How Virtual Reality is Reshaping Industrial Automation

Industrial automation has always been a part of the manufacturing process. In recent years, however, technological advancements are giving engineers and companies new opportunities to make better use of digital technologies when automating tasks on the factory floor. From virtual reality (VR) headsets that enable more intuitive control systems to augmented reality (AR) wearables that create shared 3D visualizations for workers, these modern tools are changing industrial automation as we know it — transforming businesses across all industries. By leveraging this emerging set of tangible solutions to drive speed and innovation throughout their operations, organizations can maximize efficiency and output while minimizing downtime or waste at every step of their manufacturing processes. Read on to learn more about how VR and AR have revolutionized industrial automation!

What is Virtual/Augmented Reality?

Virtual reality (VR) and augmented reality (AR) are two emerging technologies changing how we interact with our environment. VR technology is often associated with gaming, as it transports the user into a completely different world, through a headset and two handheld controllers, for interacting with virtual space. The headset has a screen displaying the contents of the app or game chosen by the user to create an enclosed and immersive experience, allowing the user to look around and interact with the world as if they were physically inside it. This idea is what Facebook, or Meta, used to create Horizon Worlds, a social space where creators can create their own worlds for community engagement or even interact with co-workers in a more business-formal setting. While Quest 2 VR headsets (made by Oculus and ran by Facebook) sales have been great, reports say that Horizon Worlds has been quite a flop with an extremely low player base. While this doesn’t exactly tell the future of VR devices, it is a reminder that this technology, as well as AR, is still very new and needs time to mature.

On the other hand, AR technology enhances the current environment by overlaying digital information on top of the natural world, such as the popular mobile game Pokémon Go, rather than isolating them into the headset. To achieve this, the headset will capture the user’s field of view to set the foundation. Next, it scans and anchors the data it is trying to display onto the actual location. To do this, it either utilizes SLAM (Simultaneous Localization and Mapping) to perceive the data received by its various sensors to map the environment, marker-based objects or QR codes, or location-based information from GPS data and other sensors. This allows the user to see what they would typically do through the semi-transparent lenses but with the added information projected on top.

In the world of industrial automation, both VR and AR have the potential to revolutionize the manufacturing process. For example, Microsoft is developing HoloLens, a headset that uses AR technology to provide workers with real-time data and instructions, reducing errors and increasing efficiency. Valve, the company behind popular video games like Half-Life and Portal, has also invested in VR technology for industrial applications. The potential for these technologies goes beyond individual companies, as some envision a “metaverse” where users can interact with each other in a fully immersive VR environment. Overall, the possibilities for VR and AR in industrial automation are exciting and limitless.

The Benefits of Using VR/AR Headsets in Industrial Automation

With their ability to create an interactive and immersive environment, these devices have become indispensable tools for engineers, manufacturers, and the workforce in general. No longer are engineers and technicians tied down to their workstations or sticking their faces into bulky manuals to analyze and troubleshoot issues. VR/AR allows them to visualize complex machinery and processes in 3D and easily manipulate or inspect them from any angle.

VR/AR headsets are also very good at visualization and planning. A worker could use their tablet or AR headset to find a specific part in inventory while the software guides them to the exact location. This could help eliminate confusion and wasted time wandering around to find the correct spot. That very same warehouse layout could have been planned and visualized before construction using that same technology. This helps identify potential incompatibilities and mistakes and can even provide real-time information on performance and bottlenecks so that improvements can be made ahead of time.

Remote work can also be taken into consideration. Non-local engineers could tap in with their VR headsets to aid and provide troubleshooting advice to the onsite workers. This saves time and provides more accurate results than simply talking over the phone with customer service.

Examples of how VR/AR in Industrial Automation Processes

Companies across the globe have been able to tackle challenges in fields such as architecture, construction, and maintenance by implementing VR/AR headsets. These innovative devices provide enhanced safety measures, improve productivity, and reduce downtime. For instance, Ford successfully incorporated VR headsets, named FIVE (Ford Immersive Vehicle Environment), into its production lines for simulation training and maintenance support. This allowed engineers to see what future model cars would look like, enabling them to look inside to plan their work further. This also allows a space where multiple designers could collaborate on one project, further increasing the quality of the product and reducing time spent on the initial product design.

Another example of using this technology is real-time employee instruction to guide workers on a task using a tablet or their AR glasses. This provides step-by-step instructions and reminds the worker of the proper equipment and hardware. This helps prevent human error in assembly and saves on lengthy training times. One example of this technology comes from Siemens and requires the user to wear an AR headset to view the product they are working on, like a gearbox, and display what part needs to go where and in what order to the wearer.

The Challenges with Implementing AR/VR Headsets

The implementation of AR/VR technology in industrial automation has the potential to revolutionize the industry. However, some challenges need to be addressed before it becomes widely adopted. One significant challenge is the cost of technology, which can be prohibitively expensive for some companies. According to 7t’s article “How much does virtual reality mobile app development cost?”, the average cost per hour for developing a virtual reality app is around $40 to $240 an hour, and the total cost of $3,000 to over $100,000 depending on how specialized and complex the application is. Industrial automation is a large field with many systems, sub-systems, and brands. Developing one app per brand or product would still result in a monumental cost. The headsets themselves are rather pricey as well, depending on which model is desired. For instance, the Microsoft HoloLens costs a staggering $3,500 whereas the Meta Quest 2 retails for $400. While these two headsets are different technologies, they still highlight an important figure to consider when adopting them. Though, when compared to hiring a fleet of technicians, the price might seem attractive.

Another challenge with AR/VR is latency issues. Latency is the delay between the physical action performed and the received feedback from the program. Generally, latency isn’t as big of a problem when the device is wired directly to the supporting PC. However, in a work environment, having a PC tethered to you generally isn’t feasible. This issue must be solved through both the hardware and software side of the headset itself and the app it will be running.

 Additionally, there are concerns about safety and the training required for employees to operate these systems safely. We have all seen videos of VR headset wearers accidentally punching their tv or running into the wall. Still, thankfully these headsets are advanced enough to prevent this from happening now. While the inherent risk of hitting something important on accident will always be an issue, motion sickness while wearing the headset is another concern for adopters partly due to the latency issues.

Another significant challenge is the reliability of AR/VR systems, particularly in intense manufacturing environments where they may be subjected to harsh conditions or high heat. There are also concerns about the accuracy of AR/VR systems, particularly when it comes to precision tasks that require a high level of accuracy. Despite these challenges, many companies actively explore AR/VR technology implementation. There have already been success stories, such as the use of AR headsets for assembling fighter jets by the US Navy. As the technology continues to improve and costs decrease, we can expect to see more widespread adoption of AR/VR technology in industrial automation.

Potential Solutions to Address Those Challenges

Fortunately, several potential solutions address the various challenges associated with AR/VR systems. Companies can invest in high-quality hardware designed specifically for industrial environments and can withstand harsh conditions or high temperatures; however, the demand must be there to produce an already sensitive headset to work in those conditions. Software-wise, tools can help accurately track movements and provide precise feedback, such as a drawn boundary that alerts the user whenever they are wandering too close to their predetermined borders for walls or other equipment. On the hardware side, most VR headsets are equipped with cameras to read their surroundings and provide real-time tracking for the user and the software. Consumers will only run into issues with latency or poorly optimized apps once further research and development fix them.

In conclusion, AR/VR technology offers a world of possibilities for industrial applications, but it is not without its challenges. Companies should be aware of the potential obstacles and take steps to ensure their systems meet industry standards. With the proper hardware, software, and research investments, organizations can maximize the effectiveness of their AR/VR technology and create an environment conducive to success.

The Future of Virtual Reality and Augmented Reality in Industrial Automation

VR and AR technologies have the potential to revolutionize the way factories are operated, from training to maintenance and even product design. The ability to superimpose the virtual onto the real differentiates AR from virtual reality, making it easier to identify problems and make repairs. In addition, the digital twins allow for simulations of factory operations that can be used to test new processes before they are implemented in the real world.

The outlook for VR/AR in an industrial automation setting is magnificent. Companies are already using these technologies to improve their operations and increase efficiency. For example, Siemens has developed a digital twin platform that allows engineers to simulate factory operations before they are implemented in the real world. This helps them identify potential issues before they become costly mistakes. Additionally, AR/VR technologies can be used to create immersive and interactive simulations for industrial automation training purposes, allowing employees to gain experience without going through expensive on-site training sessions.

Overall, VR/AR technologies have great potential in industrial automation settings. They can help companies save time and money while improving safety and efficiency at the same time. As more companies begin adopting these technologies, we will likely see even more applications being developed in this area.

The Reality of it All

VR and AR technology is a powerful tool with highly promising applications in industrial automation. It offers significant advantages, such as improved worker safety, better outcomes, and cost savings. As the technology develops, these headsets will open up exciting opportunities for businesses to save time and money while improving customer satisfaction. With more innovative automation powered by AI technology incorporated into it, we can expect work performance and output to further enhance while allowing humans to focus on more creative tasks. While there are still some challenges to be addressed before AR/VR can be widely implemented in industrial automation, it is an investable option due to its numerous benefits and future potential for growth. The only question that remains now is how long we will have to wait until we can use headsets specialized for our specific jobs. Though as we look ahead, virtual and augmented reality are poised to become essential elements of modern industrial automation and production processes and might even be an important tool in the everyday technicians’ toolbox at home.

This entry was posted on July 31st, 2023 and is filed under Automation, Technology. Both comments and pings are currently closed.