fischertechnik, a supplier of teaching materials, will be presenting its groundbreaking modular factory simulation, the Agile Production Simulation, at the Hannover Messe trade fair. The model simulates agile production processes on a small scale, illustrating the digital and physical processes in a state-of-the-art factory of the future. fischertechnik’s revolutionary factory simulation can be found in the Baden-Württemberg pavilion in hall 15, stand A06.
The factory of the future has been the subject of many research projects in science and the industry. Future-oriented companies are focusing on automation, modularity, artificial intelligence and agility to remain competitive. In order to advance these topics in the industry and research, students, apprentices and members of staff require the corresponding skills and awareness to handle complex issues.
This is where the Agile Production Simulation learning concept by fischertechnik comes in. It simulates processes such as quality control using artificial intelligence or driverless transport systems on a small scale, recreating automated processes from incoming goods to modular production and quality control. The accompanying educational material translates the hands-on simulated processes into future skills for learners. The model’s digital twin significantly enhances the learning experience.
Agile Production Simulation is a factory consisting of flexible and combinable modules. Starting at the incoming raw goods, the material flow passes through an automated high-bay warehouse, various production stations such as a milling or drilling station and AI quality control to the outgoing goods. A driverless transport system (DTS) with omniwheels transports workpieces between the individual stations, ensuring an agile production process tailored to customer needs. The DTS can be charged at a charging point without changing batteries.
Each workpiece contains an NFC tag where the production data is recorded for digital traceability. The factory produces workpieces in different colours with various processing features. Agile production enables product-specific manufacturing steps within a lean process without the need for set-up time.
Agile Production Simulation is controlled by a central control system (Raspberry Pi 4 Model B) connected to the controllers of the individual factory modules, SPS Siemens S7 1200. Various communication protocols, such as the MQTT protocol (Message Queuing Telemetry Transport), allow the modules to connect and work together.
Cloud-based real-time monitoring provides dashboards to control processes and visualise the factory status. It can also determine KPIs such as cycle times and overall equipment effectiveness (OEE). An online store simulates the customer’s workpiece order process. A moveable camera can be controlled via the dashboard to simulate the principle of remote maintenance.
The Quality Control with AI module makes the complex topic of machine learning tangible while demonstrating its uses in a production environment. Based on the concept of supervised learning, the machine learning modules are implemented with the AI tool Tensorflow.
The accompanying digital learning platform is based on a digital twin of the Agile Production Simulation and forms an educational counterpart to the physical model factory. The high-performance, immersive learning environment provides an explanation of the control system, actuators, sensors and functionality of the Agile Production Simulation.
Agile Production Simulation was developed in cooperation together with experts from the Karlsruhe Institute of Technology (KIT), the software company OMM Solutions GmbH and the University of Stuttgart. The model comes assembled in a useful case and offers a simulation solution for anyone who wants to get to grips with the factory of the future.
