Researchers at KIT and the Arts et Métiers Paris-Tech University are combining three pioneering technologies – digital twins, augmented reality and artificial intelligence – to rethink manufacturing processes.
We encounter the number three consciously or unconsciously in numerous situations: Be it in arithmetic with the rule of three, in human three-dimensional vision or with the triad in music. The number three is given special significance in many cultures and life situations, as it often describes harmonious things and symbolizes a form of perfection. It is not for nothing that we often hear the saying "All good things come in threes" after two unsuccessful attempts. But what does this have to do with KIT? In the XIRCON research project, the number three also has a special meaning. Researchers are harnessing the combination of three pioneering future technologies to simplify manufacturing processes in industry and reduce their reconfiguration time by up to 58 percent.
The problem of constant further development
Individual customer requirements or changing product variants lead to shorter product life cycles, which in turn leads to frequently changing requirements in production. The rapid adaptation of production systems to mechanical, electrical or software changes without loss of productivity is increasingly becoming an important success factor in industry. These so-called reconfiguration processes are currently mostly implemented by specialist personnel individually and without methodical support, which is often time-consuming and error-prone.
The special feature of augmented reality is the representation of an interactive environment that shows the user where they can move or interact and carry out certain actions. (Image: Amadeus Bramsiepe / KIT)
Innovative technology trio
Researchers at KIT and the French university Arts et Métiers have set themselves the task of implementing a human-centric cognitive support system to optimize reconfiguration processes, adapt production landscapes more quickly to changing requirements and minimize downtimes. To do this, they combine digital twins (DT) with augmented reality (XR) and artificial intelligence (AI). "Although these technologies are already known in production today, they are not used in combination with each other. By combining them, we wanted to exploit the advantages of all technologies and create a holistic solution," explains Prof. Dr.-Ing. Jivka Ovtcharova from the Institute of Information Management in Engineering (IMI). Digital twins can be used more intuitively by people in combination with XR technologies because they visualize digital information in a more accessible way and allow interaction with it. The XIRCON system therefore enables faster analysis of the current production status, real-time simulation during reconfiguration planning and a preview of the reconfiguration options and their methodical validation. The duo is complemented by AI, which enables individualized reconfigurations and supports their validation in terms of feasibility, key performance indicators, error avoidance and production optimization.
EXTENDED REALITY
The term extended reality is a collective term for the immersive technologies augmented reality (AR), virtual reality (VR) and mixed reality (MR), all of which supplement the real world with virtual elements. These can be AR filters, 360-degree videos or VR devices, for example. With the help of these elements, digital content can be experienced as if it were part of the real world. The three forms differ in the way in which the real and virtual worlds interact.
DIGITAL TWIN
Digital twins are representations of material or immaterial objects from the real world in digital space. When they are created, real-time data is processed using artificial intelligence and software analyses. For example, they can be a representation of a system in operation or a system component, including its current status and relevant operational history data. All plant data is transmitted directly to algorithms using physical and statistical approaches, thus helping to optimize plant operation, predict future behaviour or increase production efficiency, for example.
ARTIFICIAL INTELLIGENCE
Artificial intelligence is a branch of computer science that deals with the development of systems that can imitate human intelligence. It encompasses all efforts to transfer human learning and thinking to technical systems and thus make them intelligent. The aim is for intelligent systems to perceive their environment independently, interact with what they perceive, find answers to problems and solve them autonomously.
Researchers at IMI have developed very sophisticated system software for virtual reality that benefits XIRCON. (Image: Amadeus Bramsiepe / KIT)
Strong research partners and real-life scenarios
In the project, which is funded by the Innovation Campus Mobility of the Future (ICM), the cooperation partners of the Franco-German Institute for the Industry of the Future are developing and evaluating the DT, XR and AI modules required for the system by bringing together different areas of expertise. "We were interested in developing something for practical use right from the start. With the wbk, we have a fully functional research factory and therefore a realistic infrastructure in which we can test the developments directly in practice. In this way, we know what makes sense and what is actually needed in industry. On the other hand, we at IMI contribute the corresponding development expertise. For example, we have developed a very sophisticated system software for virtual reality (VR) at the institute. Our French partner is also very experienced in the field of VR and contributes its expertise to the development," explains Anjela Mayer, research
At IMI, Anjela Mayer and Prof. Dr.-Ing. Jivka Ovtacharova have the opportunity to connect the digital world with the real world: in the Cave, a room for projecting a three-dimensional illusionary world of virtual reality, they can map the wbk environment and test applications virtually. (Image: Amadeus Bramsiepe / KIT)
For a digitalized industry and mindset
XIRCON combines research strengths and links the two worlds of reality and virtuality. The project also provides wbk with a prototype. "Although we have a concrete example in the research environment, we are also demonstrating the feasibility and potential based on precise measured values for industry. Our wish is to initiate further projects, develop the topic further and transfer it to industry," says Mayer, looking optimistically to the future. Ovtcharova adds: "In addition to the added value for the industry, we also hope to raise awareness and mindsets in regard to digitalization. Many people perceive the physical and digital worlds as a kind of parallel universe. In fact, the digital world is an extension of our physical reality. We live analog lives, but we are increasingly communicating digitally and therefore moving much more in the digital world."
At IMI, Anjela Mayer and Prof. Dr.-Ing. Jivka Ovtacharova have the opportunity to connect the digital world with the real world: in the Cave, a room for projecting a three-dimensional illusionary world of virtual reality, they can map the wbk environment and test applications virtually. (Image: Amadeus Bramsiepe / KIT)
Researchers at IMI have developed very sophisticated system software for virtual reality that benefits XIRCON. (Image: Amadeus Bramsiepe / KIT)
Prof. Dr. Dr.-Ing. Dr. H. C. Jivka Ovtacharova, Institute for Information Management in Engineering (IMI) (Image: Amadeus Bramsiepe / KIT)
Anjela Mayer, Research assistant at IMI (Image: Amadeus Bramsiepe / KIT)
The special feature of augmented reality is the representation of an interactive environment that shows the user where they can move or interact and carry out certain actions. (Image: Amadeus Bramsiepe / KIT)
Keyfacts:
PROJECT XIRCON
eXtended Intelligence for Rapid Cognitive Reconfiguration
PROJECT PARTNERS
Institute for Information Management in Engineering (IMI), wbk Institute for Production Engineering, Arts et Métiers: Laboratoire d‘Ingénierie des Systèmes Physiques et Numériques (LISPEN)
GOAL
Implementation of a human-centered cognitive support system
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