Realizing Virtual Reality Learning Environment for Industry 4.0

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12th 2018, 12thCIRP CIRPConference Conferenceon onIntelligent IntelligentComputation ComputationininManufacturing ManufacturingEngineering, Engineering,18-20 CIRPJuly ICME '18 12th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME '18 Gulf of Naples, Italy 28th CIRP Design Conference, 2018, Nantes, France Realizing Virtual Reality LearningMay Environment for Industry 4.0

Realizing Virtual Reality Learning Environment for Industry 4.0 a, a Vasiliki Liagkou *, Dimitrios Salmasa, Chrysostomos Stylios A new methodology to analyze the functional and physical architecture of a, a Vasiliki Liagkou *, Dimitrios Salmas , Chrysostomos Styliosa Technological Educational Institute of Epirus, Kostakioi Arta, 47100, family Greece existing products for an assembly oriented product identification a

Technological Educational Institute of Epirus, Kostakioi Arta, 47100, Greece

a

Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat

* Corresponding author. Tel.: + 302681050330 ; E-mail address: [email protected] * Corresponding author. Tel.: + 302681050330 ; E-mail address: [email protected] École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France

Abstract

*Abstract Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: [email protected]

The scope of Industry 4.0 is to overlay a simulation on a real-time production line that can investigate poorly understood phenomena and aid the rectification bottlenecks. application in Industry allows production companies line to decrease and production costs, maintain product The scope ofof Industry 4.0 is VR to overlay a simulation on a4.0 real-time that candesign investigate poorly understood phenomena and quality aid the and reduce the needed toVR go application from product production. In this work, the authors present VR’s technology aspectsproduct and limitations rectification oftime bottlenecks. inconcept Industryto4.0 allows companies to decrease design andthe production costs, maintain quality Abstract for the VR developers for creating VR industrial environments produce reliable/feasible of theaspects behavior machines andsupporting reduce the time needed to go from product concept to production. In thisthat work, the authors present the simulations VR’s technology andoflimitations and real processes and developers stable operation of remotely real processes. for supporting the VR for creating VR industrial environments that produce reliable/feasible simulations of the behavior of machines In today’s business environment, the trend towards more product variety and customization is unbroken. Due to this development, the need of © Authors. by Elsevier B.V. real processes. and2018 real The processes andPublished stable operation of remotely agile and reconfigurable production systems emerged to cope with various products and product families. To design and optimize production Peer-review under responsibility of the scientific of the 12th CIRP Conference on Intelligent Computation in Manufacturing © 2018 The Authors. Published by Elsevier B.V. © 2019 as The Authors. Published Elsevier B.V. committee systems well as to choose theby optimal product matches, product analysis methods are needed. Indeed, most of the known methods aim to Engineering. Peer-review underresponsibility responsibilityofofthe thescientific scientific committee of the 12th CIRP Conference on Intelligent Computation in Manufacturing Peer-review under committee of 12th CIRP Conference Intelligent Computation in Manufacturing analyze a product or one product family on the physical level. the Different product families,onhowever, may differ largely in terms of theEngineering. number and Engineering. nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production Keywords: Virtual reality; Industry 4.0; Learning environment system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster Keywords: Virtual reality; Industry 4.0; Learning environment these products in new assembly oriented product families for the optimization of existing assembly lines and the creation of future reconfigurable assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and a1.functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) the output which depicts the Introduction HTC Vive ([2]-[3]). Each oneistool has different uses and similarity between product families by providing design support to both, production system planners and product designers. An illustrative 1. Introduction HTC Viveimmersion. ([2]-[3]). Each one tool different the usesmore and different The better thehas immersion example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of different Theitbetter immersion Virtual Reality (VR) has the ability to create and integrate complex immersion. and expensive is. It the is also requiredtheformore the thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach. Virtual Reality (VR) has the ability to create and integrate complex and expensive it is. It is also required for the any kind of environment, redesign, retest and refined them in a designing, developing and creation of the Virtual © 2017 The Authors. Published by Elsevier B.V. any kind of environment, redesign, retest and refined them in a designing, developing and creation of the Virtual virtual computer based framework. On the other hand, Virtual Environments (VE), which are actually established in Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.

virtual computer other hand, Virtual Reality has to dealbased with framework. many issuesOn andthe specific challenges in

Reality tothe deal with many and specific challenges in order to has meet hard requirements and high standards of being Keywords: Assembly; Design method;issues Family identification

order to meet the hard andVR highcould standards of being the visualization part requirements of Industry 4.0. provide new the visualization partefficient of Industry 4.0. VR could provide new solutions and more opportunities for a revolutionary solutions and more efficient for aMost revolutionary new manufacturing trainingopportunities environment. of the 1.new Introduction manufacturing environment. Most of the operational, reporting training and monitoring data and information operational, and 4.0 monitoring data and information transmitted inreporting the Industry via integrated communication Due could to inthe development in thecommunication domain(VR) of transmitted the Industry 4.0 in via the integrated chains be fast visualized virtual reality communication and an ongoing trend of digitization and chains could([1]). be VR visualized in the virtual reality (VR) environment based manufacturing system could be digitalization, manufacturing enterprises are design facing important environment ([1]). VR the based manufacturing systemstages could (ii) be used for: (i) analyzing products at early challenges today’s the market environments: continuing used for:the (i)ininteraction analyzing products at early stages (ii) studying of the customers with design the afinal products tendency towards ofcustomers product development and studying the interaction of the with the processes finaltimes products (iii) designing andreduction improving the manufacturing (iv) shortened product lifecycles. In addition, there is an increasing (iii) designing improvingremotely the manufacturing processes (iv) monitoring andand supervising the processes and many demand of customization, at thethe same time inand a global monitoring and supervisingbeing remotely processes many other applications. competition with competitors all over the world. This trend, other applications. which is inducing from macro to factor, micro  Cost of adoptingtheVRdevelopment technology is an important markets, results in diminished lot sizes due to augmenting  Cost adopting VR technology is an important whichofhas to be taken into consideration. There arefactor, many product varieties (high-volume low-volume production) [1]. which has to for be taken into to consideration. There are many technologies accessing virtual world, i.e. Oculus Rift, To cope with this augmenting variety as well as to be able to technologies for accessing virtual world, i.e. Oculus Rift, identify possible optimization potentials in the existing 2212-8271 ©system, 2017 The it Authors. Publishedtobyhave Elsevier B.V. knowledge production is important a precise

Environments (VE), which established in servers and are accessed by VRare toolsactually from everywhere using servers and are accessed VR tools from everywhere using a client-server approach.byIntegrating the VR technology in aIndustry client-server approach. technology in 4.0 requires theIntegrating evaluationtheofVR cost factor and Industry requires evaluation cost factor and benefits of4.0 specific VR the technologies andofservers. specific VR technologies and  benefits Ensuringofthat VR models will be able to servers. produce real time of product range andVR characteristics manufactured and/or  the Ensuring that VRThe models will behave ableto todeal produce time concrete results. modes with real complex assembled in this system. In this context, the main challenge in concrete Thereproduce VR modesthe have to deal with complex real time results. events and reality based most of the modelling and analysis is now not only to cope with single real events and feedback. reproduce the reality based most of the timestime on simulation products, a limited product rangesimulation or existing product families, on simulation feedback.  times Investigate and consider how and VR models can but also to be able to analyze and to compare products to define  Investigate consider how simulation and VRformodels can create and and produce a reliable environment adapting newcreate product families. Ittools, can be observed classical existing and produce a reliable environment forof adapting physical operations, engines and that structures Industry product are regrouped in function of clientsnot or physical tools, engines and structures of features. Industry 4.0. families It isoperations, mentioned that physical movements close to However, assembly oriented product families are hardly to find. 4.0. It may is mentioned that physical notwhen close to reality have negative impact ormovements wrong results the On the product family level, products differ mainly in two reality have negative impact or wrong results when the user is may transferred from the simulation interaction into main characteristics: therealism number components andinto (ii) the user is transferred(i) from the simulation interaction the real environment. The ofofthe users’ Avatar varies typereal of components (e.g. mechanical, electrical, electronical). environment. The realism of applied the users’ Avatar varies heavily and it is dependent on the technologies, i.e. Classical methodologies considering mainly single products heavily and is dependent on the applied in the case ofit teaching user actions, whichtechnologies, requires a loti.e. of or in solitary, existing families analyze the casealready of teaching user product actions, which requires a lotthe of product structure on a physical level (components level) which causes difficulties regarding an efficient definition and comparison of different product families. Addressing this

Peer-review the scientific committee 2212-8271 ©under 2017responsibility The Authors. of Published by Elsevier B.V.of the 11th CIRP Conference on Intelligent Computation in Manufacturing Engineering. Peer-review under responsibility of the scientific committee of the 11th CIRP Conference on Intelligent Computation in Manufacturing Engineering. 2212-8271©©2017 2019The The Authors. Published by Elsevier 2212-8271 Authors. Published by Elsevier B.V. B.V. Peer-reviewunder underresponsibility responsibility scientific committee of the CIRP Conference on 2018. Intelligent Computation in Manufacturing Engineering. Peer-review of of thethe scientific committee of the 28th12th CIRP Design Conference 10.1016/j.procir.2019.02.025



Vasiliki Liagkou et al. / Procedia CIRP 79 (2019) 712–717 V.Liagkou et al. / Procedia CIRP 00 (2018) 000–000

physical interaction with the object, it will not benefit the user at all.  Virtual Reality is used for real-time visualization of specific virtual models and simulation situations. Due to the constant changes in simulation technologies a constant updating is required. This means continuously updating and even the creation and redesigning of a viable use case scenario requires heavy programming effort. On the other hand, maintaining VR scenarios and so updating existing programming codes is time consuming and it is hard for users with little to no coding experience. Consequently, design adaptable virtual models need a lot of time and effort.  The nature and implementation of virtual reality realization in the industrial environment is essential. Conservative approaches based on VR glasses may cause health issues; there have been cases where users felt nausea after using glasses for a moderate amount of time. VR users need time to adapt themselves into the VR environment; sometimes when they are using glasses for long time they may feel lost and sick. Thus, the selection of the best VR implementation approach (3D glasses, VR booth or other) should be user friendly.

1400 1200 1000 800 600 400 200 0

Price

160 140 120 100 80 60 40 20 0

Durovis Dive Samsung Gear VR 60€

2. Main VR technologies and their cost

Table 1. VR equipment. VR-Equipment

Type

System

HTC's Vive ([2])

HMD

PC

VIVE Pro ([2])

HMD

PC

Occulus ([3])

HMD

PC

Avegant Glyph ([4])

HMD

PC

Playstation VR ([5])

HMD

PC

ANTVR Kit ([6])

HMD

PC

Durovis Dive([7])

HMD

Mobile Device

Samsung Gear ([8])

HMD

Mobile Device

THE GO VR HMD + GAMEPAD KIT ([9])

HMD

Mobile Device

Altergaze ([10])

HMD

Mobile Device

Kinect([11])

Motion Sensor

XBOX

PC requirements Cost

Fig. 1. Cost Range for VR Equipment for PC.

In conclusion, Industry 4.0 could benefit from using Virtual Reality models to display large and complex processes and products referring to training, simulation, maintenance and all the aspects of production line and/or at management activities.

The use and adoption of Virtual Reality technology as a new way to facilitate specific phases either for training and/or education purposes has a considerable cost. There are available many VR technologies equipment for accessing virtual world either via PC and/or mobile device. Table 1 presents the most prominent VR technology equipment and their use. Introducing VR technology and equipment in Industry 4.0 requires the evaluation of cost factor thus Fig. 1. and Fig. 2. present the cost range in dollars of the listed VR equipment.

713

THE GO VIRTUAL REALITY HMD + GAMEPAD KIT

Altergaze

Fig. 2. Cost Range for VR Equipment for Mobile Devices.

In addition to this, there are various VR tools and devices that are designed and built; but they are in experimental stage or they are used for research purposes and so they are not available in the market. The cost varies based on the immersion as well as the scenarios that the users are trained on. In the following section, we will present some indicative scenarios related to industrial processes and based on tools presented above. 3. VR for Real Time Events Virtual Reality core characteristic is the creation of a realistic looking world, which is able to simulate and present physically and in real time any physical environment. Virtual Reality is a real time interactive technology. Main devices that support the creation of an 3D virtual environment and so that to represent real time events are:       

Head Mounted Display Cave Gloves 3D Mouse Space Ball Video camera and shadows Voice recognition

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 Biological sensors  Full body suits Methodologies and approaches from Discrete Event Simulation are integrated with VR technologies to spot realtime problems. There are many Discrete Event Simulation (DES) models and experiments that produce data that can be used. In [12] the authors use sensors and a DES model for simulating real-time movement and present a VR real shop floor without the potential cost and risk of physical implementation. In [13], the authors present various research results concerning the real-time integration and operation of VR DES. Actually, the presented in [13] DES models could facilitate and evaluate sensor data collected by production data but they do not support real-time decision making and real-time updating of factory floor machines directly from scenarios facilitated and evaluated through DES. Some functionalities of Industry 4.0 include overlaying simulation on a real-time production line that can investigate various phenomena such as to aid the rectification of bottlenecks at the production line. A real-time interactive visualization of production line operations has to make use of enabled advances in computing power and the ever-shortening amounts of time taken between sensor data provision, processing, analysis and visual rendering in order to accomplish Industry 4.0 expectations. The future of VR DES, its interoperability with data providers and production line sensor streams will be a critical discipline of Industry 4.0. Physical Movement Simulation Another basic feature of the VR technology for Industry 4.0 is to record the physical movements and to effectively apply them to a virtual 3D character. If the motion capture representation in VR environment is not close to reality then user’s interaction with simulation model will give false results. Nowadays the realism of the users’ Avatar is based on various technologies and tools since new motion capture systems or tracking devices are now available. The VR representation of user’s Avatar follows two directions, the first one is to project VR environment and the second one is to build a Desktop VR environment. Projection VR involves three-dimensional (3D) virtual models projected in a room, which can be perceived from different perspectives (CAVE [14],[15]). Desktop VR relates to an environment represented on a computer screen which can be perceived stereoscopically by wearing special stereo-glasses. Moreover head mounted displays (like Oculus Rift and NVidia HMD), optical cameras, inertial sensors (usually coupling accelerometers and gyroscopes), low cost depth sensors (e.g., Microsoft Kinect) are used in order to make feasible the physical movement representation in VR simulated environment. In [16] they created a platform with the combination of the Oculus Rift and Kinect to simulate the environment of a factory, where the users are trained in the safety of manufacturing while they are working together with robots. They added sounds on every movement in order to stimulate higher immersion. In this research, they found out that users participated at the test showed a lower chance to receive an injury while working in the factory.

Table 2. shows the technology/equipment choice for tracking physical movement in various implementations of VR environment that could be applied in industrial domain. Using optical camera has high cost and it requires to place reflective markets on subject’s body or on any tracking object in the scene. Reflective markers act as reflectors and appear much brighter to the cameras than the rest of the scene. The physical movement capturing with optical camera in VR simulated environment is close enough to physical movements but a triangulation process is needed to reconstruct the 3D coordinates of each marker for each frame by combining the 2D data from each camera. Artanim [17], a non-profit foundation, is researching and developing software and hardware for the promotion of motion capture. By combing various equipment, such as RGB-D cameras and Oculus Rift, they have created different scenarios where users while wearing the equipment they can interact physically with the virtual reality environment. There are also companies like Void that are using similar technology for entertainment purposes. They created the Rapture Gear that consists of Rapture HMD, Rapture Vest, and Rapture gloves [18]. With this gear the user can experience Virtual Reality on a whole new level due to the ability to interact physically with the virtual reality. Both of those examples provide a great level of immersion that can help the users to interact with the environment and getting the same feeling as real life. Industry 4.0 includes a variety of various sub-fields where VR could be applied. In the cases requiring physical interaction we have to use motion sensors as well as HMD so that the user can have a high level of immersions. The higher the level of immersion the more prepared the user will be for the real work. For use cases that are only for training, we may use just desktop VR in order to avoid travel costs. Table 2. Technology/equipment choice for tracking physical movement. Ref Num

Deskto p VR

Proj ectio n VR

C Oculu A s Rift V E

H T C vi v e

[17] [19]

low cost dept h sens ors

Inters ense IS900

+ +

[16]

+

[14]

+

[20]

+

+

[21] [22]

optic al came ra

+ +

[23]

+

[24]

+

[25]

+

+

[12]

+

[13]

+



Vasiliki Liagkou et al. / Procedia CIRP 79 (2019) 712–717 V.Liagkou et al. / Procedia CIRP 00 (2018) 000–000

715

4. VR application scenarios For any VR model, that envisions to be a part of Industry 4.0, it is necessary to be adaptable to new events and circumstances. This requires viable use case scenarios and so heavy programming effort. Furthermore, the current VR design approaches are not standardized or well described and so they have limited ability to adapt training from one application to another. The designing of adaptable virtual models need a lot of time and effort and thus increasing awareness of existing use case scenarios for different application domains, which may remove any barrier by decreasing the initial startup time associated with the creation of a VR use case scenario. Table 3 lists several implemented use case scenarios and applications that could be used to develop a modelling and simulation VR environment for a manufacturing process. There are various software application that could be used to create Virtual Environment with specific scenarios usable for the Industry 4.0 Martin Němec et al. [25] created various scenarios for various fields such as Industry and Medicine, with the use of Unreal Engine 4. Unreal Engine 4 and Unity 3D are tools that can be used to develop VR applications but require heavy coding. There is also the solution of Second Life and OpenSim (see Fig. 3.). Those two platforms have been used for years to create virtual worlds for education and learning. Both OpenSim and Second Life are applications that are easy to install and maintain [26]. Unlike those two platforms Linden Lab, the company behind Second Life, they published a new platform named Sansar (see Fig. 4.). In this platform they upgraded the graphics to provide improved immersion but it also raised the PC requirements. The realistic look of a VR application makes the immersion better. Software such as blender and 3DS max has been used to create 3D models. Various reviewed scenarios using VR in industrial manufacturing are presented at [27]. In one of those scenarios, they created a platform that simulates an actual facility. All buildings and objects were created with the use of 3D CAD. The user with the use of HMD and haptics could perform machining operations. The creation of a method for a risk evaluation is critical for all industries. The VR has been used for evaluation and testing ([28],[37]). Table 2. List of Implemented VR Use Case Scenarios Application Area

Reference Number

Medicine VR Use Case

[29]

Learning VR Use Case

[35],[23],[38],[24],[25]

Safety VR Use Case

[30],[19],[23]

Training VR Use Case Scenario

[19], [16],[20],[37],[38],[ 24]

Industry-Manufacturing VR Use Case Scenario

[28],[16],[15],[33],[20],[27],[21],[ 35],[36],[37],[22],[12]

Maintenance VR Use case Scenario

[32]

Assembly VR Use Case Scenario

[32],[20]

Fig. 3. OpenSim VR platform.

Fig. 4. Sansar Platform.

Based on the scenarios that we reviewed we can see different technologies being used in different areas. Although OpenSimulator provides less immersion compared to platforms that have been created from Unity 3D and Unreal Engine 4, it is widely used for educational purposes and in some cases replace the classroom. VR could be used in Industry 4.0, so that to enhance its capabilities and to include new disciplines such as teaching employees about the fields of IoT and other hot themes. Training employees in manufacturing processes, assembly or safety requires the creation of the best immersion environment. This could be achieved by combining HMDs and motion sensors. 5. The Nature of VR technology One of the disadvantages of implementing VR navigation is that users experience various symptoms that are similar to motion sickness, disorientation, nausea, pallor, sweating and headaches leading to vomiting. These symptoms are related to a conflict within the biology of the brain. Our auditory and visual sensor inputs tell us that we are moving through a real space, while our inner ear is not able to detect the corresponding motion. Many these short-term side effects and problems have been reduced by adequate technological solutions and developments, which were introduced over the last few years and will continue refined as time rolls by. One measure that reduces these symptoms decrease screen

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refreshing rates. In many cases the reduction of refreshing rates for avoiding these symptoms could be of 10% to 20% and sometimes of 50% [23]. Unfortunately, another measure for reducing these symptoms is to increase resolution thus proper game designs are needed from developers gained a deeper understanding of the conditions that make a stable VR experience [38]. VR glasses may also cause some specific health problems, there have been cases where users felt nausea after using glasses for a moderate amount of time, more precisely:  The Headset Oculus Rift DK1 (see Fig. 5.) was one of the first headsets available for virtual reality development. This version featured a resolution of 1280x800px, which is quite low compared to today’s headsets. When wearing the headset some users had complaints about motion sickness, mostly due to low resolution and display refresh rate.  The Headset HTC Vive (see Fig. 6.) was made in collaboration with PC games giant Valve and works with Valve's mammoth gaming ecosystem, Steam. HTC packs in 70 sensors to offer 360-degree head-tracking as well as a 90Hz refresh rate – that's the stat that's key to keeping down latency, which is the technical term for the effect that causes motion sickness In order to decrease sickness symptoms, we have to use headsets with higher refresh rates. However, the demand for high rates of a headset is difficult to be archived since VR scenes with high resolutions could lead to reduction of screen’s resolution and low headset refresh rate. For example, if the refresh rate of the screen drops from HTC Vive native 90Hz to 45Hz or less then the rendering frequency could cause unpleasant feelings and motion sickness to some users (kinetosis) [24]. To avoid such problems, optimizations are inevitable, such as reducing rendering complexity and level of detail.

Fig. 6. Headset HTC Vive.

6. Conclusion The 4th industrial revolution is based on computers, computational power, internet, cloud computing and IoT. Industry 4.0 relies on Virtual Reality in order to decrease design and production costs, maintain product quality and overcome several technical tradeoffs like reducing rendering complexity while keeping high refresh rates or increasing resolution while providing a stable VR experience. Virtual Reality is undeniable a unique tool that has many uses, from teaching students all around the world to simulate safety scenarios but it has to be integrated with viable use case scenarios and real-time data collection so that to capture physical movement for bringing all benefits and offering a pleasant VR experience. It is a great substitute for the real life environment and can minimize the safety concerns especially for training new staff. Virtual Reality is a fast growing field. Due to the advancement of the technology, the VR gear is getting cheaper but it still quite expensive. The advancement in the network connections and especially of the 5G network will improve the experience of VR. Acknowledgements This work has been partially supported by the “TIPHYS 4.0Social Network based doctoral Education on Industry 4.0” project No 2017-1-SE01-KA203-03452 funded by ERASMUS+ of the European Commission. References

Fig. 5. Headset Oculus Rift DK1 .

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