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It is expected that ongoing digitalisation will drive the merger between the manufacturing world and the internet world, possibly leading to a next industrial revolution, currently called “Industry 4.0”. The driving forces behind this development are new business opportunities and competition advantages arising from mass production customisation as well as rapid individual product development and manufacturing. Key factors of the development towards Industry 4.0 are discussed. Threats and opportunities arising from these developments for future production are discussed. Actual examples from real-time customized manufacturing of consumer products are given. As mechatronic systems and industrial robots are widely used in manufacturing and in particular in assembly, it is discussed how they can be connected to and used in digitalised industrial systems. Different examples of remote controlled systems are presented, like remote controlled KUKA robot for handling and quality control, PLC-controlled equipment, drive systems, FESTO handling system and others. The architecture of an assembly cell is presented, where industrial robots are set-up for batch-one production or can directly receive control / production information on-line and in real-time over the factory network. Methods for remote maintenance and monitoring of systems over the internet and production operator support over the internet are presented as well.
Development of an indoor positioning system to create a digital shadow of production plant layouts
(2023)
The objective of this dissertation is to develop an indoor positioning system that allows the creation of a digital shadow of the plant layout in order to continuously represent the actual state of the physical layout in the virtual space. In order to define the requirements for such a system, potential stakeholders who could benefit from a digital shadow in the context of the plant layout were analysed. In order to generate added value for their work, the requirements were derived from their perspective. As the core of an indoor positioning system is the sensory aspect to capture the physical layout parameters, different potential technologies were compared and evaluated in terms of their suitability for this particular application. Derived from this analysis, the selected concept is based on the use of a pan-tilt-zoom (PTZ) camera in combination with fiducial markers. In order to determine specific camera parameters, a series of experiments were conducted which were necessary to develop the measurement method as well as the mathematical calculation method and coordinate transformation for the determination of poses (positions and angular orientations) of the respective facilities in the plant. In addition, an experimental validation was performed to ensure that the limit values for individual parameters determined in the requirements analysis can be met.