Sessions are planned to creatively find innovative solutions for current issues of Roadshow participants. Based on the results of already carried out workshops, events, current research and projects, this trail will constantly be evolved.
Thus, in Phase 2 the trail will be expanded from a pure teaser trail to a teaser and intensive trail. The demonstrators from Phase 1 will exemplarily be taken in a larger context and combined in such a way that all parts of the value chain can investigated intensively over several days regarding one specific production scenario. Thus, the specific needs of the visitors are attended to and the trail program can be extended demand-driven and based on the target group.
In the E³-Forschungsfabrik, human-robot interaction, various forming machines and a fully networked production hall are presented, which illustrates the Industrie 4.0 stack of the Fraunhofer IWU:
- Smart Devices (e.g. sensors) that serve as data providers,
- Linked Factory as a central component and “data hub” for the management of all data,
- Smart Analytics for analyzing data and transforming big data into smart data
- Smart Wearables for the presentation of information,
- Tracking & Tracing for object identification and localization,
- Integration in the IT infrastructure, which is constantly growing.
Sheet metal forming
The intelligent model production line for hot forming is a demonstrator for “Machine Learning for Production”. It consists of a novel contact heating system, one Servo spindle press with freely programmable path-time behavior, various (tempered) forming tools, an automated workpiece handling system and an innovative system for trimming the manufactured part. As an alternative to the contact heating system, the tempering of the semi-finished sheet products can also take place in a chamber furnace integrated in the line (statements on efficiency / production line design). The plant is automated and equipped with extensive measuring technology to ensure reproducible process conditions based on measured process variables.
Monitoring and control of manufacturing processes
A key topic at the IWU is the monitoring and control of manufacturing processes. For example, the measurement of the thermal influence of the peripheral zone can be measured during grinding. These measurements make process control during grinding possible. Within a research project the integration of newly developed measuring method in the laboratory was realized. Thus, the following potentials can be achieved for the user:
- Reduction of grinding time, increase in productivity
- Increase of the dressing interval, reduction of non-productive time and tool costs
- Improvement of process reliability and Quality
Applications of process-integrated sensors
The knowledge of the current process status is an essential prerequisite for the control of manufacturing processes. Established approaches usually rely on signals from the machine control or on sensor information from the machine periphery. However, this often does not provide adequate information quality.
Therefore, the Fraunhofer IWU develops sensor solutions that capture information from manufacturing processes very close to the process which are then passed on to the process control unit in real time . Novel physical principles such as dielectric elastomers or piezoelectric thin films are used for the comprehensive integration of the sensor technology. Complemented by wireless communication and intelligent data processing or evaluation, the sensors function as cyber-physical components and form the basis for the automatization of complex manufacturing processes. Examples are a sensor system for capturing the printed image during forming as well as a sensor for cutting force measurement during machining.
Sensors for motion, navigation, position and vibration
In digital production, but also in robotics, sensors are increasingly needed for the condition monitoring of systems, for the detection and monitoring of movements, for vibration detection with high bandwidth, for low-energy motion detection and for navigation tasks.
In the laboratory “Precision Metrology” inertial sensors and magnetic field sensors are demonstrated.
- For inertial sensor technology, the focus is on high-precision silicon-based sensors for measuring acceleration, vibration, inclination and rotation rates. The entire value chain is mapped together with the associated partners.
- Magnetic field sensors are used to uniquely determine the position, position or rotation of components, workpieces and materials.
Sensor system for monitoring infrastructure
Sensor systems not only acquire measured data, but also evaluate this data and send it to the base station or control center in order to control processes from there.
- The condition monitoring of sealing rings or greases helps operators to reduce plant and machine failures and to adapt service intervals corresponding to wear behavior. Exemplary systems for the monitoring of lubricating greases are demonstrated.
- High-precision inclination sensors are demonstrated as a monitoring structure of high-voltage. The autonomous sensor nodes are installed along the overhead line and contain inclination sensors and current and temperature sensors. Acquired data are recorded by an ultra-low power microcontroller and sent wirelessly along the overhead line to a base station.
Material and structure sensors for stress, strain, overload, humidity
The material and structure sensor technology comprises various adapted systems. The sensors for stress, strain, and overload (crack and fracture detection) are based, among other things, on silicon technologies. The nanocomposite-based overload sensors and humidity sensors use thin layers of organic materials with embedded nanoparticles. An integration in fiber composite materials is possible.
Example: Microscopic damage can form in a fiber-reinforced plastic and remain undetected over a period of time. Rigidity and strength losses are the result and lead to failure in extreme cases. One remedy is for example a multi-layered sensor film which is coated with fluorescent nanoparticles. The film changes its brightness under load and stores this state for a certain time. Thus, defects can be detected early on.
N+P INFORMATIONSSYSTEME GMBH
Augmented reality-based services in cyber-physical production systems
This demonstrator will show how intelligent sensors independently detect errors or disturbances. Intelligently linked information via ERP, MES; maintenance, plant and building management software allows the automated planning of upcoming service tasks or maintenance without production downtime. Using state-of-the-art technologies, a cross-device workflow (PC, mobile end devices, SmartWatch, Augmented Reality Microsoft HoloLens glasses) can be started to ensure the fast processing of upcoming tasks.
- SmARPro, Virtual Techniques for the Factory of the Future
- AMARETO, Virtual twin for production
- HMMI, harmonization of human-machine interaction in production
- iMain, decision support for press maintenance
- ISOSTROSE, Astrose algorithms for fault detection on high-voltage overhead lines
- Cluster of Excellence MERGE, Integration of Micro- and Nanosystems
- Leistungszentrum „Funktionsintegration für die Mikro-/Nanoelektronik“, magnetic field sensors
- Mittelstand 4.0, Competence Centre Chemnitz
- CyPhyMan, Facility Management based on Cyber-Physical Production Systems
Opportunities for Projects and Funding Instruments:
Public funding instruments, such as:
- SAB InnoTeams
- BMBF KMU Innovative
Services in industrial projects:
- individual Research and development projects
- direct orders
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