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Maintenance is an increasingly complex and knowledge-intensive field. In order to address these challenges, assistance systems based on augmented, mixed, or virtual reality can be applied. Therefore, the objective of this paper is to present a framework that can be used to identify, select, and implement an assistance system based on reality technology in the maintenance environment. The development of the framework is based on a systematic literature review and subject matter expert interviews. The framework provides the best technological and economic solution in several steps. The validation of the framework is carried out through a case study.
The increasing complexity and need for availability of automated guided vehicles (AGVs) pose challenges to companies, leading to a focus on new maintenance strategies. In this paper, a smart maintenance architecture based on a digital twin is presented to optimize the technical and economic effectiveness of AGV maintenance activities. To realize this, a literature review was conducted to identify the necessary requirements for Smart Maintenance and Digital Twins. The identified requirements were combined into modules and then integrated into an architecture. The architecture was evaluated on a real AGV on the battery as one of the critical components.
The supply of customer-specific products is leading to the increasing technical complexity of machines and plants in the manufacturing process. In order to ensure the availability of the machines and plants, maintenance is considered as an essential key. The application of cyber-physical systems enables the complexity to be mastered by improving the availability of information, implementing predictive maintenance strategies and the provision of all relevant information in real-time. The present research project deals with the development of a cost-effective and retrofittable smart maintenance system for the application of ultraviolet (UV) lamps. UV lamps are used in a variety of applications such as curing of materials and water disinfection, where UV lamps are still used instead of UV LED due to their higher effectiveness. The smart maintenance system enables continuous condition monitoring of the UV lamp through the integration of sensors. The data obtained are compared with data from existing lifetime models of UV lamps to provide information about the remaining useful lifetime of the UV lamp. This ensures needs-based maintenance measures and more efficient use of UV lamps. Furthermore, it is important to have accurate information on the remaining useful lifetime of a UV lamp, as the unplanned breakdown of a UV lamp can have far-reaching consequences. The key element is the functional model of the envisioned cyber-physical system, describing the dependencies between the sensors and actuator, the condition monitoring system as well as the IoT platform. Based on the requirements developed and the functional model, the necessary hardware and software are selected. Finally, the system is developed and retrofitted to a simulated curing process of a 3D printer to validate its functional capability. The developed system leads to improved information availability of the condition of UV lamps, predictive maintenance measures and context-related provision of information.
Condition monitoring supported with artificial intelligence, cloud computing, and industrial internet of things (IIoT) technologies increases the feasibility of predictive maintenance. However, the cost of traditional sensors, data acquisition systems, and the required information technology expert-knowledge challenge the industry. This paper presents a hybrid condition monitoring system (CMS) architecture consisting of a distributed, low-cost IIoT-sensor solution. The CMS uses micro-electro-mechanical system (MEMS) microphones for data acquisition, edge computing for signal preprocessing, and cloud computing, including artificial neural networks (ANN) for higher-level information processing. The system's feasibility is validated using a testbed for reciprocating linear-motion axes.
Process quality has reached a high level on mass production, utilizing well known methods like the DoE. The drawback of the unterlying statistical methods is the need for tests under real production conditions, which cause high costs due to the lost output. Research over the last decade let to methods for correcting a process by using in-situ data to correct the process parameters, but still a lot of pre-production is necessary to get this working. This paper presents a new approach in improving the product quality in process chains by using context data - which in part are gathered by using Industry 4.0 devices - to reduce the necessary pre-production.
Additive manufacturing is a key technology which applies the ideas of Industry 4.0 in order to enable the production of personalized and highly customized products economically. Especially small and medium sized companies often lack the competence and experience to evaluate objectively and profoundly the potential of additive manufacturing technologies in small and medium sized companies. Furthermore, the method has been validated in a small medical technology company evaluating the additive manufacturing potential of an existing surgery tool.
The use of learning factories for education in maintenance concepts is limited, despite the important role maintenance plays in the effective operation of organizational assets. A training programme in a learning factory environment is presented where a combination of gamification, classroom training and learning factory applications is used to introduce students to the concepts of maintenance plan development, asset failure characteristics and the costs associated with maintenance decision-making. The programme included a practical task to develop a maintenance plan for different advanced manufacturing machines in a learning factory setting. The programme stretched over a four-day period and demonstrated how learning factories can be effectively utilized to teach management related concepts in an interdisciplinary team context, where participants had no, or very limited, previous exposure to these concepts.
The technologies of digital transformation, such as the Internet-of-Things (IoT), artificial intelligence or predictive maintenance enable significant efficiency gains in industry and are becoming increasingly important as a competitive factor. However, their successful implementation and creative, future application requires the broad acceptance and knowledge of non-IT-related groups, such as production management students, engineers or skilled workers, which is still lacking today. This paper presents a low-threshold training concept bringing IoT-technologies and applications into manufacturing related higher education and employee training. The concept addresses the relevant topics starting from IoT-basics to predictive maintenance using mobile low-cost hardware and infrastructure.
This paper presents a description model for smart, connected devices used in a manufacturing context. Similar to the wide spread adoption of smart products for personal and private usage, recent developments lead to a plethora of devices offering a variety of features and capabilities. Manufacturing companies undergoing digital transformation demand guidance with respect to the systematic introduction of smart, connected devices. The introduction of smart connected devices constitutes a strategic decision cost due to the high future committed cost after introduction and maintaining a smart device fleet by a vendor. This paper aims to support the introduction efforts by classifying the devices and thus helping companies identify their specific requirements for smart, connected devices before initiating widespread procurement. By mapping the features of these devices based on various attributes, allows the clustering of smart, connected devices including a requirement list for their implementation on the shopfloor. Four individual commercially available smart connected devices were analyzed using the description model.
Manufacturing has to adapt to changing situations in order to stay competitive.It demands a flexible and easy-to-use integration of production equipment and ICT systems. The contribution of this paper is the presentation of the implementation of the Manufacturing Integration Assistant (MIALinx). The integration steps range from integrating sensors over collecting and rule-based processing of sensor information to the execution of required actions. Furthermore, we describe the implementation of MIALinx by commissioning it in a manufacturing environment to retrofit legacy machines for Industrie 4.0. Finally, we validate the suitability of our approach by applying our solution in a medium-size company.