Industry Scenario 2010
The Magic of Virtuality
Long before construction begins, future factories will function as virtual systems. Designers, engineers, suppliers and customers will be able to see the final product before production actually starts. This will accelerate processes, increase flexibility, prevent planning errors and lower costs.
A stereoscopic image of a virtual factory is projected on a large screen. The image, which includes 3D models of machinery as well as an overview of production processes complete with realistic sounds, is a digital representation based on geometric information generated by a powerful computer. Even people located elsewhere (above left) can follow the presentation via the Internet using data glasses and haptic gloves
Munich, Germany, October 2010. "So that's what the new jacket will look like. That's fantastic," says Cynthia Brown, as she looks at the large screen. Cynthia is standing in the virtual reality (VR) lab of the Virtuplant planning office and studying the design of an "intelligent jacket" with integrated electronic components. VR software expert Arnold Goetz pushes his computer mouse across the table to turn the jacket. At the sleeve, a small PDApersonal digital assistantwith a roll-out display comes into view. Light-colored strips of conducting material run through the fabric. Elements made of a photovoltaic film are attached at the back, hardly visible. These economical solar cells are found on the shoulders too, and there are soft plastic rechargeable batteries inside the shoulder pads.
As the mouse moves, the jacket takes up an ever greater portion of the screen, until finally the inside is visible. "That's our HealthSense device!" Cynthia nudges her colleague Oliver Bach. He has come to the presentation with her to see how the product from their biotechnology company, which monitors bodily functions and sends data to a family doctor, can be fitted into clothing. Virtuplant has digitized all of the data. Now Goetz will simulate and test the entire processin other words, everything from production of the fabric to integration of special functions.
"We'll begin with the material," says Goetz "Then comes the PDA, then your HealthSense device, and finally we'll run through the supply chain." Suddenly the image of a factory appears on a large curved screen in the virtual reality room. "But I said we don't want a blue floor in the hall," blurts out Wolfgang Globas who heads upmind&drapery, a garment-making company. He steps over to the computer table and snaps at Goetz: "I want gray. We should have stayed with the conventional planning."
"We'll have it in a second," murmurs Goetz. He calls up the palette, selects the right color with a mouse click and hands Globas a pair of 3D glasses without saying a word.
"Ah!" Globas exclaims. "Hmm. But aren't the machines too far apart? And the lengths of fabric are too wide!" "No problem," says Goetz. "During virtual operational testing, we discovered that the previous design triggers unacceptable vibrations at certain running speeds." Goetz indicates a machine by pointing to it with a laser pointer and says: "We increased the distance here. Now nothing vibrates." "I see," mutters Globas. "That's probably why the fabric used to tear now and thenbut why are the lengths wider?" "Well, with this arrangement you have about 20 % fewer rejects," Goetz answers.
"Now I'll start up operations," he says with a grin, ignoring the dumbfounded expression on the clothing manufacturer's face. He enters a few commands and the machines start moving. Immediately the sounds typical of a factory floor can be heard. "That's our latest feature," says the VR specialist proudly. "We generate an audio sample from the data," he continues. "With a chemical factory, we could even calculate material movements and heat flows in real time."
Oliver and Cynthia are elated. The entire production process is unfolding before their eyes. Goetz zooms in to check details; even the inner workings of the machines become visible. Oliver and Cynthia start to become a little impatient only when the entire cutting and sewing process is demonstrated, and virtual robots begin simulating machine maintenance. The two finally want to see exactly how their company's product is supposed to be integrated into the jacket.
At last, Goetz gets the jacket up on the big screen. "OK, now let's take a look at the PDA," he says to a round little man who had been standing in the darkness of the VR lab. "There's a problem with the display," Goetz says. "It can be extended only when the arm is outstretched; the wearer doesn't have a view of the monitor." The little man turns pale. "Oh no," he gasps. "My boss is going to blow his top; we're already behind." "Don't worry," Goetz says reassuringly. "We've used a neural network to calculate the optimal wiring, so that it works and also uses the least amount of material." The PDA maker seems somewhat relieved to hear all this. "So everything's going to be OK?" he asks. "Yes, you can tell your boss that you don't have to build a prototype and you'll be able to save at least six weeks," says Goetz.
"Now let's get back to you," he says, turning to Oliver and Cynthia. "Just a moment," says Cynthia. "We still need a second to hook up with our colleague Markus Zoller." She dials his number on her UMTS cell phone. A moment later Zoller has established a connection from his office via the Internet. The Virtuplant software feeds him the image through "data glasses," so it's as if he were sitting in the VR lab with the others. Goetz continues. "The problem is that sometimes the HealthSense device disrupts data transmission in the jacket because of its frequency. So I designed a screen and fitted it into the virtual model." Oliver and Cynthia are amazed. "You figured that out just by using our data?" says Oliver. "What did I tell you," Zoller intones from the speaker. "The man's a genius!"
"Could the jacket be ready to go to market this winter?" asks Cynthia. "That could work out," says Goetz. "I'll run through all the supplier logistics right away." He turns toward his monitors. Then Globas approaches him again. "Ahem, Mr. Goetz, do you have a second?" he asks, wrenching him from his concentration. "Somehow it looked more cheerful in blue, maybe we'd better go with that after all."
Norbert Aschenbrenner