Fraunhofer Institute for Production Technology IPT
© Fraunhofer IPT
Research project "VITAMINE_5G"
Virtual reality environment for online process monitoring
The aim of the research project "VITAMINE_5G – Virtual reality environment for Additive Manufacturing enabled by 5G" was to make manufacturing safer, more transparent and more controllable. To this end, we were setting up a digital virtual reality environment in which machine operators can view a realistic process image. The additive manufacturing process "laser metal deposition with wire", or LMD-w for short, was chosen as an example application.
Laser metal deposition with wire (LMD-w) process difficult to monitor and control
Due to the laser radiation and harmful fumes and particulate emissions, strict safety measures are necessary for LMD-w, such as safety walls with very small, dark-tinted windows. These safety measures mean that machine users have poor visibility of the manufacturing process and cannot intervene in the process while it is running. If a manufacturing defect occurs, it can only be identified in retrospect. This retrospective view makes it difficult to analyze why and where exactly the defect occurred and how it can be avoided in the future. As a result, the rejection rate for components manufactured using LMD-w is quite high, so that despite its numerous advantages, the technology is not very attractive for industrial practice.
Process data processed and transmitted to VR goggles
In the “VITAMINE_5G” research project, a new way of interacting between personnel, machines and processes was created – based on 5G technology. To this end, a 5G infrastructure was installed at the Fraunhofer IPT that enables the wireless collection, transmission and processing of build-up welding process data.
The researchers first described the machine in its individual systems and defined the necessary sensor technology. The machine components were prepared as 3D designs so that they could be used in a virtual environment.
The recorded data was enriched with tool paths generated by project partner Moduleworks and visualized in a VR application from RWTH Aachen University so that users can intuitively evaluate the process. User studies conducted by project partner HNI confirmed the high level of user-friendliness. In addition, a database solution developed by project partner Camaix ensures structured storage and further processing.
Virtual process monitoring in near real time
Huge amounts of process data are generated as they are recorded and processed. Data transmission for real-time process monitoring would be far too slow over conventional wireless digital infrastructures. For this reason, the researchers used the 5G infrastructure of the “5G-Industry Campus Europe” on RWTH Aachen University campus to transmit and process the enormous amounts of data.
A 5G router and several 5G HATs were successfully installed at the Fraunhofer IPT and integrated into the 5G research infrastructure. Stress tests were carried out using test data to determine the maximum data transfer rates over the 5G network. The installed sensors were then optimized in terms of data acquisition and data processing. To do this, the data frequencies were examined using the 5G network. The wireless connection through the 5G network was made possible by the 5G HATs, which were used to transmit the sensor data wirelessly to a computer system. The receiving computer was also equipped with a 5G HAT. In the final project phase, process data was transferred to the VR environment.
Improved process monitoring paves the way for industrial series production
The results of the research project will significantly improve process monitoring in LMD-w. The new insights into the processes gained through data acquisition increase the reproducibility of the results and make production more resilient. This will pave the way for industrial series production with LMD-w at the highest standard. The project results can also help companies integrate VR applications as well as 5G technology into their own production processes.
In perspective, the results of the research project "VITAMINE_5G" will serve as a basis for research on interactive solutions. Research work is planned on solutions to enable machine operators to interact with the machine during the process in the future. This way, they will be able to prevent an error from happening before the component is unusable.
Project partners
- Fraunhofer IPT, Aachen (coordination)
- ModuleWorks GmbH, Aachen
- BCT Steuerungs- und DV- Systeme GmbH, Dortmund, Germany
- Camaix GmbH, Eschweiler
- Dropslab Technologies GmbH, Aachen
- Visual Computing Institute, RWTH Aachen University, Aachen
- Heinz Nixdorf Institute, University of Paderborn, Paderborn
Funding
The research project "VITAMINE_5G – Virtual reality environment for Additive Manufacturing enabled by 5G" was funded by the Ministry of Economic Affairs, Industry, Climate Protection and Energy (MWIKE) of the State of North Rhine-Westphalia as part of the 5G.NRW funding competition.
Project Management Agency
Project Management Jülich
Publications from this project
| Jahr Year | Titel/Autor:in Title/Author | Publikationstyp Publication Type |
|---|---|---|
| 2024 | Virtual Reality as a Tool for Monitoring Additive Manufacturing Processes via Digital Shadows Rupp, Daniel; Kuhlen, Torsten W.; Rarbach, Sven; Wiechel, Dominik; Pottebaum, Jens; Weidemann, Tizia; Tran, Duc Thanh; Day, Robin; Zielinski, Jonas; Koenig, Valentina; Bremer, Jan; Kosche, Thomas; Grimm, Andreas; Bergs, Thomas; Weissker, Tim; Graessler, Iris |
Konferenzbeitrag Conference Paper |
| 2022 | VITAMINE_5G. VIrtual realiTy environment for Additive ManufacturINg Enabled by 5G Weidemann, Tizia; Gräfe, Stefan; Erbil, Emre |
Poster |
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