Mechatronics in the Cloud

We make the principle of mechatronic engineering tangible via a tablet," says Tim Oerter, project manager for software projects at EPLAN. The basis for this is a cloud-to-cloud connection between the Thingworx Studio IoT platform from PTC and eVIEW, the cloud service from EPLAN. Using an industrial tablet on which the Vuforia augmented reality app was installed, the 3D CAD drawing of the machine can be opened by scanning an original component of a machine/plant. The augmented reality application ensures that the real objects are directly combined with the digital representations. The engineering components from the digital structure of the machine are linked to the corresponding circuit diagrams in a 3D M-CAD model based on Autodesk Inventor. A glance through a tablet reveals the mechatronic interaction of the various disciplines.

The basis for innovative developments of this kind is digital data. So anyone who does not yet have digital mechatronic engineering should start as soon as possible."

Tim Oerter, project manager for software projects at EPLAN.

In this specific case, AR technology is used to build a complete virtual machine around a SEW Eurodrive motor, such as a real electric motor. If a service technician touches an electromechanical component on the tablet that is linked to the physical object, the corresponding page of the electrical documentation in EPLAN Electric P8 opens automatically. There, the motor is displayed with all its electrical characteristics and logical dependencies within the E-CAD circuit diagram. The app also shows how, for example, the motor's fuse component was wired, where exactly the component was installed in the machine and where the corresponding control cabinet is located. Here, another look through the tablet at the control cabinet is enough to open the digital twin of the real cabinet created with EPLAN Pro Panel. This makes it easy for technicians to follow functional definitions and access connected components, such as those installed in the control cabinet. By touching the control cabinet component on the circuit diagram, the simple change back to the camera view of the tablet takes place. Now all the digital data assigned to the component can be retrieved in the real control cabinet.

Play back changes

If, for example, maintenance is required on a fuse component, the system flashes to  indicate exactly where the component is located. After checking the component, the technician decides whether replacement is necessary. In this case, the system provides support beyond engineering: The technician opens the EPLAN Data Portal directly in the application and selects the corresponding replacement components, such as a fuse switch. The electrical engineering and commercial data are stored in the portal, so that the ordering process can also be started without difficulty. However, the exact same component is not always selected for maintenance - not all required components are always available. If the maintenance employee decides to use a different component or to change the wiring in the control cabinet, these changes should ideally also flow back into the electrical engineering project. An "as-built documentation" is the goal, which was also considered in the showcase of EPLAN and PTC. For this purpose, a redlining function was integrated, with which the corresponding change notes are noted in the system by the service technician. These can then be transferred to the EPLAN project. The electrical designer can view the redlining comments in EPLAN Electric P8. He can check the technician's comment, add it to the circuit diagram or consult the technician if, for example, it should be the component of another manufacturer due to contractual obligations.

The simple navigation between the physical object and the digital twin in maintenance is already a reality. For service and maintenance this means: always up-to-date paperless documentation. It quickly leads to the required component and thus minimizes machine downtime, as time-consuming searching and finding is a thing of the past.

Further Augmented Reality Scenarios

The possibilities of innovative AR applications are far from exhausted with the current example of EPLAN and PTC. For example, sensor data from a control cabinet could be derived via OPC UA. Scenarios are therefore conceivable in which all sensor data is read into the IoT platform. The benefits would be obvious: In this case, the cabinet itself "speaks out" what the problem is. In short, the sensor data would provide information on the status of each component, and the service technician could act at an early stage in the sense of predictive maintenance. There is still much to be expected in the exciting context of IoT and AR applications. The specialists at EPLAN are open for this - also for other connections, which in principle can be implemented with different IoT environments. The prerequisite is openness, which in times of industry 4.0 is not only promoted between systems, but also more and more between software manufacturers.

A Gebhardt machine will also be exhibited on the campus of RTWH Aachen in the E4TC showroom and presented jointly by EPLAN and partner PTC. Both companies are members of the European 4.0 Transformation Center - a unique network of science and industry.