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5GSensPRO research project

Modular production upgrading with sensor technology and 5G

When machining of complex workpieces takes the existing machines of a company to the limits of their flexibility, the time for upgrading has come: with sensor technology that transmits large amounts of data using 5G and cloud technology almost without delay and equips the machine with new functions for process monitoring and control.

Together with seven industrial partners, MARPOSS Monitoring Solutions GmbH is developing a modularly expandable sensor cloud system for existing machines: This system comprises sensors, control- , evaluation- and visualization software, interfaces and communication protocols to monitor and adaptively control highly dynamic production processes more thoroughly.

The "5GSensPRO" project aims are creating a flexible production environment that meets the growing demands of manufacturing complex parts. In the project, the project consortium is therefore developing a modular sensor technology environment that flexibly extends tools and production machines by various new functions.

The project partners are jointly designing and testing the 5GSensPRO system using the example of a highly dynamic manufacturing process for turbomachinery components. Sensors are attached onto the component and integrated directly into the manufacturing process. The presentation of sensor data and process control using smart devices in a virtual production environment offers the user a completely new way of interacting with the overall system.

Together, the project partners are designing and testing the 5GSensPRO system using the example of a highly dynamic manufacturing process for turbomachinery components. Sensors are attached onto the component and integrated directly into the manufacturing process. The visualization of sensor data and the process control using smart devices in a virtual production environment offers the user a completely new way of interacting with the overall system.

According to the future prospects of the consortium, the combination of intelligently networked sensors, 5G technology and flexibly expandable cloud systems shall in the future contribute to transforming conventional machine parks into semi-autonomously acting systems with adaptable processing stations and optimal capacity utilization. Together with cloud-based data pipelines and derived models, companies will then be able to forecast not only production results but also maintenance requirements and failure risks more reliably than before.

5G offers the chance to meet the new requirements for wireless communication within a network of machines, servers and intelligent sensors: With the new standard for mobile communications, large amounts of data can be transferred at high speed and with low latencies between sensors and cloud- and mainframe computing systems, in order to ensure time-critical communication at field level, for example for control applications.

The partners in the "5GSensPRO" project concentrate on the interaction of six modules:

  • Intelligent sensor hardware with a base unit for data pre-processing and radio transmission via 5G
  • Software for sensor control and evaluation of the recorded data
  • Tracking functions based on mobile phone technology for the identification of components and automatic allocation of the appropriate process and logistics data
  • Uniform, system-wide communication protocols for data transmission and coupling of sensors and other components for quick and easy expansion of the overall system
  • Visualization interfaces, for example for smart devices and other end units
  • Smart Sensor Cloud as infrastructure for data processing, analysis and transfer to other Systems

Partners in the 5GSensPRO project

  • Fraunhofer Institute for Production Technology IPT, Aachen
  • MARPOSS Monitoring Solutions GmbH, Egestorf
  • Meastream GmbH, Eschweiler
  • Oculavis GmbH, Aachen
  • QSQ, Erkelenz
  • CP Tech GmbH, Büren (associated)
  • Ericsson GmbH, Herzogenrath (associated)
  • MTU Aero Engines AG, Munich (associated)

The project "5GSensPRO - 5G-based sensor technology for monitoring in production" is funded by the European Regional Development Fund (ERDF) 2014-2020 (funding code: ERDF 0801636).

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