Innovation: 5G wireless communication for data analysis of highly dynamic machining processes
Smart sensors are mounted directly on the component and thus have unprecedented process proximity. This high resolution of the physical phenomena in the form of the process data improves the understanding of the processes and thus also their control, so that further optimizations become possible.
The 5G wireless communication allows the system to be used in any manufacturing strategies with complex relative motion between the component and the machine, which are typical of modern and innovative products. The data rates and latencies of 5G technology open up new possibilities in the real-time control of highly dynamic processes with processing speeds that meet the requirements for the economic efficiency of modern production facilities.
The new system provides plants with a control approach that paves the way for adaptive control, adaptation to changing operating conditions and the ability for long-term self-optimization by additionally including historical data in the analysis.
Implementation: Exemplary installation of sensor technology in a milling process for turbomachinery construction
The 5GSensPRO system is demonstrated in the project using the example of the production of so-called BLISKs for turbomachinery construction. Flexible process monitoring that is as accurate as possible is ensured here with a modular multi-sensor approach in which the sensors are mounted directly on the component. The new 5G mobile communications standard ensures wireless communication of the sensor system with the base station and the machine tool.
The data is stored and aggregated in a cloud system in which the virtual workpiece is provided in the form of a digital twin. It is also planned that the production machine will be able to recognize the current component with the help of a tracking function and thus clearly assign all process and logistics data.
The display of sensor data and process control using smart devices in a virtual production environment offer the user a completely new way of interacting with the overall system.
Perspective: Networked sensor technology transforms machine parks into flexible, semi-autonomous systems with optimized capacity utilization
In the future, the combination of intelligently networked sensors, 5G technology and flexibly expandable cloud systems will help transform conventional machine parks into semi-autonomous systems with flexible processing stations and optimal capacity utilization. In conjunction with cloud-based data pipelines and derived models, companies will then be able to forecast not only production results but also maintenance requirements and downtime risks more reliably than before.
Overview of the 5GSensPRO modules
- Intelligent sensor hardware with a base unit for data pre-processing and radio transmission via 5G
- Software for sensor control and evaluation of the acquired data
- Tracking function based on mobile radio for identification of the component and automatic assignment of the appropriate process and logistics data
- Uniform, system-wide communication protocol for data transmission and coupling of sensors and other components for fast and uncomplicated expansion of the overall system
- Visualization interface, for example for smart devices and other end devices
- Smart Sensor Cloud as infrastructure for data processing, analysis and transfer to other systems
- Fraunhofer Institute for Production Technology IPT, Aachen
- Marposs Monitoring Solutions GmbH, Egestorf
- Meastream GmbH, Eschweiler
- Oculavis GmbH, Aachen
- QSQ, Erkelenz
- CP Tech GmbH, Büren (associated)
- Ericsson GmbH, Herzogenrath (associated)
- MTU Aero Engines AG, München (associated)