The automation of production systems is characterized by a high level of technical complexity and strong interdisciplinarity. The planning of an industrial plant requires the coordination and integration of various specialist disciplines such as mechanics, process and electrical engineering or software with regard to the procedure and the work results. In this context, automation acts as a link to ensure the correct interaction of the various disciplines. As a result of the Industry 4.0 approach and the associated increase in IT penetration in the manufacturing industry, the relevance of the digitalization of production is increasing significantly.

In order to scientifically address the challenges of modern production systems in the context of Industry 4.0, the Efficient Systems research area at the FAPS chair has an industry-ready demonstrator. This is used to present the topics of continuous engineering, Industrial Internet of Things (IIoT), dynamic self-configuration and human-machine collaboration in an application-oriented manner at store floor level for the purposes of research and teaching. The task of the intelligent assembly cell is to find a possible assembly sequence of given product components at runtime, to plan the assembly independently with the available resources and to control the process.

The assembled components are checked for correct geometry and color using 3D image processing. At the demonstrator, the data is supplemented by information generated by intelligent sensors and control technology and processed decentrally by information technology services. Complex analyses and evaluations take place in a scalable, cloud-based architecture. Semantic data models are used to derive optimization measures and send them back to the machines as configuration orders.

The end-to-end engineering methods provide a database that avoids redundant data procurement and storage. The employee connects simulation tools with the database in order to link the current model and the simulation-based tested version of the product and virtually safeguard it. As soon as a condition monitoring system detects a fault during operation of the system, the cause is automatically diagnosed, recommendations and action guidelines are created to rectify the fault and the information is sent to the higher-level control system. Faults are efficiently rectified with the help of wearables and AR technology.

In addition to condition monitoring, this assembly cell is also designed to display energy consumption. The energy consumption of individual components is read out via various measuring devices, stored and output via the HMI. A web-based portal was implemented for remote monitoring, which displays the demonstrator's information as required based on user roles. The data obtained on energy-related behavior can be used for other tasks. For example, it is planned to control the production of the assembly cell not only via the process, but also to incorporate energy efficiency considerations into a control program.

In the context of process management, virtual commissioning plays an important role right from the design phase. Virtual commissioning is often an activity that is outsourced to the OEM. However, the standards are determined by the customer.

In order to be able to commission the systems virtually in advance, it is essential to consider energy management and the behavior of the energy components in the virtual environment.

Here, it is important to know the energy consumption of the individual manufacturing and handling steps, as well as the availability of energy sources and storage within a plant or production line. The creation of realistic models is proving to be the greatest challenge in this context, which is currently being solved together with students and industrial partners.

F. Faltus/E. Fischer/J. Franke/pb

Chair of Manufacturing Automation and Production Systems (FAPS) at Friedrich-Alexander-Universität Erlangen-Nürnberg © FAPS

Briefly explained: The FAPS
The Chair of Factory Automation and Production Systems (FAPS) at Friedrich-Alexander-Universität Erlangen-Nürnberg conducts research in numerous areas related to robotics. Under the direction of Prof. Dr.-Ing. Jörg Franke, the FAPS currently employs around 100 people at two locations in a total of six different research areas: Biomechatronics, Efficient Systems, Electronics Production, Electrical Engineering, On-board Networks and Home Automation. Various hardware systems and demonstrators from the Efficient Systems research area are aimed at students and companies. FAPS sees itself as a system integrator for innovative mechatronic solutions, which are researched, developed and holistically optimized through interdisciplinary collaboration between the technology fields at the chair and in cooperation with partners. www.faps.fau.de

Scientific Society for Assembly, Handling and Industrial Robotics (MHI e.V.) © MHI

Briefly explained: The MHI e.V.
The Wissenschaftliche Gesellschaft für Montage, Handhabung und Industrierobotik e.V. (MHI e.V.) is a network of renowned university professors - institute directors and chair holders - from German-speaking countries. The members conduct both fundamental and application-oriented research on a wide range of current topics in the fields of assembly, handling and industrial robotics. Further information on the society, its members and activities: www.wgmhi.de.