Computer aided manufacturing technology

A CNC milling machine can perform complex tasks in the shortest possible time. With its help, metal and wood workpieces can be manufactured economically, precisely, quickly and always with the same quality. Especially in metal and wood processing, these features are of great demand to enable the manufacturing and completion of products. 

Due to the four-axis technology of a CNC milling machine, time-consuming and accurate adjustment and reclamping work is no longer necessary. The workpiece only needs to be calibrated once per workpiece, and predefined and programmed steps enable fast production changes. Different milling and drilling heads can be changed automatically and the machine can also mill, engrave, cut and drill. 

Thanks to the automatic tool change, different milling and drilling heads can be used quickly and precisely in one production step. This multitool is primarily used in woodworking and metalworking companies to quickly and precisely manufacture various products. 

Where can you access this demonstrator?
Hub Cottbus. At the BTU Cottbus-Senftenberg
BTU Cottbus-Senftenberg; Siemens-Halske-Ring 14; 03046 Cottbus

Hub Wildau. At the University of Applied Sciences Wildau
Technical University of Applied Sciences Wildau; Hochschulring 1; 15745 Wildau

Use of a worker assistance system to provide information

A worker assistance system supports workers to complete tasks correctly and tap into the potential of digitization. At the heart of such digital assistance systems is a software solution that displays all the required information of the work steps while documenting the entire process.  

Therefor, preparation time can be reduced and digitally recorded, documentation effort is reduced and training is simplified. These systems provide the basis for process optimization, quality management, employee support for infrequent or flexible tasks or for routine tasks, e.g. recording relevant data, reporting and recording errors, training new employees - the ideal basis for standardized work instructions from batch size 1 to complex task areas. This gives it a clear advantage over hardware-bound pick-by-light systems (or pick-by-voice, pick-by-scan or pick-by-vision). The purely software-operated system can be used more flexibly and independently of the workstation, especially in modern, variant-rich production, but can be connected to the desired hardware via appropriate interfaces. 

The worker assistance system only requires a commercially available PC with web connection and corresponding smart devices for the employees. 

Where can you access this demonstrator?
Hub Wildau. At the University of Applied Sciences Wildau
Technical University of Applied Sciences Wildau; Hochschulring 1; 15745 Wildau

Automated, intelligent networking of machines in modern production systems

Modern production systems are characterized by automated, intelligent networking of machines and processes through the use of information and communication technologies. 

Manufacturing Execution Systems (SME) are also used to map the value stream of a company in real time. This feature is not possible in Enterprise Resource Planning (ERP). The requirement for process capability, now a verification obligation, results in the need for the manufacturer to align all value-adding processes with the process result and with the customer. MES process control systems are defined by a direct link to the distribution system of the process, enabling control of production in real time. The potential gain from the implementation of MES matches to the need for immediate, up-to-date online information. This allows users of the MES computer system to make the best possible decisions about the use of inventory, operating resources and the workforce. 

Other benefits include: Reduction in manufacturing cycle time, data entry time, work-in-process inventory, lead time and paper use. In addition, customer service is improved and it becomes possible to react better to upredictable events.  
SME systems hold especially for large companies a great advantage. In advance, the potential savings should be compared to the acquisition costs.  

Where can you access this demonstrator?
The demonstrator can be tested directly at the company and be easily integrated into the existing infrastructure. This way, companies see directly the benefits of digitization in a low-threshold way and train their employees on modern technologies.

Optimization of work-processes, error reduction through built-in quality control and shortened the general assembly time

Modern production systems are characterized by automated, intelligent networking of machines and processes through the use of information and communication technologies. Even in automation, especially in assembly, there is still work that has to be done manually. 

In the Roadshow Mobile PickSecure a system was developed to optimize this work, to reduce errors through built-in quality control and to shorten the general assembly time, e.g. by means of better and simplified material provision. Sensors and signals are used to determine the removal of the correct materials in the correct assembly sequence. In addition, the material stock is monitored. Therefore an upcoming bottleneck situation can be avoided by loading of the assembly workstation in a timely manner. 
Area of application: The assistance system presented in this demonstrator is suitable in modified forms for any assembly operation. Both small businesses and large internationally operating companies can benefit from this methods. The demonstration scenario presented is particularly suitable for assemblies with a high number of variants.

Where can you access this demonstrator?
This demonstrator can be tested directly at your company, as it can be transported with little effort from the Hub in Wildau and easily integrated into existing processes at your location. This makes it easier for companies to assess their digitalisation potential and also allows their staff to train on the use of new technologies.

Self-learning conveyor system for energy-efficient bulk material transport

Bulk solids represent the most widely transported main material and, due to their complex behavior, present great challenges for plant design. Precise and thoughtful planning as well as the experience of the designer are essential in the construction of economically well bulk handling plants. However, since a test phase with the actual bulk solids is useful during design, this is not often possible with existing plants.

SeLFeeS, the test and experimental environment using the example of "corn" with the final product "popcorn", supports many goals by processing bulk solids in different steps. Based on realistic tests and immediate evaluations, prototypical applications can be quickly implemented and ideas derived first-hand. 

The system consists of several stations connected by conveyor belts and a dosing screw at the end. Quality assurance of the bulk material is performed by means of color sensors, camera technology and load cells. Eddy current and heated air jets are used to turn corn kernels into popcorn. 

The interconnected production and logistics process of Selfees shown is representative of a large number of processes frequently encountered in the food and feed, pharmaceutical, cosmetics, chemical and plastics industries.  

Through a modular design and various extensions, SeLFeeS also offers the ability to develop and evaluate AI applications, as well as quality measures for monitoring from raw material to finished product. 

Where can you access this demonstrator?
Hub Wildau. At the University of Applied Sciences Wildau
Technical University of Applied Sciences Wildau; Hochschulring 1; 15745 Wildau

Test bed for the development of new gripper technologies

The force measuring stand contributes to the implementation of Industry 4.0 through an intelligent measuring and testing systems, the use of special gripper technologies and communication protocols. Thanks to optimised processes, automation and digitalisation are also possible for challenging materials such as flexurally flexible materials. 

It is no longer possible to imagine our everyday life without flexurally flexible materials. Whether in the clothing or automotive industry or in the production of fibre composites - they play a centrl role. In the production process, especially destacking, feeding, separating or removing and defined depositing, automated handling has a limited pracitcability. Due to their properties, flexible materials are very susceptible to strong deformations caused by external influences, so that process steps are currently only partially automated or handled with a high degree of manual effort. 

Modern hydroadhesive gripper technologies are the key to solving this problem. 
To test and calibrate this technology under field conditions, a test stand was developed at the TH-Wildau. The heart of this system is a 6-component force measuring sensor, which makes it possible to precisely determine the holding forces of the grippers in connection with numerous workpieces. In this way, the usability of gripper technologies can be optimised and adapted to the requirements of different applications. 

The force measuring stand also has sensors for ambient temperature and humidity, a PLC and a human-machine interface. These components are all digitally networked with each other and are in constant exchange. This system detects malfunction measurements and enables precise and efficient production through automatic correction of measurement results. All in all, the force measuring stand represents an important demonstration object for modern test stands and measuring systems. 

Areas and sectors of application: This technology is particularly suitable for companies that carry out R&D as well as for research institutions. The following industries can benefit from the knowledge gained from research with this technology: Automation, Material sciences, Logistics

Where can you access this demonstrator?
Hub Wildau. At the University of Applied Sciences Wildau
Technical University of Applied Sciences Wildau; Hochschulring 1; 15745 Wildau

A wearable robot that complements the human locomotor system

The exoskeletton is a wearable robot designed to augment the human musculoskeletal system and thus support and reduce physical burden on workers.

Active and passive exoskeletons offer promising solutions for preventing back and spinal problems, the most common cause of sick lieave and early retirement. 

They can be worn over workwear like a backpack and be integrated into the workflow after a security briefing, instructions, and a brief adjustment period. Both productivity aswell as quality of life are improved by providing support, a win-win for employees as employers. 

Passive exoskeletons store energy in rubber bands while the worker bends down, propelling the worker upwards while lifting and straighening loads.

Active exoskeletons use electrical motors and a rechargable battery to provide support when needed.  
Several small and medium-sized companies have already been visited for feasibility testing, especially in trade-related non-industrial settings, in the context of research and transfer and could be of great impact for more a attractive workplace.

Where can you access this demonstrator?
Hub Wildau. At the University of Applied Sciences Wildau
Technical University of Applied Sciences Wildau; Hochschulring 1; 15745 Wildau

KILEAN is a teaching and transfer system

For the understanding and development of AI-based applications, suitable, complex application scenarios are required with which development and testing can be carried out.

KILEAN provides as a teaching and transfer complex value creation process, prepares foreseeable trends for teaching, research and transfer and creates a corresponding teaching platform.

This practical presentation of Ki-based applications in a modern production environment enables the sustainable and long-term education and training of tomorrow's skilled workers. KILEAN plays a central role in the interdisciplinary training of AI specialists and strengthens cross-system AI application competencies.

Topics include autonomous driving, image processing, process optimization (initial logistics, operational production, marketing or sales) and human-machine interaction, which examples can be tested. The system shows various sensor systems, product variations such as different coloured containers, variations of the bulk material such as corn, millet, balls alias tablets, individual components (cubes in different colours and shapes); packaging including cardboard boxes to be folded, labelling and storage in small load carriers for shipment of the products from incoming orders via product merging, heat treatment, quality assurance and delivery.

In addition, AI use cases in the areas of infrastructure, human resources and technology development can be used. A test platform for the application of data-driven methods, such as from the field of deep learning, machine learning or even for expert systems is made possible by a smart AI infrastructure. For self-sufficient operation, various driverless transport systems support the transport of the components between the individual systems. The modular design allows different work plan sequences as well as location changes for further experimentation and processing installationen.

Using the example of the system, a production plant for processing bulk materials is depicted, which is equipped with a Manufacturing Execution System (MES), a web shop and energy measuring boxes. Based on the open source approach and open interfaces and communication protocols such as OPC-UA, Node-Red, MQTT as well as various databases a wide variety of approaches for data processing, for example for AI applications, can be picked up or tapped into. With its 18 stations, the system itself represents an extensive and complex development environment and thus represents the scope of a classic company by means of matrix production.

Kilean systems mediate operation of systems during commissioning, defects or for regular maintenance, servicing and assembly processes. Fear of contact with such complex systems can thus be reduced. In addition, the system also records long-term data sets for new AI applications, so that future synergies can be created and worked out.

Technologies: artificial intelligence, autonomous driverless vehicles, machine learning, forced learning, digital partnerships, visualization of process data, RFID, robotics.

Where can you get to know this demonstrator?
Hub Wildau. At the Technical University Wildau
Technical University Wildau; Hochschulring 1; 15745 Wildle

Digital upgrade of existing plants - making older machines and plants fit for networked production

In the course oft he advancing Industry 4.0, intelligent networking of machines and processes in a changing, competing environment, retrofitting of old and proven machines is often pursued.

Using the example of a drilling machine, the once analogue machine can be integrated into the company´s digital network and controlled. In the process, a wide range of process and safety-relevant parameters, as well as temperatures, current and voltage are recorded, too. 

Various advantages result from intelligent networking for machine operators: old machines can be integrated and monitored remotely. Individual steps can be better coordinated and the utilisation oft he machine can be better planned. The integration of a user-specific assistance system can increase efficiency and productivity. Predictive maintenance measures, early detection of wear and maintenance intervals are also recorded and mapped individually fort he operation by means of process data. 

Technologies: Digtial Twin Technology, image processing, AR, sensor technology, measurement control system 
Used for Conventional machines by retrofitting individual solutions

Where can you access this demonstrator?
Hub Wildau. At the University of Applied Sciences Wildau
Technical University of Applied Sciences Wildau; Hochschulring 1; 15745 Wildau

ViCtoR - Connect Four game against a KI-combined robot

In automation technology, the human factor is often neglected. Current trends are breaking down the previous relationship, in which employees have to follow the machines. The ViCtoR system contributes to making machines empathetic. We are researching how vital signs can be used to make machine configuration parameters as comfortable as possible for the human collaborator.

ViCtoR allows humans to compete against an AI in a game of four-in-a-row while simultaneously measuring the vital signs of the human opponent. In addition to the intellectual challenge, the human is confronted with movements by the robot. The collected data from the human is used to adjust movement patterns as well as reconfigure the AI's game strategy.

The system serves SMEs, government agencies and start-ups as an example of how artificial intelligence works, learns and reacts. Victor raises awareness and enthusiasm for the topics of robotics, AI, human-robot cooperation and robot integration. It emphasises flexibility and knowledge transfer. 

Technologies: Digital twin technology, robotics, human-robot cooperation, vital measurement, sensor technology, Airskin sensor technology/touch detector, image processing, mobile ECG and blood pressure measurement, gripping system.

Used in medical laboratories, production, carpentry, bakery. Especially monotonous or repetitive tasks such as loading machines, quality controll, loading or unloading charge carriers

Where can you access this demonstrator?
Hub Wildau. At the University of Applied Sciences Wildau
Technical University of Applied Sciences Wildau; Hochschulring 1; 15745 Wildau