With the aim of making assembly workplaces more efficient, Fraunhofer IGD has integrated augmented reality (AR) and machine learning in the development of a system for user-guided fabrication of complex product configurations. The human operator is guided through the real process of assembly along the CAD specification of a digital product configuration. In addition to overlaying the contours of the relevant CAD model, the system also recognizes the predefined sequence of assembly and provides the worker with direct visual feedback on the correctness of the assembly step as well as the accurate positioning and orientation of a component. This not only ensures a successful outcome to the assembly process, but also enables simultaneous verification against CAD specification.
The human operator can additionally receive direct support from a remotely connected expert in a virtual 1:1 on-site presence. The situation on the assembly line is recorded and transmitted to the remote expert using innovative volumetric reconstruction methods. Conversely, the expert can explain his or her recommendations to the worker in direct virtual presence and provide assistance either by means of direct actionable instructions or virtual annotations on the product itself. The system is scalable and supports assembly workers via mobile or head-mounted XR (extended reality) output units.
With the AR-based assembly workstation, complex product setups are efficiently supported and simultaneously verified against CAD specification. The system thus replaces the assembly instructions that are still mostly available in a physical format which imposes the difficult task on the human operator of transferring information from 2D assembly instructions to the 3D world. Thanks to an innovative method of remote support, even highly complex assemblies can be carried out quickly and cost-effectively. The subsequent acceptance of the assembly then takes place fully automatically and is immediately verified according to the existing CAD specification.
