Cost guzzler and source of data overload or rather production helper and quality assurer? When it comes to the use of sensor technology in production, experience varies. However, the advancing automation and digitalization of production require the targeted use of innovative sensor technology. This is why the international trade fair alliance Intec, Z and GrindTec will be offering this key industrial topic its own platform at Leipziger Messe from March 7 to 10, 2023, where users and suppliers can exchange information on current solutions and future trends. Topics such as sensor technology in mechanical engineering, intelligent manufacturing with sensor technology, the use of AI in sensor technology and the effects of sensor technology on sustainability will be the focus of the special show and the specialist forum "Sensor technology - use and prospects in manufacturing" - and will show why sensor technology is indispensable in production.

Small building blocks with great potential

Sensors measure various physical and chemical variables. They monitor conditions and are important components for enabling the trouble-free operation of a wide range of systems. "Sensor technology offers great potential for finding the right answers to the megatrends of our time. For example, the small components help to use energy more carefully. They support intelligent digitalization and automation in business, transport and many other areas of our lives. In Leipzig, we will be discussing in particular how modern sensor concepts and applications can make industrial production more efficient and sustainable. There will be many practical examples of this in the specialist forum and special show," explains Dr. Andreas Middendorf from the Fraunhofer Institute for Reliability and Microintegration IZM. As a member of the program advisory board, he is jointly responsible for the content of the format.

Ever sharper "eyes" required

The use of sensors in production technology is nothing new. However, the demands placed on these "eyes" are becoming ever more demanding. "Sensors monitor production and trigger the right reactions from machines and systems in good time to enable zero-defect production. However, these 'eyes' must see ever more clearly, i.e. more precisely, and detect their surroundings even faster. In modern automation, high-precision, real-time measurement technology is indispensable," says Olaf Gerstner. The sales engineer from Micro-Epsilon Optronic GmbH will present such applications and their benefits in his lecture. For example, the company's sensor solutions monitor the safe running of turbines and large electrical machines, help to prevent burr formation in injection molding machines, ensure non-contact thickness measurement in battery cell production or take over position control in 3D printing systems. Visitors to the Micro-Epsilon Optronic stand at Intec can also find out about the wide range of applications for the sensors.

Combating staff shortages with automation

Andreas Plauschin, Sales Manager at OPTOGON Industrielaser Manufaktur, talks about how optical recognition, camera-guided robotics and camera-based automatic laser processing support intelligent production. The company develops and produces industrial laser processing systems for marking, engraving and structuring workpieces made of a wide variety of materials. In addition to standardized series, customer-specific systems are designed and implemented. "The services essentially include the automatic recognition of workpieces using 2D or 3D image processing and camera-guided robotics for bin picking, i.e. the correct 'grip in the box', automatic workpiece processing and finally the visual inspection of the lasered result. With high-precision cameras and specialized industrial sensors, we can design process-reliable automation. We will also be demonstrating such a solution at our stand at Intec," says Andreas Plauschin.

The sales manager points out that, in addition to larger companies, more and more smaller businesses are requesting individual automation solutions. "In the past, employees often fed and removed the components for laser processing manually. As the necessary personnel are now scarce, companies are increasingly turning to automation to maintain and further optimize their production processes," says Andreas Plauschin. "Another advantage: automation never sleeps and also works at weekends."

Quality in view at all times

3plusplus GmbH is presenting an application for turning operations at the special sensor show in Leipzig. The system measures the roughness of workpieces without contact during the machining process and ensures that the machine readjusts the required component parameters in good time if necessary. Other geometric features of the workpiece such as radii, chamfers or the condition of the tool can also be monitored. "The user saves time and money as they can check the quality of their production in real time and not just afterwards. The application can be easily retrofitted. No training is required for operation," says Dirk Fromme from the Product Management department at 3plusplus, citing key advantages.

In addition to maintaining existing customer contacts and acquiring new ones, the developer of individual software for automation and measurement technology as well as worker guidance has another goal in Leipzig: "We are always looking for partners with whom we can further develop our services. In roughness measurement, for example, we see potential in combination with AI and the connection of additional sensors," emphasizes Dirk Fromme.

Sensor technology for energy-efficient IT applications

However, the growing use of electronics and AI also has a downside. "The more digital technologies we use, the more energy consumption increases. However, we want to achieve the exact opposite and use sensor technology to design sustainable information and communication technology that contributes to reducing our carbon footprint," says Dr. Middendorf. Researchers in the Green ICT project are working towards this goal. Teams from Fraunhofer and Leibniz institutes are building a competence center for resource-conscious ICT applications and infrastructures under this title. Dr. Lutz Stobbe, Sustainable Networks and Computing (SNC), Fraunhofer Institute for Reliability and Microintegration IZM, will present the content and objectives of the project, which was launched in August 2022, at the expert forum.

Provoke for more clarity

There are still many questions to be answered and some (pre)judgments to be dispelled, and not just when it comes to sensory technology and sustainability. These include, for example: Is sensor technology of any use at all? What use are all the measured values? Only external parties earn money from them. "We deliberately want to discuss such questions and opinions in a very pointed way at the specialist forum. We call this format 'Provokium' because we want to discuss provocative theses with the audience and stimulate debate. Ultimately, we want to come up with answers that provide more clarity on the benefits of sensor solutions and show ways to use them correctly," emphasizes Dr. Middendorf.

In the future, less will also be more in sensor technology. "Virtual simulations such as digital twins and the linking of sensor technology and AI will help us to need fewer real sensors in the long term and only use them at key points. Distributed sensor technology of this kind makes it possible to reduce data volumes and data density and drive forward communication in real time," says Dr. Middendorf, referring to future trends in sensor technology.