Automation: Augmented reality (AR), transport technology and cobots

Showing information, operating instructions or three-dimensional objects on the display of glasses: This is made possible by augmented reality (AR).

The IPH is currently equipped with

• Vuzix Blade 2D AR glasses
• 2D AR glasses Realwear HMT-1
• 3D AR glasses HoloLens 1
• 3D AR glasses HoloLens 2
• 2D/3D AR glasses Xreal One Pro

At IPH, we use AR glasses to demonstrate the wide range of possible applications to our customers and to support them in the digitalization of production.

AR glasses are used in assembly, for example: if each work step is superimposed on the field of vision, employees can take on new tasks without a long training period. AR glasses can support order picking by showing warehouse employees which shelves contain the products they are looking for. AR glasses are also useful for the remote maintenance of machines and systems: employees on site can share their field of vision with specialists anywhere in the world who can provide remote guidance for troubleshooting.

We are also developing new applications for AR glasses at IPH. In the ViSIER research project, for example, we are using augmented reality to give forklift drivers an all-round view at the wheel – disruptive obstacles are simply hidden in the display and appear transparent. The MouSe research project also aims to improve the safety and operational efficiency of manually operated industrial trucks through the use of augmented reality. In the KraNavi research project, we are using augmented reality to develop an intuitive assistance system for autonomous transport using overhead cranes.

We use the following cobots and industrial robots at IPH for research, demonstration and training purposes:

• Cobot UR10 from Universal Robots (see photo)
• Cobot UR5e from Universal Robots
• TS 80 high-speed scara robot from Stäubli
• Agilus KR 6 R700 sixx industrial robot from KUKA

To test robotic vision solutions, we use:

• RealSense D405 (2x) and D435 (1x) 3D cameras, and
• Basler blaze Time-of-Flight (ToF) camera blaze-112 

We primarily use the robots to develop automation solutions for our customers and to test the feasibility of new automation approaches. The robots can also be used in research projects and training courses.

How can 3D printers be integrated into an existing production chain? To demonstrate this, we have set up a process chain in which all process steps are fully automated. An industrial computer assigns jobs to the individual 3D printers, monitors the printing progress and communicates with the robot, which removes the printed components from the systems and passes them on to either an assembly station or the warehouse.

The components are produced in a printer farm, a rack with nine additive systems. By using several smaller printers, a relatively high production volume can be achieved with relatively low investment costs.

We use an automated guided vehicle system developed at IPH with custom-built transfer stations for research, demonstrations and training courses. This setup allows us to test different concepts for automated internal material transport under realistic conditions. One focus is the passive transfer of load carriers, such as small load carriers (SLCs), between the vehicle and the transfer station.

The automated guided vehicle (AGV) and the transfer stations serve as a platform for experiments and research projects. We also use them to demonstrate how automated guided vehicle systems work and where they can be used. Our research experience also informs our consulting work, particularly when helping companies select and introduce suitable systems.

In research projects such as FTS-Ready, LernFFZ and MouSe, we address current questions relating to automated guided vehicle systems, automated industrial trucks and intralogistics.

Our complete Industry 4.0 system demonstrates the possibilities of automation, digitalization and networking in miniature.

The system provides a practical demonstration of cube assembly, from removal from a magazine to processing with a press and storage in a miniature high-bay warehouse. The cube can then be removed from the rack with the help of a robot.
The factory, which is made up of series components, is fully networked, programmable and secure and provides a comprehensive overview of Industry 4.0 technologies.

We use the NVIDIA Isaac Sim simulation platform to create physically realistic virtual models of production and logistics environments. Built on NVIDIA Omniverse, the platform allows us to model machines, robots, workpieces and entire facilities in detail. Physical effects such as gravity, friction and collisions are taken into account. The resulting realistic models serve as a basis for digital twins.

We also use Isaac Sim to generate synthetic data for training neural networks. Cameras and other sensors are simulated virtually, and scenes can be varied by adjusting lighting, materials, positions and backgrounds. This allows us to generate large, automatically annotated image datasets for applications such as object detection and robotics. It significantly reduces the time and effort needed to capture and label real images manually.