Michael Grafe

Virtual and augmented reality support for discrete manufacturing system simulation

Nowadays companies operate in a difficult environment: the dynamics of innovations increase and product life cycles become shorter. Furthermore products and the corresponding manufacturing processes get more and more complex. Therefore, companies need new methods for the planning of manufacturing systems. One promising approach in this context is digital factory/virtual production-the modeling and analysis of computer models of the planned factory with the objective to reduce time and costs. For the modeling and analysis various simulation methods and programs have been developed. They are a highly valuable support for planning and visualizing the manufacturing system. But there is one major disadvantage: only experienced and long trained experts are able to operate with these programs. The graphical user interface is very complex and not intuitive to use. This results in an extensive and error-prone modeling of complex simulation models and a time-consuming interpretation of the simulation results. To overcome these weak points, intuitive and understandable man-machine interfaces like augmented and virtual reality can be used. This paper describes the architecture of a system which uses the technologies of augmented and virtual reality to support the planning process of complex manufacturing systems. The proposed system assists the user in modeling, the validation of the simulation model, and the subsequent optimization of the production system. A general application of the VR- and AR-technologies and of the simulation is realized by the development of appropriate linking and integration mechanisms. For the visualization of the arising 3D-data within the VR- and AR-environments, a dedicated 3D-rendering library is used.

A registration method based on texture tracking using ARToolKit

In this paper, we propose a computer-vision based registration method for augmented reality based on template matching. Computer-vision tracking methods for augmented reality applications typically use a special fiducial markers such as squares or circles. Our new method uses a black square fiducial of ARToolKit to obtain the initial tracking condition, but does not use it in subsequent iterative tracking phases. Several natural feature points are extracted from the tracked object by offline image analysis. While tracking the object, some of these feature points are selected for template matching and the object pose and position are calculated. Even when the initial tracking square is no longer in view, our method produces robust tracking at real time frame rates.

A modular architecture of a PC-based driving simulator for advanced driver assistance systems development

Interactive driving simulators support a variety of applications in the automotive field such as development of new in-vehicle systems and training purposes. Due to the improvement of computer technology, PC-based driving simulators are achievable and still can provide reasonable control and feedback cues. Representative simulation models can be utilized to produce realistic vehicle behavior as well as the interaction with other traffic participants. This paper presents a modular architecture for a PC-based driving simulator. It serves as a virtual prototyping platform for development, testing and initial training purposes, specifically, in the field of Advanced Driver Assistance Systems (ADAS). Furthermore, it can be used as an effective educational tool in the field of serious games. The simulation environment consists principally of various real-time capable simulation models developed with MATLAB/Simulink, such as vehicle dynamics model, road and traffic models and a model for ADAS simulation. These are arranged in a modular structure which allows for interchangeable simulation models, and hence, flexible and maintainable simulation environment. The structure of the PC-based driving simulator and the design of the simulation models are discussed. Prototypical implementation of two ADAS functions is presented to show the usability and validity of the developed platform for ADAS proof of concept, testing and basic drivers training.

To support multidisciplinary communication in VR-based virtual prototyping of mechatronic systems

A typical mechatronic product includes mechanical parts, software techniques, electrical and electronic components. This interdisciplinary character significantly increases the complexity of mechatronic products. Therefore, inefficient communication between the engineers, who come from different domains, becomes one of the main challenges in the development of mechatronic systems. Although, innovations in the field of virtual prototyping can help the engineers to handle a complex system and then accelerate the development processes, the technique itself does not offer a solution to the problem of multidisciplinary communications. In this paper, we present a practical solution of supporting knowledge sharing and communication within a multidisciplinary developing group, whose members need to work cooperatively for doing virtual prototyping of mechatronic systems in VR environment.

Cyberbikes - Interactive Visualization of Manufacturing Processes in a Virtual Environment

This paper describes CYBERBIKES, a real-time simulation of an enterprise that produces bicycles. The system is designed as a virtual environment. It is based on a realistic 3-D model of an industrial enterprise coupled with the representation and control of production processes. Furthermore, the flow of information like production data is visualized by means of clear metaphors. The user is immersed in the virtual environment by using a head mounted display through which he/she can explore the various departments of the industrial enterprise and learn how information technology influences modern production processes.

Interdisciplinary knowledge sharing in solution elements based virtual prototyping of mechatronic systems

A typical mechatronic product includes mechanical parts, software techniques, electrical and electronic components. This interdisciplinary character significantly increases the complexities of mechatronic products. Therefore, inefficient communication between the engineers who come from different domains becomes the main challenge that the designer should face to. However, innovations in the field of virtual prototyping offer potential solutions to this problem. In this paper, we present our solution of sharing knowledge within a multi-disciplinary work group by using the concept of solution elements and virtual reality techniques in our virtual mechatronic prototyping system.

Real-time representation of complex lighting data in a nightdrive simulation

For the development of new automobile lighting systems, special raytracing methods are used to completely simulate the illumination properties of the new product. For further evaluation, real test drives with real prototypes are still necessary. But changing weather and lighting conditions make the test drive results not fully comparable. Therefore, a high number of test drives have to be performed. This leads to a time-consuming and cost-intensive development process. Virtual test drives at night combined with a realistic simulation of a lighting systems illumination characteristics can minimize the number of real nightdrives and allow reproducible testing conditions as well as comparable results. A close-to-reality simulation poses high demands on the real-time method for calculating and displaying illumination data in a virtual scene. This paper introduces a real-time illumination method for use in a nightdrive simulation.

Optical tracking stabilization using low-pass filters

Optical tracking usually depends on adequate, good and stable lighting conditions. If the lighting conditions become unstable and often changing, the results are usually an unstable optical tracking and a jumping of the superimposed image. In this article, we propose low-pass filters for the stabilization of the superimposed image and for the compensation of jittering effects while performance, robustness and accuracy of the optical tracking system is not influenced.

AR-based training and support of assembly workers in automobile industry

In this paper, we present an interactive and context sensitive AR-system, which provides workers at the assembly line with all necessary information. Each assembly step of the components and the used tools is displayed using animations, 3D-objects and texts and inserted into the workers field of view via a small HMS. An corresponding Ar-system is used for the education and training of new workers. The complex steps of assembly processes are displayed using the same 3D-objects and texts. Thus staff working at manufacturing systems or assembly lines can be trained with a low degree of personal supervision. Every worker is able to assembly every structural component or automobile part at any time.

Augmented Reality as a New User Interface for the Layout Planning of Manufacturing Systems

Industrial enterprises are working in a difficult business environment: high dynamics, short innovation cycles and rising product complexity. This requires a fast and error-free planning of the manufacturing process. Subsequent necessary modifications of the manufacturing system and environment (e.g., movement of a column, redirection of a pipe system, exchange of machines) in a late phase are very time and cost intensive. Therefore, the planning of manufacturing systems is becoming an increasingly continuous task, with time and correctness being a critical success factor.