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Item type:Publication, Access status: with files , Industry 5.0 in aircraft production and MRO: challenges and opportunitiesGlobally interconnecting machines, processes, and resources driven by exploring and advancing new technologies defined Industry 4.0 (I4.0), resulting in, e.g., Cyber-Physical Production Systems (CPPS). The aircraft industry particularly struggled with transforming production and Maintenance, Repair, and Overhaul (MRO) processes, replacing humans with machines and automating as well as digitalizing significant parts of their value- and non-value-adding activities. However, in the face of current social and environmental challenges, future industries will need to shift from purely technology-driven to value-driven, working sustainably with resources, including human capital. Together, these approaches constitute the idea of Industry 5.0 (I5.0). On the one hand, the aviation industry faces the challenge that even I4.0 concepts and technologies are not yet fully exploited or implemented. On the other hand, due to the specific characteristics of aircraft production and MRO as well as the environmental impact of the product, a tremendous potential arises regarding placing human well-being back into the center of adding value and decreasing environmental footprint while building an industry that is resilient and fortified against disruptions of this era. In line with the I5.0 terminology, in this work, we outline the challenges and opportunities of integrating I5.0 principles into the aircraft production and MRO industries, focusing specifically on the scope of selected use cases.Publicationtype: Journal Article63 41 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Use of augmented reality for iterative robot program optimisation in robot-automated series production processesThe inspection, analysis, and modification of robot programs in series production processes is a challenging recurring task in the automotive industry. Especially the holistic analysis of detected defects and the subsequent derivation and application of corrective measures to the underlying robot program is a complex task requiring extensive knowledge in multiple fields. Existing scientific literature has demonstrated that the utilisation of Augmented Reality (AR) assisted robot programming systems (ARRPS) improves programming efficiency as well as intuitiveness when compared to traditional programming methods. However, the accuracy especially of mobile AR devices limits the applicability of AR in industrial applications. We propose to leverage the iterative nature of the optimisation process common in series production and utilise the visual capabilities of the human worker to define corrective measures based on the inspected real process result. This mitigates the impact of limited tracking accuracy as the optimisation is based on the visual perception of the user and thus decoupled from the accuracy of the employed AR device. We implemented our system based on the requirements of a sealing workstation of the Mercedes-Benz Group in Germany. A conducted experiment validates the functionality and indicates that the presented strategy of iterative AR assisted robot programming enables optimisations with a similar accuracy as the Teach-In programming as well as a significantly reduced programming time. This suggests that utilising an ARRPS can be highly beneficial in the inspection, analysis, and modification of sealing applications common in automotive series production processes. As the presented iterative AR assisted robot programming is neither limited to sealing nor to the automotive sector it can be adapted for various robot-automated applications like path-welding, gluing, or painting and can extend its utility to related sectors such as aviation or the marine industry.Publicationtype: Conference Paper27 86 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Industry 5.0 in aircraft production and MRO: technologies, challenges, and opportunities(2023-03); ; ; ; Globally interconnecting machines, processes, and resources driven by exploring and advancing new technologies defined Industry 4.0, resulting in, e.g., Cyber-Physical Production Systems (CPPS). The aircraft industry particularly struggled with transforming production and Maintenance, Repair, and Overhaul (MRO) processes, replacing humans with machines, and automating as well as digitizing significant parts of their value- and non-value-adding activities. However, given current societal and environmental challenges, future industries must change from technology-driven only to value-driven, working sustainably with resources, including human capital, the idea behind Industry 5.0. On the one hand, the aircraft industry challengingly faces these demands since even Industry 4.0 concepts and technologies are not fully exploited or implemented; on the other hand, due to the specific aircraft production and MRO as well as the environmental impact characteristics of the product, tremendous potential arises regarding placing human well-being back into the core of adding value, decreasing environmental footprint, while building a resilient and fortified industry against disruptions of this era. In line with the Industry 5.0 terminology, in this work, we outline the objectives, challenges, enabling technologies, and opportunities for sustainable, resource-efficient, human-centric, and resilient concepts, systems, and procedures in aircraft production and MRO.Publicationtype: Preprint130 324 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Input and tracking system for augmented reality-assisted robot programmingAugmented Reality-assisted robot programming systems (ARRPS) aim to make the programming of industrial robots more efficient by providing an AR-based human machine interface that allows operators to program robots intuitively and quickly. This work aims to contribute to the field by presenting an input and tracking system based on the VIVE Lighthouse technology that can act as a basis for ARRPS systems, improving maturity, costs and accessibility. To evaluate the system, ARRPS core functionality has been implemented so as to demonstrate its basic feasibility. An extensive evaluation of the system accuracy has been conducted, as this is one of the key criteria for potential adoption of the technology. The feasibility could be successfully demonstrated and it could be shown that the end-to-end mean absolute error of the robot path point placement amounts to 11 mm in a workspace of 0.6 x 0.6 x 0.25 m3 volume. Finally, the robustness and setup time of the system still need to be improved.Publicationtype: Book part37 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Usability of augmented reality assisted commissioning of industrial robot programsThis paper analyses the usability of Augmented Reality (AR) in the commissioning and programming of industrial robots. Conducting two individual studies with a total of 31 participants we analysed the three dimensions of usability: effectiveness, efficiency, and user satisfaction by comparing our developed AR system with the conventional Teach-In programming method during the commissioning and modification of offline created robot programs. The results indicate that, while less accurate and hence effective, the AR system is more efficient and has a higher user satisfaction. Beyond that a posture analysis indicates that during a timeframe of 30 min the additional weight of the AR device does not significantly worsen the posture of a worker. Complemented by the positive result of the System Usability Score (SUS) that rates the analysed AR system with a good usability, the overall results indicate that while still limited by its achievable accuracy AR is an intuitive medium to conduct robot programming and commissioning.Publicationtype: Book part33 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Feasibility of Augmented Reality in the Scope of Commission of Industrial Robot PlantsThis paper analyses the synergetic potential of Augmented Reality (AR) and offline programming (OLP) in the commission of industrial robots. We discuss that AR could utilise existing programming paradigms present in the OLP to simplify the online commission in manufacturing plants with its ability to freely combine digital and real content. Focussing on the complementary use of AR and OLP a theoretically promising use case is derived. The use case is implemented in a simplified mock-up and a user study is conducted to practicably evaluate the feasibility. Ten participants commissioned an offline created program using the developed AR application. As nine out of ten participants could achieve a valid commission by using the developed AR application, the study indicates the feasibility of the presented use case.Publicationtype: Conference Paper65 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Accuracy of marker tracking on an optical see-through head mounted displayThis work assesses the accuracy of mono and stereo vision-based marker tracking on the Microsoft HoloLens as a representative of current generation AR devices. This is motivated by the need to employ object tracking in industrial AR applications. We integrate mono and stereo vision-based marker tracking with the HoloLens. A calibration procedure is developed that allows users to assess the accuracy of the calibration alignments by walking around the virtual calibration target. This can be generally applied when calibrating additional tracking systems with ready-made AR systems. Finally, the accuracy that can be achieved with the developed system is evaluated (comparing the influence of different parameters).Publicationtype: Conference Paper146 18