Many aerospace and automotive companies are already using augmented reality. Machine manufacturers, on the other hand, have always lagged behind. Now, there are more and more use cases of manufacturers using augmented reality (AR), and in times of travel restrictions, it is an emerging trend in the manufacturing industry.
To answer many questions from machine manufacturers, we first dive deeper into how AR works in mechanical engineering and what its benefits are for this industry. At the end of this article you will find a use case where a machine builder uses a HoloLens in combination with an IIoT platform to remotely commission their machines during travel restrictions.
What is augmented reality?
Augmented reality is a technology that adds computer-generated images to the real world, allowing the user to analyze the real-world situation in more detail. In AR, digital images and graphics intersect with the real world, and the person wearing an AR headset can interact by dragging and dropping items. After receiving input from the devices, the AR application recognizes the target, processes the image, and adds photos, video, and audio to create an illusion that takes users into a virtual world.
How augmented reality works in manufacturing
In manufacturing, augmented reality can be used for various purposes, such as remote support, signaling unsafe working conditions and measuring all kinds of changes. Text, statistics and images can be presented as digital aspects in the real world. A machine manufacturer or customer can look at a machine or component and see the operating temperature, the amount of items produced, errors and many other measurement data.
AR is an extra layer on top of the standard remote access. When the operator puts on an augmented reality headset (such as Microsoft Hololens and Magic Leap One), the machine builder or engineer can see exactly what the customer or his colleague sees in real time without being on site and can log into the machine via a secure VPN connection to see what is happening inside the machine.
They can provide targeted feedback and instructions via text, audio, video or by sharing documents such as a manual. The customer or colleague with the AR headset has his hands free to repair and change things in the machine or even to put machines into operation.
In addition, augmented reality can be used perfectly for training purposes in production. It provides training on the factory floor and reduces training time by up to 50%. Training modules only need to be recorded once and help machine manufacturers learn how to perform their tasks using an AR headset. It is especially helpful for tasks that are too complex to explain with text or video.
Schematic layout of Augmented Reality (AR – HoloLens) in combination with remote access for remote assistance.
Differences between virtual, augmented and mixed reality
You might be wondering what the difference is between virtual reality (VR), augmented reality (AR), and mixed reality (MR). VR gives you a simulated reality with the exclusion of the real world, while AR keeps the real world at the center and overlays computer-generated enhancements. This makes AR much more useful in the manufacturing industry than VR.
MR is however the most useful, because it brings VR and AR together. It stands out for its highly interactive aspect with realistic 3D images that appear in the real world. When you put on your headset, you can use your own hands to interact with and manipulate both physical and virtual objects through next-generation sensing.
The differences between virtual reality (VR), augmented reality (AR) and mixed reality (MR).
The benefits of augmented reality
AR brings several benefits to machine builders, such as the ability to assist customers remotely and build stronger relationships with customers.
No misunderstandings or miscommunication
You no longer have to worry about text and images not being interpreted correctly, as people using AR are trained and guided by virtual overlays of what to do on top of reality. Even if they are not tech-savvy, they are able to repair machines with assistance via an AR headset.
Solve problems faster
With augmented reality, organizations can respond quickly to malfunctions or defects, because they can give instructions to the person at the location of the machine. Because everything is visualized, it is easier to understand what needs to be done. At the same time, it reduces the travel time and costs for the technician who normally has to come on site to solve the problem.
Building a strong customer relationship
Using AR can help you build stronger relationships with your customers, as you are no longer just offering products, but also partnering to solve their problems. The technician no longer needs to travel, which saves a lot of time, allowing you to serve more customers in a short period of time. In addition, customers get more efficient production processes.
Use case: Application of augmented reality in mechanical engineering
This use case describes how a Dutch manufacturer of industrial process fluids remotely commissions their machines at the customer’s premises using the IXON Cloud and a HoloLens. Normally, their engineer visits the customer for commissioning. Because their customers are located all over the world, they have to fly a lot and stay on site for one or two weeks for measurements, preparation and cabling.
During the COVID-19 pandemic, machines had to be sent to the customer, because the engineer could not go on site due to travel restrictions. The manufacturer chose to implement IXON Cloud in combination with a HoloLens, so that their employees in the Netherlands can see what the customer is doing, just as if they were there.
Their customer, located in the Middle East, received the machine together with the IXrouter which they connected to the internet for a secure VPN connection to the IXON Cloud. The Siemens PLC and HMI they used were then accessible via the IXON Cloud web portal with HTTP and VNC access. The HoloLens is accessible through its own web portal and only needed an internet connection. Therefore, they connected the HoloLens to the internet via the IXrouter Wi-Fi hotspot for a stable video stream.
The manufacturer has one colleague close to the customer in the Middle East, not a technician but a product manager. However, via the HoloLens he was able to do technical work and help the engineers in the Netherlands to get the job done. The Dutch engineer had access to the PLC and HMI via VPN with TIA portal running on his own PC and used IXON Cloud to see what the product manager was doing on the HMI and to support him directly by operating the HMI from his desk. He had a view of everything the product manager was doing via the HoloLens and the web portal software actually allowed him to point and indicate a part in the machine.
Take your business to the next level with IIoT and AR
By combining IIoT and remote access with AR technologies you create added value for your customers. They will have a faster problem solving and better communication experience, resulting in a more efficient production process. Moreover, AR is applicable in the short term and the Return on Investment (ROI) will be achieved quickly. Augmented reality will undoubtedly revolutionize production and is worth considering for manufacturers. So, what are you waiting for?
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