Summer School | Production Technology meets Industry 4.0

Introduction and IT

We introduce you to the Cluster of Excellence “Internet of Production” and give highlights from the achieved research results. This module provides a framework for the other modules of the Summer School. The vision of the Internet of Production describes a common research roadmap of RWTH Aachen University concerning Industry 4.0. Therefore, you receive an overview of current research topics, and discuss potentials and risks for producing industries in the context of the Internet of Production.

Practical Applications of IoT in Industry 4.0

Industrial Internet of Things describes a pattern that enables the formation of dynamic networks in modern industrial environments. The IIoT characterizes a specialized form of the Internet of Things (IoT) paradigm and has the major goal of enabling interoperability between all devices that have access to the internet. The IIoT has the goal to establish such holistic information exchange capabilities between all devices in a factory by means of open, lightweight and easy-to-use standards. This module focuses on how to enable IIoT for existing production systems and gives practical examples on scenarios in practical manufacturing sites.

Assembly Robotics and Smart Automation

The lectures are divided into a theoretical and a practical module. First, you learn about robotic theory, including design and components of robotic systems. You examine robot types and see how workrooms and coordinate systems function. We work on topics like human-machine-cooperation, programming and simulation. In the practical part you learn about the robot programming language RAPID and the arrangement of robot tools and –work objects. You examine the programming of robot movements, as well as the design of simple handling tasks.

Modern Factory Layout Planning

First, you consider factory planning in general and then focus on factory layout planning. With an overview of nowadays challenges, you understand planning processes and planning tools that are used. The practical session is characterized by a use case where a factory layout is planned by hand at first and then using the visTABLE®touch Software, a common tool for virtual 2D and 3D layout planning.

Simulation of Lean Principles

This lecture aims to introduce lean production and Industry 4.0 as the two central pillars of successful production management in nowadays’ manufacturing companies. Theoretical principles and practical experience from industry help you understand the concept of Lean Production. We illustrate the characteristics and challenges of a non-lean factory. We contrast these by presenting a series of methods from Lean Production and outline the advantages. Based on implemented use cases in the demonstration factory Aachen, we present and discuss the application area, the functionality and the advantages of the individual technologies.

CPS, Internet of Things & Data Integration

Based on the capabilities of the IIoT, the devices of modern factory environments are able to exchange information independent of their location and of the nature of the data. In order to integrate the existing data into some storage system, such as a database or a data warehouse system, the information to be integrated needs to comply to certain standards. These standards make sure that the data is stored in a proper format and that the integrated information is understandable at a later point in time, regardless of the data source. In this module, we focus on so-called syntactical and semantic standards that enable such information integration in a uniform and reusable way by means of meta-data. By making use of models to standardize the representation of information, the data can be perfectly prepared for data analytics and later steps of the value creation chain of data. In terms of this module, semantic standards such as the Message Queue Telemetry Transport (MQTT) protocol as well the OPC Unified Architecture (OPC UA) standard are examined to show the benefits of using such modeled information for later steps.

Data Visualization

In order to be able to use data in a beneficial way, we first need to understand the data. Presenting complex, multidimensional data in a tabular fashion does not meet the need of humans, who, in difference to computers, are visual beings. Therefore, visualizations are a powerful key tool in data analysis. Different processes yield different data. It is easy for us to create one-dimensional, two-dimensional and even three-dimensional data plots.
You will not only learn how to create simple visualizations of up to three-dimensional data, but you will also learn how to visualize multidimensional data to make them understandable by human beings. We consider different methods and also best practices on when to choose which visualization for a given purpose.

Smart Analytics und Data Mining

Statistics has been the key method to data analysis for a long time now. Driven by the mathematical foundations it is used everywhere from finance over elections to the understanding of pandemics.
With the rising power of today’s computers, we are now able to not only create simple statistics but we utilize the computing power to create Smart Analytics.
You learn how to analyse data in a modern way and how statistics and data analysis are the foundations of artificial intelligence, which is supposed to be “the next big thing” in our future world. We show you how to get started with data analysis using the Python programming language and its most famous libraries. You will be able to try your skills on well chosen real world examples.

Starting with a short introduction to general AI, we will provide a brief overview about topics of relevance in contemporary AI with a special focus for the needs and challenges in engineering. On this basis, we develop the importance of learning-based control (LBC) as a particular sub-field of AI and its special relevance for AI in engineering. LBC roughly denotes the intersection of systems and control engineering with machine learning. We discuss different aspects and subproblems of LBC including model learning, learning-based model-predictive control, reinforcement learning, and automatic controller tuning. For two of these problems, we will then go into more detail and discuss exemplary problemsand tutorial style with interactive and practical programming elements. This way, you get to know the important AI subfield of LBC and gain hands-on experience on relevant problems.

Computational Based Design of New Materials and Processes

You learn about integrating computational materials modelling into materials and process design towards advanced steels with tailored properties and optimizing production processes. Then you discuss advanced high strength steels for carbody application, and analyse them with a variation of tools.

Additive Digital Manufacturing

Additive manufacturing offers the possibility to produce complex parts without the design constraints of traditional manufacturing technologies. The module will illustrate the process chain of additive manufacturing optimized parts. In a practical session you learn how to use software tools to structural optimize the part geometry for lightweight design. After that, the optimized geometry will be manufactured via 3D Printers.

Innovations and Trends in Metal Forming

In metal forming, the part geometry and the material microstructure are very important product properties. In this lecture you receive an overview of the interdependencies that have to be considered for the planning and optimization of a process. Process parameters, the machine behavior and the microstructural evolution have to be taken into account. We familiarize you with the simulation methods which are used on various scales. You will consider trends in metal forming by analizing examples of current research in the areas rolling, forging and sheet metal forming.

Innovative Plastics Technology powered by Internet of Production

In this module, we focus on the latest developments in automation and digitalization. After a short introduction to the chemical basis of modern plastics, we discuss the injection molding process in further detail and take it as an example on how modern simulation and combination technologies are used to produce highly complex parts. Via industry derived case studies, you get the chance for hands-on experiences in human centered design.