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

Fully automated production line as learning and test environment for digital solutions

The Wildau Smart Testbed (WST) is a fully automated production line, including logistics and picking robots. Serving as learning and testing environment for digital solutions it aims to streamline processes. The modular structure of the Testbed allows for easy learning and testing experiences, and the system can be scaled up to form a complex network with other systems in a factory environment.

The WST offers a variety of test and presentation options for development companies, PLC manufacturers, as well as production companies which are considering automating their product lines. The use of mechatronics, robotics, sensor technology, pneumatics, and drive technology, among others, provides insights into possibilities of a fully automated and intelligent production line.

The Testbed also features various drives, motors, and pneumatic cylinders that can be controlled in combination with the system, as well as different sensor technologies like lasor or color sensors for various test tasks. Handling components such as vacuum switches, pressure switches, and pneumatic muscles are used to assemble and ultimately, the WST's manufacturing execution system (MES) generates customer-specific orders, monitors the processes, and derives production key figures.

Technology: Mechatronics, robotics, mobile robotics, sensor technology, pneumatics, drive technology, commissioning, communication technology, HMI visualization, automated guided vehicles, digital twin technology, AR, energy monitoring, Scada-system

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

Virtual factory environment for visualization and problem solving

For SMEs VR is becoming increasingly interesting, because it is now affordable and accessible and helps to save explicit and implicit knowledge loss by high employee turnover. 

VR can identify production losses and challenges early on at a much more cost-effective rate. Product and production environments can be easily inspected without huge, expensive set-up.

Interactive testing without danger makes VR interesting for interacitve learning aswell. 

VR offers a wide range of applications for companies, who are looking to partly digitize their processes and learnings. When digitalizing construction and process data sufficiently, this can even boost the marketability in the age of Industry 4.0.

Virtual factory environment, that was created at the university, can be used to visualize interactively work on problems and possible solutions in the value chain. By means of gamification, assembly processes based on CAD and assembly instructions can be experienced without the real product environment.

Technology: Digital twin technology, AR/VR

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

Autonomous driverless transportation system

Transportation and Space Constraints: The transportation of materials within a company can consume employee resources and hindering their availability for value-adding processes. A rigid conveyor system, as conveyor belts, demand signigicant space and are not suitable for dynamic or frequently changing processes.

MIR - Mobile Industrial Robot - is an autonomously acting driverless transport system with a Universal Robot UR5 attached. This demonstrator showcases various solutions in the area of robotics, intralogistics and human-robot collaboration.

Thanks to adaptive route planning, MIR can react independently to environmental changes, without  requiring separate travel paths. The execution order can dynamically be adjusted, optimizing operational processes. A customizable browser-based user interface enables simple commands on a low-entry level of knowledge. As the attached robot is suitable for human-robot collaboration, implementing flexible automation solutions without protective fence are also possible. Handling and assembly tasks included.

Both learning and training events, especially in the area of programming, are a good use of MIR. 

Technology: AI, AGV, Real-time location system, robotics

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