Augmented Reality (AR) is an immersive technology that uses the inherent potential of real-time visualisation, simulation and contextual information to improve efficiency, safety and quality in industrial processes.
The Augmented Reality applications that Aritex Code offers have already helped companies to evolve towards digitalisation and Industry 4.0. In this article we’re going to show you 5 success stories where AR played a pivotal role.
Contents
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- 1-Maintenance instructions for industrial equipment with Augmented Reality
- 2-Augmented Reality to optimise training and preventive maintenance in automotive sector
- 3-Quality control, training and digital thread deployment based on AR
- 4-Augmented Reality: the stepping stones towards differentiation and customer service
- 5-Aeronautics: Maximum efficiency and traceability guaranteed with AR
1-Maintenance instructions for industrial equipment with Augmented Reality
Howden specialises in engineering projects where its equipment functions as mission critical features for its clients. The company’s products range from mine ventilation and wastewater treatment to heating and refrigeration. One of the company’s needs was to provide its clients with tools to optimise maintenance processes and so reduce delays caused by downtime.
The challenge was to shift from a reactive approach to preventive maintenance, and also make it easier to maintain complex machinery and eliminate potential human errors.
The solution appeared in the form of Vuforia Studio, a software by PTC that enabled instructions guided via Augmented Reality to be generated.
Maintenance instructions in 3D with Vuforia Studio
Based on Howden’s 3D models, which are developed during the design phase for each piece of equipment, the AR content creators extracted data from ThingWorx, the IIoT platform by PTC, and superimposed them on the real model with the Vuforia Studio software.
With this approach they could provide relevant information to solve problems and effectively keep the equipment in working order to prevent breakdowns and downtime.
Thanks to ThingWorx, every maintenance task is also registered to maintain a healthy volume of useful data, and subsequent maintenance activities are streamlined with a log.
2-Training and preventive maintenance based on AR in the automotive sector
Reducing cycle times is essential in the vehicle manufacturing sector if efficiency and competitiveness are to be optimised. It’s a sector that requires constant inclusion of workforce in production lines, and so new operators need an adequate onboarding.
Training courses normally require the participation of more experienced operators. And obviously, they have to take time off from the production line in order to train the newcomers.
But now, thanks to training courses based on Augmented Reality by Aritex Code that use Vuforia Expert Capture technology, new operators complete a self-training process, guided by this new technology that teaches them step by step by superimposing precise assembly instructions over the real image.
In so doing, companies in the automotive sector achieve two things:
- They reduce training times for new operators.
- They free expert operators from training obligations and allow them to remain at their posts.
The result is a marked improvement in the training of new employees and greater efficiency on the production line.
Preventive maintenance with the help of Augmented Reality
Just like Howden and its revolutionary approach of providing clients with maintenance instructions for industrial machinery, many industries have now taken the plunge and are doing the same thing, enabling their maintenance teams to care for their equipment with Augmented Reality.
The first advantage is that the software clearly indicates the steps to be followed. Then the system itself detects if the outcome of each part of the process is the correct one. And if it isn’t, it warns the operator to check the task. At the same time, if the operator detects an anomaly, he can immediately report and record it on the system via a picture or video, with added annotations if necessary.
He can even remotely consult another technician thanks to AR teleservice functions.
All the information that the system gathers is analysed by artificial intelligence and machine learning systems, which then provide solutions based on data and previous experiences. It then goes on to form a repository of resources available to the entire maintenance team.
3-Quality control, training and digital thread deployment based on Augmented Reality
‘Volvo, for life’. You may recognise this slogan, which expresses the intentions of the Volvo Group, one of the most important manufacturers of cars, lorries, buses, construction equipment and industrial motors in the world, to position itself as a strategic benchmark out for quality and excellence in engineering.
The Volvo manufacturing plants are such that every engine offers 4,500 information variants for just one plant and requires 40 checks. A task reserved for the most experienced technicians in Volvo, who have to pass through a complex training process.
What’s more, every engine has 200 possible QA variants, which are constantly reviewed and updated. Being adequately informed about all these variations is an added challenge, especially if it’s all done on paper.
The digital thread based on ThingWorx, the solution of choice
Volvo decided to use PTC’s solutions, not only for the set of AR functions configured in Vuforia Studio, but also because of its comprehensive solution for creating and amplifying a digital thread. It opted to use ThingWorx to integrate design information (CAD) and data about the product life cycle management, and so facilitate real-time data synchrony in one real single source.
The digital thread ensures that the quality assurance team has access to the latest engine configurations and the support materials almost in real time.
The Vuforia software also enables operators to retrieve updated configurations in 3D instead of paper, which leads to evident improvements in productivity, quality control and general process efficiency.
The AR solution is provided with mixed reality, which superimposes the 3D data and the quality assurance details onto the physical engines and uses artificial vision to screen and anchor the content.
4-AR: the stepping stones towards differentiation and customer service
Innovation is one of the foundations of Cannondale, a global leader in the cycling sector. And not just in designing high-performance bicycles, clothing and accessories for cycling. It’s also an innovator in customer service.
To improve the maintenance and repair of Cannondale bikes, which is often carried out by independent retailers, this US based company needed a tool that could respond to its marketing priorities, and that would provide technical guidance and assistance with product design for staff in the retail workshops to ensure that they could do the best repair job.
Vuforia View, a free AR application at the community’s service
The team at Cannondale already had computer aided design software (CAD) made by PTC, so the data and step-by-step instructions that they had already developed could easily be published on Vuforia Studio.
In just one week the internal team developed an initial demonstration that showed the potential of AR in providing precise information about maintenance and repair to all their distributors. It’s now even available for private users who’ve bought a Cannondale bike.
Simply by reading a VuMark code (similar to a QR) via Vuforia View, a free application available on any app platform can be instantly accessed for all the necessary information, from the bike’s characteristics and features to a wide array of AR manuals for maintenance and repair. It also identifies the parts that need to be replaced and orders them from the factory.
With all this, Cannondale has managed to reduce repair times and increase the satisfaction levels of its customers, bike sellers and their customers’ customers, the bike users themselves. One result of all this work is that appreciation of the company has grown amongst the cycling community.
A unique shopping experience with Augmented Reality
The same AR tool also helps to improve the sales process. When a potential customer goes to a store, interested in buying a bike, but with no particular preference for a particular make or model, the seller can scan the VuMark code of a Cannondale bike and show the customer what to expect from it and what its characteristics are. This makes for a unique purchasing experience that is not currently offered by any other company in the sector.
5-Aeronautics: Maximum efficiency and traceability guaranteed with Augmented Reality
Aritex has a long and honourable tradition of developing engineering projects for companies in the aeronautics sector. That’s why we’re more aware than most that reliability and precision are two absolutely vital factors in this sector.
Aritex Code, the branch of Aritex that specialises in digital transformation and Industry 4.0, has also developed projects for aeronautics companies.
One particular project ensured reliability in parts machining, which is a highly complex process that should be completed under very stringent quality standards.
Augmented Reality to guide machining of aircraft parts
Certain parts of the fuselage of a plane, helicopter, etc., have to conduct electricity. A special metallised paint is used for this purpose. But at the same time, the parts of the same piece that would take the electricity to the cabin interior have to be isolated. To do this, a series of special adhesive pieces are placed at certain points of each part.
Thanks to PTC’s Vuforia Studio, operators have a visual guide that indicates exactly where the adhesive pieces have to go. It also enables checks in real time to ensure that they have been put in the right place. Systems such as these help operators not to make mistakes. And if one is made, the same system enables the process to be traced to establish the reason for the error and prevent it from happening again.
Aritex Code, experts in applying Augmented Reality to Industry 4.0
The team at Aritex Code have developed many AR-based projects for Industry: The most common applications are in training, maintenance and teleservice.
But AR can form part of the solution to many other problems: Assembly instructions, plans for new facilities, and reinforcing and facilitating the transfer of internal company knowledge, this closing the specialisations gap.
All these and many other AR-based solutions can increase a company’s efficiency and boost its competitive edge.
