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Professorship for Machine Tools and Forming Technology
Division Process Informatics and Virtual Product Development

Division
Process Informatics and Virtual Product Development

Simulation, Visualization, Integration

The division Process Informatics and Virtual Product Development with its interdisciplinary team researches innovative virtual technologies for their application in an industrial environment. The applications range from Virtual Reality supported design reviews or trade show presentations with the help of mobile VR systems to complex Industry 4.0 solutions. The division with its Virtual Reality Center Production Engineering (VRCP) is equipped with a variety of VR/AR systems (5-Sided-CAVE, powerwall, mobile VR system 'moVE', robot workplace for human machine interaction, etc.).

The AVARE network was initiated by the division in 2015 and focuses on small and medium-sized companies. The goal is to enable them to access virtual technologies as these are becoming more and more important, especially in time of Industry 4.0. In addition AVARE actively supports the application of funds and initiation of projects. (more information: avare.info).

The lectures "Virtual Reality Technologies in Mechanical Engineering" and "Principles of Process Informatics" as well as the seminar "Virtual Reality Modeling" give students the opportunity to learn the VR basics. A wide range of project, seminar, bachelor and master thesis are offered. Furthermore there are workshops, expert discussions and demonstrations to communicate the potentials of VR technologies to a large audience.

Dr.-Ing. Philipp Klimant

Head of Division

+49 (0)371 531-36911
philipp.klimant@...
2/M206

Dipl.-Wirt.-Ing. Franziska Klimant

Second Head of Division

+49 (0)371 531-37528
franziska.klimant@...
2/M204b

Dipl.-Ing. Christoph Allmacher

Research Associate

+49 (0)371 531-32036
christoph.allmacher@...
2/M203a

Dipl.-Ing. René Apitzsch

Research Associate

+49 (0)371 531-33845
rene.apitzsch@...
2/M203a

M.Sc. Jennifer Brade

Research Associate

+49 (0)371 531-33513
jennifer.brade@...
2/M204a

Dipl.-Ing. / Dipl.-Soz.arb./Soz.päd. (FH) Manuel Dudczig

Research Associate

+49 (0)371 531-36284
manuel.dudczig@...
2/M204b

Dipl.-Ing. (FH) Karin Eßbach

Technical Employee

+49 (0)371 531-37925
karin.essbach@...
2/M204b

M.Sc. Christian Kollatsch

Research Associate

+49 (0)371 531-32885
christian.kollatsch@...
2/M203b

M.Eng. Alexander Kögel

Research Associate

+49 (0)371 531-33020
alexander.koegel@...
2/M204a

M.Sc. Mario Lorenz

Research Associate

+49 (0)371 531-39366
mario.lorenz@...
2/M204a

Ing. Luigi Pelliccia, Ph.D.

Research Associate

+49 (0)371 531-33949
luigi.pelliccia@...
2/M203b

M.Sc. Marco Schumann

Research Associate

+49 (0)371 531-37992
marco.schumann@...
2/M203a

Dipl.-Ing. Marco Witt

Research Associate

+49 (0)371 531-38953
marco.witt@...
2/M203b

Dipl.-Wirt.-Ing. Eckhart Wittstock

Research Associate

+49 (0)371 531-37667
eckhart.wittstock@...
2/M204a

VR machine simulation

  • Coupling of a real NC unit with a virtual machine model.
  • Security zones in the virtual model (marked red) ensure a safe stop of the machine tool before the collision.
  • NC-VR machine simulation: Hardware-in-the-loop coupling of a real NC unit with a VR machine model
  • NC/PLC commissioning and verification of NC-programs
  • Collision detection at the VR machine model
  • Video:
  • Anti-collision: Software for damage prevention at machine tools during running operation
  • Contact:
    Dipl.-Ing. Marco Witt

Augmented Reality

  • Overlay of process-relevant data, user-specific edited and shown by use of Augmented Reality.
  • Creation of individual Augmented Reality applications
  • Simplification and acceleration of the development process
  • Integration of tracking, camera, machine, and control data
  • User-friendly, nearly real-time visualization on mobile devices
  • Usage at assembly lines and machine tools for monitoring, service and design reviews
  • Contact:
    M.Sc. Christian Kollatsch

Human-Robot Interaction

  • Human-Robot Interaction supported by Virtual Reality and gesture control
  • Human-Robot Interaction supported by Virtual Reality and gesture control
  • Development of cooperative scenarios between human and machine
  • Setup of virtually supported scenarios
  • Integration of multimodal communication (haptic, visual, acustic)
  • Implementation of gripper tests
  • Implementation of handling tasks (with human interaction)
  • Coupling of virtual scenes with robot equipment
  • Contact:
    Dipl.-Ing. / Dipl.-Soz.arb./Soz.päd. (FH) Manuel Dudczig

Web-based presentation

  • Presentation of complex content by use of Web3D. Intuitive interaction directly with the 3D model inside the browser.
  • 3D web presenter of the Cluster of Excellence eniPROD
  • 3D web presenter of Innovation Alliance Green Carbody Technologies (InnoCaT)
  • Creation of web-based presentation for complex technical projects, products and processes
  • Flexible structure of presentation (no linear sequence of slides)
  • 3D Model as key element of presentation
  • Integration of slides, images and videos
  • Contact:
    Dipl.-Ing. René Apitzsch

Development support for mechanical and plant engineering

  • Design review in 5-Sided-CAVE allows the inspection of the whole machine tool.
  • Design review with mobile VR system
  • Ergonomic analysis using motion capturing
  • VR supported design review with mobile VR system 'moVE' on-site or in the 5-sided CAVE at the VRCP
  • Preparation of CAD data for creating the necessary VR models for the design review
  • VR supported risk assessment and ergonomic analysis
  • Contact:
    Dipl.-Wirt.-Ing. Franziska Klimant

3D data capturing

  • Mobile laser scanning of different objects, such as factory halls, building structures
  • Virtual Karl-Marx-Monument created out of a point cloud
  • Motion tracking by use of motion capture suit
  • Laser scanning: Mobile 3D laser scanning of any object, such as factory halls, building structures
  • Provision of point clouds in defined resolution
  • Analysis and processing of captured point clouds to be visualized and used for further specific applications
  • Motion capturing: Data collection via motion capture suit
  • Contact:
    Dipl.-Wirt.-Ing. Franziska Klimant

Integration of simulation data

  • Connection of aFEM and Virtual Reality
  • Visualization of measurement results of the experimental modal analysis and thermal deformation analysis of machine tools
  • Adaptive FEM: Postprocessing of the adaptive Finte Element Method (aFEM) through coupling with VR technologies
  • Simulation of stresses, linear and non-linear elastic as well as thermo-elastic deformations
  • Experimental property analysis: Visualization of measurement results of the experimental modal analysis and thermal deformation analysis of machine tools
  • Contact:
    M.Sc. Marco Schumann

Creation of exhibition models

  • Exploded view of motor spindle
  • Parallel kinematic machine tool
  • Mass forming
  • Creation of VR models for trade shows based on CAD data
  • Visualization of process cycles
  • Functional and visual model upgrading
  • On demand: rental of our mobil VR system
  • Contact:
    Dr.-Ing. Philipp Klimant
 
  • Vision of the demonstrator system
  • 3D-LivingLab robot
  • Strategic project within the Twenty20 Alliance 3Dsensation
  • Goal is the development of a modular demonstrator system to present the potential of human-machine interaction
  • More information about the Alliance 3Dsensation: 3D-sensation.de
  • Contact:
    Dr.-Ing. Philipp Klimant
  • Duration: 01.03.2017 - 28.02.2019
 
  • Logo von AMARETO
  • AMARETO-Partner
  • Partner: TU Chemnitz, TU Dresden, TU Bergakademie Freiberg, Fraunhofer IWU
  • More information about the AMARETO project: amareto.info
  • Contact:
    Dr.-Ing. Philipp Klimant
  • Duration: 01.01.2017 - 30.09.2020
 
  • The vision of the HIPS project
  • Joint project within the Artificial Joint Endoprosthetics Network with 4 partners from industry and research
  • Development of a surgery simulation and training system for hip implant surgeries
  • Contact:
    Ing. Luigi Pelliccia, Ph.D.
  • Duration: 01.09.2016 - 31.08.2018
 
  • Logo
  • Partner
  • Joint project with 6 partners from industry and research
  • Our goal is the development of a virtual twin through the integration of real-data of the new highly integrative process chain in a consistent data model
  • More information: innoteam-height.de (German)
  • Contact:
    M.Sc. Jennifer Brade
  • Duration: 01.08.2016 - 31.07.2020
 

Intelligent Collision Avoidance for CNC Machine Tools

  • Joint project with 4 partners from industry and research
  • Our goal is the development of an online collision avoidance system for machine tools
  • Main tasks are the automation of the 3D modelling, the development of a dynamic material removal simulation at the work piece, and the use of axis setpoints as input values for the online collision avoidance simulation
  • Contact:
    M.Sc. Marco Schumann
  • Duration: 01.07.2016 - 30.06.2018

SMA Aspirator - Development of an Surgical Irrigation and Suction System Using Shape Memory Alloy

  • Joint project within the Twenty20 Alliance Smart³
  • Development of an controller for an shape memory alloy (SMA) suction-irrigation device, which combines suction and irrigation functions into a single unit
  • More information about the Alliance Smart³: smarthoch3.de
  • Contact:
    M.Sc. Mario Lorenz
  • Duration: 01.07.2016 - 31.12.2017

FOLLOWme - Intralogistics with Automated Guided Vehicle System (AGV)

  • Joint project within the Twenty20 Alliance 3Dsensation
  • Goal is the development of automated guided vehicles for intralogistics including the concept development of the human-machine-interface and the realization of a pick-by-AR-solution for picking processes.
  • More information about the Alliance 3Dsensation: 3D-sensation.de
  • Contact:
    Dipl.-Ing. / Dipl.-Soz.arb./Soz.päd. (FH) Manuel Dudczig
  • Duration: 01.03.2016 - 28.02.2019

AVARE - Network for Application of Virtual and Augemented Reality

  • Focus on research of application of virtual technologies
  • Network of research facilities and companies, solving existing problems in the field of production engineering with virtual technologies
  • More information: avare.info (German)
  • Contact:
    Dipl.-Wirt.-Ing. Eckhart Wittstock
  • Started: 01.10.2015

Network Artificial Joint Endoprosthetics

Development of a Measurement System for the Capturing of the Patients 3D Geometry and Strain Distribution for the Attachment of Leg Prostheses

  • Joint project with four partners from industry and research facilities
  • Development of a FEA simulation model for calculating the pressure distribution of leg prostheses
  • Contact:
    M.Sc. Mario Lorenz
  • Duration: 01.10.2014 - 31.12.2016

Development of a Surgery Planning Software with an Intuitive Interaction Concept for Hip Replacement Surgery

  • Cooperation project with 6 partners from industry and research facilities
  • Development of a gesture and voice control for a surgery planning software
  • Contact:
    M.Sc. Christian Kollatsch
  • Duration: 01.09.2013 - 31.03.2016

HARPO - Heuristic Augmented Reality supported Packing Process Optimization

  • Raising the resource efficiency of a warehouse by visualizing an optimized packaging pattern directly inside the box using Augmented Reality.
  • Smaller boxes and less filling material are possible.
  • Checking if the packed box is in accordance to the given packing pattern leads to less packaging failures.
  • Contact:
    M.Sc. Mario Lorenz
  • Duration: 01.11.2013 - 29.02.2016

eniPROD - Energy-Efficient Product and Process Innovation in Production Engineering

  • Cluster of Excellence within the Saxon Initiative of Excellence
  • Contact:
    Dr.-Ing. Philipp Klimant
  • More information: eniPROD
  • Duration: 2009 - 2014

Development of an Interactive Internet Presentation via Web3D of the Five Saxon Clusters of Excellence (2009-2014)

  • Project within the Saxon Initiative of Excellence
  • More information: excellent-saxony.eu
  • Contact:
    Dr.-Ing. Philipp Klimant
  • Duration: 01.06.2014 - 31.03.2015

3D Simulation of the Manufacturing Process of Highly Complex Parts on Special Purpose Machines

  • Modular construction systems are used within the planning and manufacturing of special purpose machines to create efficient production strategies.
  • The target of this project was a simulation, which can be used to validate the production and performance of such machines, including different variants of the machine.
  • Contact:
    Dipl.-Ing. Marco Witt
  • Duration: 01.01.2013 - 31.05.2015

CAD2VR

  • Automatic convertion of CAD data into a Virtual Reality environment
  • Focus on model reduction and preservation of animations and kinematic chains
  • Contact:
    M.Sc. Mario Lorenz
  • Duration: 01.05.2012 - 31.05.2014

uTRUSTit - Usable Trust in the Internet of Things

  • EU project (FP7) with partners from Austria, Norway, Sweden, Belgium and Hungary
  • Video:
  • Contact:
    Dipl.-Wirt.-Ing. Franziska Klimant
  • More information: uTRUSTit
  • Duration: 01.09.2010 - 31.08.2013

VR-Based Simulation of Material Removal for Chipping Processes

  • The VR-based material removal simulation allows visualizing the resulting deflections of the static machine behavior on the virtual work piece
  • Contact:
    Dipl.-Ing. Marco Witt
  • Duration: 01.06.2010 - 31.12.2012

AMEL - Minimization of Energy Consumption in Logistic Systems

  • Development of strategies and algorithms for an assistence system for the minimization of the energy consumption in logistic systems
  • Contact:
    M.Sc. Mario Lorenz
  • Duration: 01.10.2009 - 30.09.2011

Development of Methods and Tools for the Adaptive Lifecycle Support of Production-Related Services in the Field of Mechanical Engineering

  • Project with the industry partners NILES-SIMMONS Industrieanlagen GmbH and SIGMA Chemnitz GmbH as well as the Fraunhofer IWU
  • Investigation of the possibilities to support services in the machine tool industry using VR
  • Development of methods, demonstrated in a training environment for maintenance staff
  • Contact:
    Dipl.-Wirt.-Ing. Eckhart Wittstock
  • Duration: 01.08.2008 - 31.12.2011

Skymocap

  • Example of using the motion capture system 'moven' outside the field of mechanical engineering
  • Industry funded project with Xsens Technologies B.V.
  • Evaluation of the motion capture sytem 'moven' under free fall conditions
  • Contact:
    Dr.-Ing. Philipp Klimant
  • Duration: August 2008
 

AVILUS+ - Applied Virtual Technologies with Long Term Focus in Product and Production Life Cycles

  • Joint project with Fraunhofer institutes IWU, IFF, IAO, IESE, IGD, IPK as well as TUM and DFKI
  • Contact:
    Dipl.-Wirt.-Ing. Franziska Klimant
  • More information: AVILUS+
  • Duration: 01.05.2008 - 28.02.2011

VR-Based NC-Machining and Analysis Simulation for Free-Form Surface Manufacturing using 5-Axis Milling Machines

  • Coupling of a real NC unit with a VR machine model for an early optimisation and fault analysis of NC programs
  • Contact:
    Dr.-Ing. Philipp Klimant
  • Duration: 01.09.2007 - 31.08.2009

VR/AR Strategies for Mobile and Collaborative Work in the Field of Production Technologies - VAR 2

  • Project partner: ETH Zurich
  • Local and distributed cooperation in VR/AR environments to increase the acceptance of VR/AR applications in the area of production engineering
  • Contact:
    Dr.-Ing. Philipp Klimant
  • Duration: 01.09.2007 - 28.02.2010

VR/AR Technologies for the Development and Analysis of Manufacturing Plants - VAR 1

  • Project partner: ETH Zurich
  • Creation of a basis for the efficient use of VR and AR in the field of design and numerical analysis of machine tools
  • Focusing on the creation of an immersive work environment for designing tasks as well as on VR and AR based visualization methods for FEM data sets
  • Contact:
    Dr.-Ing. Philipp Klimant
  • Duration: 01.08.2005 - 31.12.2006

ViVERA - Virtual Competence network for Virtual and Augmented Reality

  • Joint project with Fraunhofer institutes IWU, IFF, IAO, IGD, IPK
  • Goal was to cross-link the competences of VR- and AR-developers, the identification of future research needs, the bundling and convertion of experiences of developers and users for other application areas
  • More information: ViVERA
  • Contact:
    Dr.-Ing. Philipp Klimant
  • Duration: 01.10.2004 - 30.09.2007

VRAx - VR-Based Building Set for Technology Optimised Machine Tool Modelling

  • Joint project with Fraunhofer institutes IWU, IFF, IAO, IGD and IPK
  • Development of an advanced VR-based building set oriented platform for the design of machine tools
  • Contact:
    Dr.-Ing. Philipp Klimant
  • Duration: 01.01. 2004 - 31.12. 2006

VAR² - Extend Reality

  • The 3rd Conference on Research and Use of VR/AR-Technologies "VAR² - Extend Reality" took place from December 2nd till December 3rd 2015. Key subjects were basic technologies of virtual techniques as well as applications of VR and AR.
  • The 2nd Conference on Research and Use of VR/AR-Technologies "VAR² - Extend Reality" was held in Chemnitz, Germany from January 31st till February 1st, 2013 with topics ranging from "Virtual Engineering" to "Interaction in Virtual Scenes".
  • On May 15th 2008 experts in the field of VR/AR and future industrial users met in Chemnitz for the kickoff event of an international course of seminars about industrial applications of VR/AR technologies.
  • The conference proceedings can be purchased from secretary's office.
  • Homepage: www.var2.org

IC.IDO Virtual Reality Excellence Award 2008

  • Project 'NavIMode' (Navigation Interface for Modeling)
  • Advanced interaction technology for designers in VR environments
  • Contact:
    Dr.-Ing. Philipp Klimant

5-Sided-CAVE

  • Virtual inspection of a factory hall inside the 5-Sided-CAVE
  • Machine model with machining process inside the 5-Sided-CAVE
  • Vision of an energy-self-sufficient factory in the 5-Sided-CAVE
  • Passive stereo with 20 projectors
  • Edge length of each projection screen: 3 m
  • Optical tracking

VR Supported Workplace for Human-Robot Interaction

  • VR supported workplace for Human-Robot Interaction
  • VR supported workplace for Human-Robot Interaction
  • Lightweight robot Kuka LBR iiwa 7 R800 (with integrated momentum sensors)
  • Parallel, tongs, 3 finger, vacuum, bernoulli, inner and pin gripper
  • Flexible clamping surface with pneumatic media supply
  • Integrated active stereoscopic powerwall
  • Projection surface 1.8m * 1.2m
  • Optical workspace detection

Powerwall

  • Interactive factory planning at the powerwall
  • Passive stereoscopy with two projectors
  • Projection surface 2.80m * 2.25m
  • Optical Tracking
  • Seminar room with seven computer workstations

VR Lecture Hall at Fraunhofer IWU

  • VR Lecture Hall at Fraunhofer IWU
  • VR Lecture Hall at Fraunhofer IWU
  • 180 seats
  • Passive stereoscopic backward-projection with four projectors
  • Projection surface 6.50m * 2.60m
  • Optical Tracking

moVE - mobile Virtual Environment

  • Mobile VR system moVE
  • Mobile VR system moVE
  • Mobile VR system moVE
  • Mobile VR system moVE
  • Fujitsu Celsius M730 Power (64GB RAM, nVidia Quadro K6000)
  • Two digital projectors
  • Flexible projection surface 2.0m * 1.5m
  • Optical Tracking

FARO Laser Scanner

  • FARO laser scanner LS880
  • Terrestrial laser scanner FARO LS880
  • Phase comparison method for up to 120000 points per second
  • Maximum range 76m
  • Systematic distance deviation: ±3mm for 25m distance

Motion Capture

  • Ergonomic analysis with motion capturing
  • Handshake with the virtual world
  • Ergonomic analysis with motion capturing
  • Inertial motion capture system from XSENS
  • Suit with 17 inertial motion trackers integrated
  • Location-independent data recording (acceleration, velocity, position)

Planning Table

  • Coupling of visTABLE planning table with VR
  • visTABLE from plavis GmbH
  • 2D/3D planning system with touchscreen
  • Connectable with immersive VR systems

VR / AR

  • Visualization of machine tools inside the factory hall by use of Augemented Reality
  • ESI IC.IDO
  • Fraunhofer IGD instantreality
  • LivingSolids
  • AR-Framework ARViewer
  • Unity

3D Modeling

  • Rendered model of a crank shaft
  • Autodesk 3ds Max, Maya, Softimage, Motion Builder, Mudbox
  • Dosch 3D / AXYZ design
  • Autodesk Inventor Professional, AutoCAD, Showcase, Alias
  • PTC Creo (Pro/ENGINEER), Solidworks Premium, Solid Edge, CATIA

Special Applications

  • Visualization of the results of a FEM simulation by the use of AR
  • FARO Scene / Record / Cloud
  • Geomagic Studio
  • visTABLE touch
  • Dymola
  • MATLAB

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