Simulation Making future technologies tangible

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At the Hanover Fair, Fischertechnik presents its modular factory simulation: the Agile Production Simulation. The model simulates processes of agile manufacturing in a confined space, thereby clarifying digital and tactile processes in a future factory.

The factory of the future is the subject of numerous research projects in science and industry. Forward-thinking companies rely on automation, modularity, artificial intelligence and agility to remain competitive. To advance these topics in industry and research, students, trainees, and employees need the necessary know-how and awareness to deal with complex issues.

Better learning experience with the digital twin.

The learning concept "Agile Production Simulation" by Fischertechnik, which is shown at the Hannover Messe, starts here. It simulates processes such as quality assurance using artificial intelligence, the functionality of driverless transport systems, and replicates automated processes: from goods receipt to modular production to quality assurance, all in a compact space. The accompanying didactics translate the hands-on simulated processes into future skills for learners and teachers. The digital twin of the model significantly intensifies the learning experience.

Here's how the factory simulation works.

The Agile Production Simulation is a factory made up of flexibly combinable modules.

• The material flow begins at the goods receipt for raw materials, leads through an automated high-bay warehouse, various production stations such as a milling or drilling station, to a quality assurance station with AI, and finally to the goods dispatch. An automated guided vehicle (AGV) with omnidirectional wheels transports workpieces between individual stations and ensures agile production processes that can be flexibly adapted to customer requirements. If necessary, the AGV can be charged at the charging station without swapping batteries.

• In the spirit of digital traceability, each workpiece contains an NFC tag onto which production data is written. The factory produces workpieces in different colors with different processing features. Agile production allows product-specific manufacturing steps within a lean process without setup times.

• The Agile Production Simulation is controlled by a central controller (Raspberry Pi 4 Model B) that is networked with the controllers of the individual factory modules, Siemens S7 1200 PLC. Different communication protocols such as the MQTT protocol (Message Queuing Telemetry Transport) enable all modules to work together in a networked manner.

• A cloud-based real-time monitoring system provides dashboards for job control and for visualizing the factory state. Key performance indicators such as cycle times or overall equipment effectiveness (OEE) can also be determined. An online shop simulates the order of workpieces by the customer. The mobile camera can be controlled from anywhere via the dashboard to simulate the principle of remote maintenance.

• The Quality Control with AI module makes the complex topic of machine learning tangible and illustrates its benefits in the production environment. Based on the concept of supervised learning, the part of machine learning is implemented with the AI tool Tensorflow.

The immersive learning environment prepares you for the factory of the future.

The associated digital learning platform is based on a digital twin of the Agile Production Simulation and serves as the educational counterpart to the tactile model factory. The immersive learning environment explains the control, actuators, sensors and functionality of the Agile Production Simulation.

The Agile Production Simulation was developed in collaboration with experts from KIT Karlsruhe, the software company OMM Solutions GmbH and the University of Stuttgart. The system is delivered pre-assembled in a practical case and is intended to offer a solution for everyone who wants to prepare for the factory of the future.

Fischertechnik at the Hannover Messe: Baden-Württemberg Pavilion, Hall 15, Stand A06